WO2023176342A1 - Production method for resin sheet - Google Patents
Production method for resin sheet Download PDFInfo
- Publication number
- WO2023176342A1 WO2023176342A1 PCT/JP2023/006408 JP2023006408W WO2023176342A1 WO 2023176342 A1 WO2023176342 A1 WO 2023176342A1 JP 2023006408 W JP2023006408 W JP 2023006408W WO 2023176342 A1 WO2023176342 A1 WO 2023176342A1
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- WIPO (PCT)
- Prior art keywords
- end mill
- cutting
- adhesive layer
- resin sheet
- workpiece
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B1/00—Methods for turning or working essentially requiring the use of turning-machines; Use of auxiliary equipment in connection with such methods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C3/00—Milling particular work; Special milling operations; Machines therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C3/00—Milling particular work; Special milling operations; Machines therefor
- B23C3/12—Trimming or finishing edges, e.g. deburring welded corners
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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
Definitions
- the present invention relates to a method for manufacturing a resin sheet.
- the outer peripheral end surface may be subjected to finishing processing.
- cutting with an end mill may be performed.
- Cutting with an end mill is usually performed on a workpiece made of a plurality of stacked resin sheets.
- the cutting edge of the end mill may leave marks called cutter marks. Such cutter marks are particularly noticeable at the bottom of the workpiece. When such cutter marks occur, an additional problem may arise in that the surface roughness of the cutting end surface increases.
- the present invention has been made to solve the above-mentioned conventional problems, and its main purpose is to easily and efficiently produce resin sheets that suppress the occurrence of cutter marks even when using thick workpieces.
- the purpose is to provide a method for manufacturing.
- a method for manufacturing a resin sheet according to an embodiment of the present invention includes stacking a plurality of resin sheets to form a workpiece, and cutting the outer peripheral surface of the workpiece with an end mill. Cutting with the end mill is performed while applying ultrasonic vibrations in the vertical direction of the end mill.
- the frequency of the ultrasonic vibration is between 30 kHz and 50 kHz.
- the amplitude of the ultrasonic vibration is between 0.5 ⁇ m and 30 ⁇ m.
- the end mill has a helix angle of 65° or less.
- the thickness of the workpiece is 5 mm or more.
- the resin sheet is a laminate.
- the resin sheet includes an optical film.
- the optical film includes a polarizer.
- the resin sheet includes an adhesive layer and/or a pressure-sensitive adhesive layer.
- the resin sheet manufacturing method it is possible to suppress the occurrence of cutter marks even when using a thick workpiece. As a result, the resin sheet can be manufactured easily and with high efficiency.
- FIG. 1 is a schematic perspective view for explaining an example of the structure of an end mill used for end face processing of a resin sheet in a manufacturing method according to an embodiment of the present invention.
- FIG. 2 is a schematic plan view of the end mill of FIG. 1 viewed from the rotation axis direction.
- FIG. 2 is a schematic perspective view for explaining an example of end face processing of a resin sheet in a manufacturing method according to an embodiment of the present invention.
- 2 is an electron microscope image showing a comparison of the states of the end faces of a polarizing plate with an adhesive layer of Example 1 and a polarizing plate with an adhesive layer of Comparative Example 1.
- 3 is an electron microscope image showing a comparison of the states of the end faces of the polarizing plate with an adhesive layer of Example 3 and the polarizing plate with an adhesive layer of Comparative Example 3.
- the method for manufacturing a resin sheet according to an embodiment of the present invention includes stacking a plurality of resin sheets to form a workpiece, and cutting the outer peripheral surface of the workpiece with an end mill.
- cutting with an end mill is typically performed as end face processing of a resin sheet.
- cutting with an end mill is performed while applying ultrasonic vibrations in the vertical direction of the end mill.
- the resin sheet examples include any suitable resin sheet that can be subjected to end surface processing.
- the resin sheet may be a film composed of a single layer, or may be a laminate.
- Specific examples of resin sheets include optical films, heat insulating sheets, general-purpose engineering plastic sheets, resin windows, surface protection films, fiber reinforced plastic (FRP) sheets, packaging films, and food films.
- the resin sheet includes an optical film. Since optical films require more precise edge processing than other resin sheets or films, the effects of the embodiments of the present invention are significant.
- Specific examples of optical films include polarizers, retardation films, polarizing plates (typically laminates of polarizers and protective films), conductive films for touch panels, surface treatment films, and films for these purposes.
- a laminate suitably laminated according to the purpose for example, a circularly polarizing plate for antireflection, a polarizing plate with a conductive layer for a touch panel
- the resin sheet includes an adhesive layer and/or a pressure-sensitive adhesive layer. Therefore, the resin sheet can be, for example, an optical film including an adhesive layer and/or a pressure-sensitive adhesive layer. In an optical film containing an adhesive layer and/or a pressure-sensitive adhesive layer, the effects of the embodiments of the present invention are even more remarkable.
- FIG. 1 is a schematic perspective view for explaining an example of the structure of an end mill that can be used for end face processing of a resin sheet;
- FIG. 2 is a schematic plan view of the end mill in FIG. 1 viewed from the direction of the rotation axis.
- the end mill 20 includes a main body 22 that rotates around a rotating shaft 21; and a cutting blade 23 provided on the outer circumference of the main body 22 and having a cutting edge 23a, a rake surface 23b, and a relief surface 23c.
- the end mill 20 is integrally formed of a hard metal material such as cemented carbide or high-speed tool steel, and has a substantially cylindrical shaft shape centered on the rotating shaft 21.
- a hard metal material such as cemented carbide or high-speed tool steel
- one end in the illustrated example, the upper end
- a shank portion 25 that remains cylindrical. Both ends of the end mill may serve as shank parts.
- the shank portion 25 of the end mill is held by the main shaft of a machine tool such as a machining center and rotated around the rotating shaft 21, so that the cutting blade in contact with the object cuts the object.
- the end mill is held on the machine tool in a cantilevered manner; if both ends are provided as shanks, the end mill is held on the machine tool in a double-sided manner.
- the end mill can preferably be held in a cantilevered state on the machine tool (i.e., only one end can be used as the shank part). .
- the cutting blade 23 is provided on the outer circumference of the main body 22.
- the cutting blade 23 has a cutting edge 23a, a rake surface 23b, and a relief surface 23c.
- the rake face 23b is a wall face facing the rotation direction T of the cutting blade 23.
- the rake face 23b defines an arc concave on the side opposite to the rotation direction T in a cross section in a direction perpendicular to the rotation axis, and is shaped so as to move toward the side opposite to the rotation direction T toward the outer circumference. It is extending.
- the relief surface 23c is the outer peripheral surface of the cutting blade 23, and intersects with the rake surface 23b to define the cutting edge 23a.
- the escape surface 23c is also substantially the outer peripheral surface of the end mill 20.
- the relief surface 23c is preferably roughened. Any suitable treatment may be employed as the surface roughening treatment. A typical example is blasting.
- a typical example is blasting.
- By roughening the relief surface when the object to be cut (typically, a resin sheet) includes an adhesive layer and/or an adhesive layer, it is possible to prevent the adhesive and/or adhesive from being applied to the cutting blade. Adhesion may be suppressed and, as a result, blocking may be suppressed.
- blocking refers to a phenomenon in which the resin sheets in a workpiece adhere to each other with the adhesive on the end surfaces when the resin sheets include a pressure-sensitive adhesive layer and/or an adhesive layer. The residue contributes to adhesion between the resin sheets.
- the number of cutting blades (number of end mill blades), any appropriate number of blades can be adopted depending on the purpose.
- the number of blades may be one, two, three, four as in the illustrated example, or five or more.
- the number of blades is two or four. With such a configuration, the rigidity of the blade is ensured, pockets are ensured, and the shavings can be discharged satisfactorily.
- the plurality of cutting blades may be formed at equal intervals in the circumferential direction as in the illustrated example, or may be formed at unequal intervals in the circumferential direction (not shown). You can. Further, when the number of cutting blades is plural (two or more), typically, the rotation trajectories of the plurality of cutting blades around the rotation axis 21 are made to coincide with each other.
- the cutting blade is typically a twisted blade.
- the effects of embodiments of the present invention can be significant when the cutting blade is a twisted blade.
- the helix angle ⁇ of the cutting blade is preferably 65° or less, more preferably 10° to 65°, even more preferably 15° to 60°, particularly preferably 15° to 50°, and especially Preferably it is 20° to 45°, most preferably 25° to 40°. When the helix angle of the cutting blade is within this range, the effects of the embodiments of the present invention can be even more significant.
- the rake angle ⁇ 1 of the cutting blade is preferably ⁇ 10° to 45°, more preferably 0° to 45°, and even more preferably 10° to 45°; the cutting edge angle ⁇ 2 is preferably 20°. ⁇ 100°, more preferably 20° to 90°, still more preferably 20° to 80°. If the rake angle ⁇ 1 and the cutting edge angle ⁇ 2 of the cutting blade are within such ranges, it is possible to form a machined surface with excellent smoothness.
- "rake angle” refers to the angle between a straight line connecting the rotating shaft 21 and the cutting edge 23a and a straight line extending from the cutting edge 23a along the rake face 23b in a cross section perpendicular to the rotating axis.
- Blade angle is the angle formed by a straight line extending from the cutting edge 23a along the rake surface 23b and a straight line extending from the cutting edge 23a along the relief surface 23c in the cross section in the direction perpendicular to the rotation axis. be. Note that when the rake face defines an arc in the cross section in the direction perpendicular to the rotation axis as in the illustrated example, the line extending along the rake face is a tangent to the rake face extending from the cutting edge.
- the relief surface is the outer circumferential surface of the cutting blade and defines an arc in the cross section perpendicular to the rotation axis, so the line extending along the relief surface is essentially the tangent to the relief surface extending from the cutting edge. be.
- the outer diameter of the end mill can be appropriately set depending on the purpose. More specifically, the outer diameter of the end mill is preferably 0.5 mm to 30 mm, more preferably 0.5 mm to 20 mm, and still more preferably 0.5 mm to 16 mm. If the outer diameter of the end mill is within this range, it can be processed without any problems using a machine tool that is capable of general end mill processing. Furthermore, in the embodiment of the present invention, the smaller the outer diameter (for example, 15 mm or less, and for example, 10 mm or less), the more significant the effect of the combination with applying ultrasonic vibration becomes. Specifically, cutter marks can be suppressed even better. Note that the outer diameter of the end mill is twice the distance of a straight line connecting the rotating shaft and the cutting edge (that is, the diameter of the rotating orbit of the cutting blade).
- FIG. 3 is a schematic perspective view for explaining the outline of end face processing of a resin sheet (here, a polarizing plate with an adhesive layer) in a manufacturing method according to an embodiment of the present invention.
- a workpiece W is shown in this figure.
- a workpiece W is formed by stacking a plurality of polarizing plates with adhesive layers.
- a polarizing plate with an adhesive layer is typically cut from a raw roll into any appropriate size and shape.
- the polarizing plate with an adhesive layer may be cut into a rectangular shape, a shape similar to a rectangular shape, or an appropriate shape (for example, circular) depending on the purpose. may have been done.
- the polarizing plate with an adhesive layer is cut into a rectangular shape, and the workpiece W has outer circumferential surfaces (cut surfaces) 1a and 1b facing each other and outer circumferential surfaces (cut surfaces) 1c and 1d perpendicular thereto. have.
- Cutting is performed by any suitable means. Specific examples of the cutting means include punching with a punching blade (eg, Thomson blade) and laser irradiation.
- a release liner may be temporarily attached to the surface of the adhesive layer of the polarizing plate with an adhesive layer, and/or a release liner may be temporarily attached to the surface of the polarizing plate with an adhesive layer opposite to the adhesive layer.
- a surface protection film may be temporarily attached to the surface.
- the total thickness of the workpiece is, for example, 5 mm or more, preferably 10 mm or more, more preferably 15 mm or more, still more preferably 20 mm or more, and particularly preferably 30 mm or more.
- the total thickness of the workpiece is preferably 150 mm or less, more preferably 100 mm or less. The upper limit of the total thickness of the workpiece may be mainly due to constraints on the configuration of the machine tool.
- the workpiece W is preferably clamped from above and below by clamping means (not shown).
- the clamping means e.g. jig
- the clamping means may be constructed of soft or hard material. When it is made of a soft material, its hardness (JIS A) is preferably 60° to 80°. If the hardness is too high, pressure marks caused by the clamping means may remain. If the hardness is too low, positional deviation may occur due to deformation of the jig, resulting in insufficient cutting accuracy.
- cutting is performed using an end mill while applying ultrasonic vibrations in the vertical direction of the end mill.
- the end mill 20 is held by a machine tool (not shown), is rotated at high speed around the rotation axis of the end mill, and is fed out in a direction crossing the rotation axis, while cutting the cutting blade onto the outer peripheral surface of the workpiece W. It is used by making abutment and cutting. That is, cutting is typically performed by bringing a cutting blade of an end mill into contact with the outer circumferential surface of the workpiece W to make a cut.
- ultrasonic vibrations are applied to the end mill in the vertical direction (direction parallel to the rotation axis). In other words, the end mill is used for cutting by being rotated at high speed around the rotation axis while vibrating in the vertical direction at the ultrasonic frequency.
- Cutting (end face processing) with an end mill may be performed on the entire outer circumferential surface of the workpiece W, or may be performed on a predetermined position on the outer circumferential surface.
- the portion not cut with the end mill does not need to be cut, and other cutting means (for example, a file blade such as a rotary grindstone, a double-headed milling cutter) are used. It may be cut by.
- cutting (end face processing) with an end mill is performed on the entire outer circumferential surface of the workpiece.
- ultrasonic vibrations are applied to the end mill throughout cutting by the end mill.
- Cutting end face processing with an end mill is performed in any appropriate manner depending on the purpose. For example, cutting may be performed in a single stroke along the outer circumferential surface; after cutting a pair of opposing outer circumferential surfaces, another pair of opposing outer circumferential surfaces may be cut.
- the number of times the end mill cuts the outer peripheral surface of the workpiece may be one time, two times, three times, or more.
- cutting with the end mill is performed while applying ultrasonic vibration in the vertical direction of the end mill (direction parallel to the rotation axis).
- ultrasonic vibration By performing cutting while applying ultrasonic vibration, cutter marks can be suppressed even on thick workpieces. As a result, the surface roughness of the cut end surface can be reduced. Accordingly, when the resin sheet is a laminate, interlayer peeling (delamination) can be significantly suppressed. Moreover, when the resin sheet includes an optical film (particularly a polarizer), cracks can be significantly suppressed. Furthermore, when the resin sheet includes a pressure-sensitive adhesive layer and/or an adhesive layer, adhesive chipping and blade staining can be significantly suppressed.
- adhesive chipping refers to the phenomenon in which the adhesive layer or the edge of the adhesive layer is missing
- blade staining refers to the phenomenon in which the adhesive in the adhesive layer or the adhesive in the adhesive layer adheres to the cutting blade, causing cutting. A phenomenon in which performance (processing performance) deteriorates beyond the allowable range.
- ultrasonic vibrations can be applied to the end mill by attaching the end mill to a so-called ultrasonic spindle.
- Ultrasonic spindles are well known as cutting tools for hard materials (typically ceramics, sapphire, and quartz glass), but the present inventors have applied this cutting technology to very thin and soft resin sheets (especially polarizers, etc.). It has been found that the above-mentioned excellent effects can be obtained by applying the present invention to an optical film (optical film). That is, the effects obtained by the embodiments of the present invention are unexpectedly excellent effects.
- the frequency (frequency) of the ultrasonic vibration applied to the end mill is preferably 30 kHz to 50 kHz, more preferably 32 kHz to 48 kHz, still more preferably 34 kHz to 46 kHz, particularly preferably 36 kHz to 44 kHz. , particularly preferably from 38 kHz to 42 kHz. If the frequency is in this range, interlayer peeling (delamination), cracks, and adhesive chipping may occur when the resin sheet includes an optical film (particularly a polarizer) and an adhesive layer and/or an adhesive layer. And blade fouling can be suppressed even better.
- the amplitude of the ultrasonic vibration applied to the end mill is preferably 0.5 ⁇ m to 30 ⁇ m, more preferably 1 ⁇ m to 20 ⁇ m, even more preferably 3 ⁇ m to 15 ⁇ m, and particularly preferably 5 ⁇ m to 10 ⁇ m. If the amplitude is within this range, interlayer peeling (delamination), cracks, adhesive chipping, and Blade staining can be suppressed even better.
- the conditions for end face processing using an end mill can be appropriately set depending on the type of resin sheet, desired shape, etc.
- the rotational speed (number of rotations) of the end mill is preferably 100 rpm to 50,000 rpm, more preferably 200 rpm to 40,000 rpm, and still more preferably 300 rpm to 30,000 rpm.
- the feed speed of the end mill is preferably 10 mm/min to 5,000 mm/min, more preferably 20 mm/min to 3,000 mm/min, and even more preferably 25 mm/min to 1000 mm/min. .
- the end mill may be held on the machine tool in a cantilevered state, or may be held in a both-end supported state. Considering the application of ultrasonic vibration to the end mill, it is preferable to hold it in a cantilevered state.
- the surface roughness of the end face of the resin sheet obtained by the manufacturing method of the embodiment of the present invention can be expressed using, for example, the arithmetic mean height Sa.
- the arithmetic mean height Sa may vary depending on the helix angle of the cutting blade of the end mill. For example, when the twist angle is 30°, the arithmetic mean height Sa is preferably 0.30 ⁇ m to 0.65 ⁇ m, more preferably 0.35 ⁇ m to 0.55 ⁇ m. For example, when the twist angle is 50°, the arithmetic mean height Sa is preferably 0.30 ⁇ m to 1.00 ⁇ m, more preferably 0.40 ⁇ m to 0.80 ⁇ m.
- the arithmetic mean height Sa of the resin sheet included in the center and lower part of the workpiece is the same when no ultrasonic vibration is applied.
- the arithmetic mean height Sa obtained is 1.00, it is preferably 0.50 to 0.85, more preferably 0.55 to 0.80.
- the arithmetic mean height Sa may be measured according to ISO 25178, for example.
- Example 1 By a conventional method, the composition of the surface protection film (60 ⁇ m) / cycloolefin protective film (47 ⁇ m) / polarizer (5 ⁇ m) / cycloolefin protective film (24 ⁇ m) / adhesive layer (20 ⁇ m) / release liner in order from the viewing side. A polarizing plate with an adhesive layer was produced. In addition, as the surface protection film, a surface protection film having a structure of PET base material (50 ⁇ m)/adhesive layer (10 ⁇ m) was used. This adhesive layer-attached polarizing plate was punched out to a size of 5.7 inches (approximately 140 mm in length and 65 mm in width).
- a workpiece was made by stacking several punched polarizing plates with adhesive layers. The total thickness of the workpiece was 16 mm. While the obtained workpiece was held between clamps (jigs), end face processing was performed using an end mill. The end mill had an outer diameter of 2 mm, a number of blades of 2, and a helix angle of 30°. For edge processing, the entire outer periphery of the workpiece was processed in a single stroke, and the processing was performed twice: rough processing and finishing processing. In both rough machining and finishing machining, cutting was performed while applying ultrasonic vibration to the end mill.
- the frequency of the ultrasonic vibration was 39 kHz, and the amplitude was 5 ⁇ m.
- the amount of scraping in the rough machining was 0.05 mm, and the amount of scraping in the finishing machining was 0.005 mm.
- the feed rate of the end mill was 50 mm/min, and the rotation speed was 2,500 rpm.
- the obtained polarizing plate with an adhesive layer was evaluated as described in (1) to (5) above.
- the results of (1) to (4) are shown in Table 1, and the results of (5) (SEM image) are shown in FIG.
- ⁇ Comparative example 1> A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 4.
- Example 2 A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1 except that the helix angle of the cutting blade of the end mill was 40°. The obtained polarizing plate with an adhesive layer was evaluated as described in (2) to (4) above. was evaluated. The results are shown in Table 1.
- Example 3 A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1 except that the helix angle of the cutting blade of the end mill was 50°. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 5.
- Example 3 A polarizing plate with an adhesive layer was obtained in the same manner as in Example 3, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 5.
- the resin sheet obtained by the manufacturing method according to the embodiment of the present invention can be used in a wide range of applications.
- the resin sheet can be, for example, an optical film.
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Abstract
Provided is a method that makes it possible to easily and highly efficiently obtain a resin sheet while suppressing the occurrence of cutter marks, even when a thick workpiece is used. According to the embodiments of the present invention, a production method for a resin sheet involves layering a plurality of resin sheets to form a workpiece and cutting an outer circumferential surface of the workpiece with an end mill. Ultrasonic vibration is applied in the vertical direction of the end mill while the end mill is cutting. According to one embodiment, the vibration frequency of the ultrasonic vibration is 30–50 kHz. According to one embodiment, the amplitude of the ultrasonic vibration is 0.5–30 μm.
Description
本発明は、樹脂シートの製造方法に関する。
The present invention relates to a method for manufacturing a resin sheet.
用途に応じた種々の樹脂シートが幅広く利用されている。樹脂シートは、所定の形状に切断された後、外周端面を仕上げ加工に供する場合がある。このような仕上げ加工においては、エンドミルによる切削が行われる場合がある。エンドミルによる切削は、通常、樹脂シートを複数枚重ねたワークに対して行われる。ここで、製造効率を考慮すると、分厚いワークに対して切削を行うことが好ましい。しかし、分厚いワークに対して切削を行う場合、いわゆるカッターマークと称されるエンドミルの切削刃の刃痕が認められる場合がある。このようなカッターマークは、ワーク下部において特に顕著である。このようなカッターマークが発生すると、切削端面の表面粗さが大きくなるという付随的な問題が生じ得る。
Various resin sheets are widely used depending on the purpose. After the resin sheet is cut into a predetermined shape, the outer peripheral end surface may be subjected to finishing processing. In such finishing machining, cutting with an end mill may be performed. Cutting with an end mill is usually performed on a workpiece made of a plurality of stacked resin sheets. Here, in consideration of manufacturing efficiency, it is preferable to cut a thick workpiece. However, when cutting a thick workpiece, the cutting edge of the end mill may leave marks called cutter marks. Such cutter marks are particularly noticeable at the bottom of the workpiece. When such cutter marks occur, an additional problem may arise in that the surface roughness of the cutting end surface increases.
本発明は上記従来の課題を解決するためになされたものであり、その主たる目的は、分厚いワークを用いる場合であってもカッターマークの発生が抑制された、樹脂シートを高効率でかつ簡便に製造し得る方法を提供することにある。
The present invention has been made to solve the above-mentioned conventional problems, and its main purpose is to easily and efficiently produce resin sheets that suppress the occurrence of cutter marks even when using thick workpieces. The purpose is to provide a method for manufacturing.
本発明の実施形態による樹脂シートの製造方法は、樹脂シートを複数枚重ねてワークを形成すること、および、該ワークの外周面をエンドミルで切削すること、を含む。該エンドミルによる切削は、該エンドミルの上下方向に超音波振動を付与しながら行われる。
1つの実施形態においては、上記超音波振動の振動数は30kHz~50kHzである。
1つの実施形態においては、上記超音波振動の振幅は0.5μm~30μmである。
1つの実施形態においては、上記エンドミルのねじれ角は65°以下である。
1つの実施形態においては、上記ワークの厚みは5mm以上である。
1つの実施形態においては、上記樹脂シートは積層体である。1つの実施形態においては、上記樹脂シートは光学フィルムを含む。1つの実施形態においては、上記光学フィルムは偏光子を含む。
1つの実施形態においては、上記樹脂シートは接着剤層および/または粘着剤層を含む。 A method for manufacturing a resin sheet according to an embodiment of the present invention includes stacking a plurality of resin sheets to form a workpiece, and cutting the outer peripheral surface of the workpiece with an end mill. Cutting with the end mill is performed while applying ultrasonic vibrations in the vertical direction of the end mill.
In one embodiment, the frequency of the ultrasonic vibration is between 30 kHz and 50 kHz.
In one embodiment, the amplitude of the ultrasonic vibration is between 0.5 μm and 30 μm.
In one embodiment, the end mill has a helix angle of 65° or less.
In one embodiment, the thickness of the workpiece is 5 mm or more.
In one embodiment, the resin sheet is a laminate. In one embodiment, the resin sheet includes an optical film. In one embodiment, the optical film includes a polarizer.
In one embodiment, the resin sheet includes an adhesive layer and/or a pressure-sensitive adhesive layer.
1つの実施形態においては、上記超音波振動の振動数は30kHz~50kHzである。
1つの実施形態においては、上記超音波振動の振幅は0.5μm~30μmである。
1つの実施形態においては、上記エンドミルのねじれ角は65°以下である。
1つの実施形態においては、上記ワークの厚みは5mm以上である。
1つの実施形態においては、上記樹脂シートは積層体である。1つの実施形態においては、上記樹脂シートは光学フィルムを含む。1つの実施形態においては、上記光学フィルムは偏光子を含む。
1つの実施形態においては、上記樹脂シートは接着剤層および/または粘着剤層を含む。 A method for manufacturing a resin sheet according to an embodiment of the present invention includes stacking a plurality of resin sheets to form a workpiece, and cutting the outer peripheral surface of the workpiece with an end mill. Cutting with the end mill is performed while applying ultrasonic vibrations in the vertical direction of the end mill.
In one embodiment, the frequency of the ultrasonic vibration is between 30 kHz and 50 kHz.
In one embodiment, the amplitude of the ultrasonic vibration is between 0.5 μm and 30 μm.
In one embodiment, the end mill has a helix angle of 65° or less.
In one embodiment, the thickness of the workpiece is 5 mm or more.
In one embodiment, the resin sheet is a laminate. In one embodiment, the resin sheet includes an optical film. In one embodiment, the optical film includes a polarizer.
In one embodiment, the resin sheet includes an adhesive layer and/or a pressure-sensitive adhesive layer.
本発明の実施形態によれば、樹脂シートの製造方法において、分厚いワークを用いる場合であってもカッターマークの発生を抑制することができる。その結果、樹脂シートを高効率でかつ簡便に製造することができる。
According to the embodiments of the present invention, in the resin sheet manufacturing method, it is possible to suppress the occurrence of cutter marks even when using a thick workpiece. As a result, the resin sheet can be manufactured easily and with high efficiency.
以下、図面を参照して本発明の具体的な実施形態について説明するが、本発明はこれらの実施形態には限定されない。なお、見やすくするために図面は模式的に表されており、さらに、図面における長さ、幅、厚み等の比率、ならびに角度等は、実際とは異なっている。さらに、詳細な形状および図中の記号の意味を理解しやすくするために、図面間で形状が正確に対応していない場合がある。
Hereinafter, specific embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these embodiments. Note that the drawings are shown schematically for ease of viewing, and the ratios of length, width, thickness, etc., angles, etc. in the drawings are different from the actual ones. Further, in order to facilitate understanding of detailed shapes and the meanings of symbols in the figures, the shapes may not correspond exactly between the drawings.
A.樹脂シートの製造方法の概要
本発明の実施形態による樹脂シートの製造方法は、樹脂シートを複数枚重ねてワークを形成すること、および、ワークの外周面をエンドミルで切削すること、を含む。エンドミルによる切削は、当該製造方法において、代表的には樹脂シートの端面加工として行われる。本発明の実施形態においては、エンドミルによる切削は、エンドミルの上下方向に超音波振動を付与しながら行われる。以下、樹脂シート、エンドミル、および樹脂シートの製造方法の順に具体的に説明する。 A. Outline of the method for manufacturing a resin sheet The method for manufacturing a resin sheet according to an embodiment of the present invention includes stacking a plurality of resin sheets to form a workpiece, and cutting the outer peripheral surface of the workpiece with an end mill. In this manufacturing method, cutting with an end mill is typically performed as end face processing of a resin sheet. In an embodiment of the present invention, cutting with an end mill is performed while applying ultrasonic vibrations in the vertical direction of the end mill. Hereinafter, the resin sheet, the end mill, and the method for manufacturing the resin sheet will be specifically explained in this order.
本発明の実施形態による樹脂シートの製造方法は、樹脂シートを複数枚重ねてワークを形成すること、および、ワークの外周面をエンドミルで切削すること、を含む。エンドミルによる切削は、当該製造方法において、代表的には樹脂シートの端面加工として行われる。本発明の実施形態においては、エンドミルによる切削は、エンドミルの上下方向に超音波振動を付与しながら行われる。以下、樹脂シート、エンドミル、および樹脂シートの製造方法の順に具体的に説明する。 A. Outline of the method for manufacturing a resin sheet The method for manufacturing a resin sheet according to an embodiment of the present invention includes stacking a plurality of resin sheets to form a workpiece, and cutting the outer peripheral surface of the workpiece with an end mill. In this manufacturing method, cutting with an end mill is typically performed as end face processing of a resin sheet. In an embodiment of the present invention, cutting with an end mill is performed while applying ultrasonic vibrations in the vertical direction of the end mill. Hereinafter, the resin sheet, the end mill, and the method for manufacturing the resin sheet will be specifically explained in this order.
B.樹脂シート
樹脂シートとしては、端面加工に供され得る任意の適切な樹脂シートが挙げられる。樹脂シートは、単一層で構成されるフィルムであってもよく、積層体であってもよい。樹脂シートの具体例としては、光学フィルム、断熱シート、汎用エンジニアリングプラスチックシート、樹脂窓、表面保護フィルム、繊維強化プラスチック(FRP)シート、包装フィルム、食品用フィルムが挙げられる。1つの実施形態においては、樹脂シートは光学フィルムを含む。光学フィルムは他の樹脂シートまたはフィルムに比べて精密な端面加工が要求されるところ、本発明の実施形態による効果が顕著なものとなる。光学フィルムの具体例としては、偏光子、位相差フィルム、偏光板(代表的には、偏光子と保護フィルムとの積層体)、タッチパネル用導電性フィルム、表面処理フィルム、ならびに、これらを目的に応じて適切に積層した積層体(例えば、反射防止用円偏光板、タッチパネル用導電層付偏光板)が挙げられる。1つの実施形態においては、樹脂シートは、接着剤層および/または粘着剤層を含む。したがって、樹脂シートは、例えば接着剤層および/または粘着剤層を含む光学フィルムであり得る。接着剤層および/または粘着剤層を含む光学フィルムにおいては、本発明の実施形態による効果がさらに顕著なものとなる。 B. Resin Sheet Examples of the resin sheet include any suitable resin sheet that can be subjected to end surface processing. The resin sheet may be a film composed of a single layer, or may be a laminate. Specific examples of resin sheets include optical films, heat insulating sheets, general-purpose engineering plastic sheets, resin windows, surface protection films, fiber reinforced plastic (FRP) sheets, packaging films, and food films. In one embodiment, the resin sheet includes an optical film. Since optical films require more precise edge processing than other resin sheets or films, the effects of the embodiments of the present invention are significant. Specific examples of optical films include polarizers, retardation films, polarizing plates (typically laminates of polarizers and protective films), conductive films for touch panels, surface treatment films, and films for these purposes. A laminate suitably laminated according to the purpose (for example, a circularly polarizing plate for antireflection, a polarizing plate with a conductive layer for a touch panel) can be mentioned. In one embodiment, the resin sheet includes an adhesive layer and/or a pressure-sensitive adhesive layer. Therefore, the resin sheet can be, for example, an optical film including an adhesive layer and/or a pressure-sensitive adhesive layer. In an optical film containing an adhesive layer and/or a pressure-sensitive adhesive layer, the effects of the embodiments of the present invention are even more remarkable.
樹脂シートとしては、端面加工に供され得る任意の適切な樹脂シートが挙げられる。樹脂シートは、単一層で構成されるフィルムであってもよく、積層体であってもよい。樹脂シートの具体例としては、光学フィルム、断熱シート、汎用エンジニアリングプラスチックシート、樹脂窓、表面保護フィルム、繊維強化プラスチック(FRP)シート、包装フィルム、食品用フィルムが挙げられる。1つの実施形態においては、樹脂シートは光学フィルムを含む。光学フィルムは他の樹脂シートまたはフィルムに比べて精密な端面加工が要求されるところ、本発明の実施形態による効果が顕著なものとなる。光学フィルムの具体例としては、偏光子、位相差フィルム、偏光板(代表的には、偏光子と保護フィルムとの積層体)、タッチパネル用導電性フィルム、表面処理フィルム、ならびに、これらを目的に応じて適切に積層した積層体(例えば、反射防止用円偏光板、タッチパネル用導電層付偏光板)が挙げられる。1つの実施形態においては、樹脂シートは、接着剤層および/または粘着剤層を含む。したがって、樹脂シートは、例えば接着剤層および/または粘着剤層を含む光学フィルムであり得る。接着剤層および/または粘着剤層を含む光学フィルムにおいては、本発明の実施形態による効果がさらに顕著なものとなる。 B. Resin Sheet Examples of the resin sheet include any suitable resin sheet that can be subjected to end surface processing. The resin sheet may be a film composed of a single layer, or may be a laminate. Specific examples of resin sheets include optical films, heat insulating sheets, general-purpose engineering plastic sheets, resin windows, surface protection films, fiber reinforced plastic (FRP) sheets, packaging films, and food films. In one embodiment, the resin sheet includes an optical film. Since optical films require more precise edge processing than other resin sheets or films, the effects of the embodiments of the present invention are significant. Specific examples of optical films include polarizers, retardation films, polarizing plates (typically laminates of polarizers and protective films), conductive films for touch panels, surface treatment films, and films for these purposes. A laminate suitably laminated according to the purpose (for example, a circularly polarizing plate for antireflection, a polarizing plate with a conductive layer for a touch panel) can be mentioned. In one embodiment, the resin sheet includes an adhesive layer and/or a pressure-sensitive adhesive layer. Therefore, the resin sheet can be, for example, an optical film including an adhesive layer and/or a pressure-sensitive adhesive layer. In an optical film containing an adhesive layer and/or a pressure-sensitive adhesive layer, the effects of the embodiments of the present invention are even more remarkable.
C.エンドミル
図1は、樹脂シートの端面加工に用いられ得るエンドミルの構造の一例を説明するための概略斜視図であり;図2は、図1のエンドミルを回転軸方向から見た概略平面図である。エンドミル20は、回転軸21を中心として回転する本体22と;本体22の外周部に設けられた、刃先23aとすくい面23bと逃がし面23cとを有する切削刃23と;を有する。 C. End Mill FIG. 1 is a schematic perspective view for explaining an example of the structure of an end mill that can be used for end face processing of a resin sheet; FIG. 2 is a schematic plan view of the end mill in FIG. 1 viewed from the direction of the rotation axis. . Theend mill 20 includes a main body 22 that rotates around a rotating shaft 21; and a cutting blade 23 provided on the outer circumference of the main body 22 and having a cutting edge 23a, a rake surface 23b, and a relief surface 23c.
図1は、樹脂シートの端面加工に用いられ得るエンドミルの構造の一例を説明するための概略斜視図であり;図2は、図1のエンドミルを回転軸方向から見た概略平面図である。エンドミル20は、回転軸21を中心として回転する本体22と;本体22の外周部に設けられた、刃先23aとすくい面23bと逃がし面23cとを有する切削刃23と;を有する。 C. End Mill FIG. 1 is a schematic perspective view for explaining an example of the structure of an end mill that can be used for end face processing of a resin sheet; FIG. 2 is a schematic plan view of the end mill in FIG. 1 viewed from the direction of the rotation axis. . The
エンドミル20は、超硬合金、高速度工具鋼等の硬質な金属材料によって一体に形成されて、回転軸21を中心とした略円柱の軸状をなしている。図示例のエンドミルにおいては、切削刃が形成されていない1つの端部(図示例では上端部)は円柱状のままのシャンク部25とされている。エンドミルの両端部がシャンク部とされてもよい。エンドミルのシャンク部25がマシニングセンタ等の工作機械の主軸に保持されて、回転軸21回りに回転されることにより、対象物に当接した切削刃が当該対象物を切削する。1つの端部がシャンク部とされる場合、エンドミルは工作機械に片持ち状態で保持され;両端部がシャンク部とされる場合、エンドミルは工作機械に両持ち状態で保持される。エンドミルの上下方向への超音波振動の付与(詳細は後述)を考慮すると、エンドミルは、好ましくは工作機械に片持ち状態で保持され得る(すなわち、1つの端部のみがシャンク部とされ得る)。
The end mill 20 is integrally formed of a hard metal material such as cemented carbide or high-speed tool steel, and has a substantially cylindrical shaft shape centered on the rotating shaft 21. In the illustrated end mill, one end (in the illustrated example, the upper end) where no cutting blade is formed is a shank portion 25 that remains cylindrical. Both ends of the end mill may serve as shank parts. The shank portion 25 of the end mill is held by the main shaft of a machine tool such as a machining center and rotated around the rotating shaft 21, so that the cutting blade in contact with the object cuts the object. If one end is a shank, the end mill is held on the machine tool in a cantilevered manner; if both ends are provided as shanks, the end mill is held on the machine tool in a double-sided manner. Considering the application of ultrasonic vibrations in the vertical direction of the end mill (details will be described later), the end mill can preferably be held in a cantilevered state on the machine tool (i.e., only one end can be used as the shank part). .
切削刃23は、上記のとおり、本体22の外周部に設けられている。切削刃23は、刃先23aとすくい面23bと逃がし面23cとを有する。すくい面23bは、切削刃23の回転方向Tを向く壁面である。図示例のすくい面23bは、回転軸に直交する方向の断面において、回転方向Tとは反対側に凹んだ円弧を規定しながら、外周側に向かうに従い回転方向Tとは反対側に向かうように延びている。逃がし面23cは切削刃23の外周面であり、すくい面23bと交差して刃先23aを規定する。逃がし面23cは、実質的には、エンドミル20の外周面でもある。逃がし面23cは、好ましくは、粗面化処理されている。粗面化処理としては、任意の適切な処理が採用され得る。代表例としては、ブラスト処理が挙げられる。逃がし面に粗面化処理を施すことにより、切削対象物(代表的には、樹脂シート)が粘着剤層および/または接着剤層を含む場合に切削刃への粘着剤および/または接着剤の付着が抑制され、結果として、ブロッキングが抑制され得る。なお、ブロッキングとは、樹脂シートが粘着剤層および/または接着剤層を含む場合において、ワークにおける樹脂シート同士が端面の粘着剤等で接着する現象をいい、端面に付着する粘着剤等の削りカスが樹脂シート同士の接着に寄与することとなる。
As described above, the cutting blade 23 is provided on the outer circumference of the main body 22. The cutting blade 23 has a cutting edge 23a, a rake surface 23b, and a relief surface 23c. The rake face 23b is a wall face facing the rotation direction T of the cutting blade 23. In the illustrated example, the rake face 23b defines an arc concave on the side opposite to the rotation direction T in a cross section in a direction perpendicular to the rotation axis, and is shaped so as to move toward the side opposite to the rotation direction T toward the outer circumference. It is extending. The relief surface 23c is the outer peripheral surface of the cutting blade 23, and intersects with the rake surface 23b to define the cutting edge 23a. The escape surface 23c is also substantially the outer peripheral surface of the end mill 20. The relief surface 23c is preferably roughened. Any suitable treatment may be employed as the surface roughening treatment. A typical example is blasting. By roughening the relief surface, when the object to be cut (typically, a resin sheet) includes an adhesive layer and/or an adhesive layer, it is possible to prevent the adhesive and/or adhesive from being applied to the cutting blade. Adhesion may be suppressed and, as a result, blocking may be suppressed. In addition, blocking refers to a phenomenon in which the resin sheets in a workpiece adhere to each other with the adhesive on the end surfaces when the resin sheets include a pressure-sensitive adhesive layer and/or an adhesive layer. The residue contributes to adhesion between the resin sheets.
切削刃の数(エンドミルの刃数)としては、目的に応じて任意の適切な刃数が採用され得る。刃数は、1枚であってもよく、2枚であってもよく、3枚であってもよく、図示例のように4枚であってもよく、5枚以上であってもよい。好ましくは、刃数は2枚または4枚である。このような構成であれば、刃の剛性が確保され、かつ、ポケットが確保されて削りカスを良好に排出することができる。刃数が複数(2枚以上)である場合、複数の切削刃は、図示例のように周方向に等間隔に形成されていてもよく、図示しないが周方向に不等間隔に形成されていてもよい。さらに、刃数が複数(2枚以上)である場合、複数の切削刃は、代表的には回転軸21回りの回転軌跡が互いに一致させられる。
As the number of cutting blades (number of end mill blades), any appropriate number of blades can be adopted depending on the purpose. The number of blades may be one, two, three, four as in the illustrated example, or five or more. Preferably, the number of blades is two or four. With such a configuration, the rigidity of the blade is ensured, pockets are ensured, and the shavings can be discharged satisfactorily. When the number of cutting blades is plural (two or more), the plurality of cutting blades may be formed at equal intervals in the circumferential direction as in the illustrated example, or may be formed at unequal intervals in the circumferential direction (not shown). You can. Further, when the number of cutting blades is plural (two or more), typically, the rotation trajectories of the plurality of cutting blades around the rotation axis 21 are made to coincide with each other.
切削刃は、代表的にはねじれ刃である。切削刃がねじれ刃である場合に、本発明の実施形態による効果が顕著なものとなり得る。切削刃のねじれ角Θは、好ましくは65°以下であり、より好ましくは10°~65°であり、さらに好ましくは15°~60°であり、特に好ましくは15°~50°であり、とりわけ好ましくは20°~45°であり、最も好ましくは25°~40°である。切削刃のねじれ角がこのような範囲である場合に、本発明の実施形態による効果がさらに顕著なものとなり得る。
The cutting blade is typically a twisted blade. The effects of embodiments of the present invention can be significant when the cutting blade is a twisted blade. The helix angle Θ of the cutting blade is preferably 65° or less, more preferably 10° to 65°, even more preferably 15° to 60°, particularly preferably 15° to 50°, and especially Preferably it is 20° to 45°, most preferably 25° to 40°. When the helix angle of the cutting blade is within this range, the effects of the embodiments of the present invention can be even more significant.
切削刃のすくい角θ1は、好ましくは-10°~45°であり、より好ましくは0°~45°であり、さらに好ましくは10°~45°であり;刃先角θ2は、好ましくは20°~100°であり、より好ましくは20°~90°であり、さらに好ましくは20°~80°である。切削刃のすくい角θ1および刃先角θ2がこのような範囲であれば、平滑性に優れた加工面の形成が可能となる。本明細書において、「すくい角」とは、回転軸に直交する方向の断面において、回転軸21と刃先23aとを結ぶ直線と、刃先23aからすくい面23bに沿って延びる直線と、のなす角度であり;「刃先角」とは、回転軸に直交する方向の断面において、刃先23aからすくい面23bに沿って延びる直線と、刃先23aから逃がし面23cに沿って延びる直線と、のなす角度である。なお、すくい面が図示例のように回転軸に直交する方向の断面において円弧を規定している場合には、すくい面に沿って延びる線とは、刃先から延びるすくい面の接線である。また、逃がし面は切削刃の外周面であり、回転軸に直交する方向の断面において円弧を規定するので、逃がし面に沿って延びる線とは、実質的には刃先から延びる逃がし面の接線である。
The rake angle θ1 of the cutting blade is preferably −10° to 45°, more preferably 0° to 45°, and even more preferably 10° to 45°; the cutting edge angle θ2 is preferably 20°. ~100°, more preferably 20° to 90°, still more preferably 20° to 80°. If the rake angle θ1 and the cutting edge angle θ2 of the cutting blade are within such ranges, it is possible to form a machined surface with excellent smoothness. In this specification, "rake angle" refers to the angle between a straight line connecting the rotating shaft 21 and the cutting edge 23a and a straight line extending from the cutting edge 23a along the rake face 23b in a cross section perpendicular to the rotating axis. "Blade angle" is the angle formed by a straight line extending from the cutting edge 23a along the rake surface 23b and a straight line extending from the cutting edge 23a along the relief surface 23c in the cross section in the direction perpendicular to the rotation axis. be. Note that when the rake face defines an arc in the cross section in the direction perpendicular to the rotation axis as in the illustrated example, the line extending along the rake face is a tangent to the rake face extending from the cutting edge. In addition, the relief surface is the outer circumferential surface of the cutting blade and defines an arc in the cross section perpendicular to the rotation axis, so the line extending along the relief surface is essentially the tangent to the relief surface extending from the cutting edge. be.
エンドミルの外径は、目的に応じて適切に設定され得る。より詳細には、エンドミルの外径は、好ましくは0.5mm~30mmであり、より好ましくは0.5mm~20mmであり、さらに好ましくは0.5mm~16mmである。エンドミルの外径がこのような範囲であれば、一般的なエンドミル加工が可能な工作機械を用いて不具合なく加工することができる。さらに、本発明の実施形態においては、外径が小さいほど(例えば15mm以下、また例えば10mm以下であれば)、超音波振動を付与することとの組み合わせの効果が顕著なものとなる。具体的には、カッターマークをさらに良好に抑制することができる。なお、エンドミルの外径は、回転軸と刃先とを結ぶ直線の距離を2倍したもの(すなわち、切削刃の回転軌道の直径)である。
The outer diameter of the end mill can be appropriately set depending on the purpose. More specifically, the outer diameter of the end mill is preferably 0.5 mm to 30 mm, more preferably 0.5 mm to 20 mm, and still more preferably 0.5 mm to 16 mm. If the outer diameter of the end mill is within this range, it can be processed without any problems using a machine tool that is capable of general end mill processing. Furthermore, in the embodiment of the present invention, the smaller the outer diameter (for example, 15 mm or less, and for example, 10 mm or less), the more significant the effect of the combination with applying ultrasonic vibration becomes. Specifically, cutter marks can be suppressed even better. Note that the outer diameter of the end mill is twice the distance of a straight line connecting the rotating shaft and the cutting edge (that is, the diameter of the rotating orbit of the cutting blade).
D.樹脂シートの製造方法
以下、樹脂シートの一例として粘着剤層付偏光板を採用した場合の製造方法について説明する。粘着剤層付偏光板の平面形状が図示例の平面形状に限定されないことは当業者に自明である。また、本発明の実施形態が粘着剤層付偏光板以外の任意の適切な樹脂シートにも適用され得ることは、当業者に自明である。すなわち、本発明の実施形態は、任意の適切な形状を有する任意の適切な樹脂シートの製造に適用され得る。 D. Manufacturing method of resin sheet Hereinafter, a manufacturing method when a polarizing plate with an adhesive layer is adopted as an example of a resin sheet will be described. It is obvious to those skilled in the art that the planar shape of the adhesive layer-attached polarizing plate is not limited to the planar shape of the illustrated example. Furthermore, it is obvious to those skilled in the art that the embodiments of the present invention can be applied to any appropriate resin sheet other than a polarizing plate with an adhesive layer. That is, embodiments of the present invention can be applied to manufacturing any suitable resin sheet having any suitable shape.
以下、樹脂シートの一例として粘着剤層付偏光板を採用した場合の製造方法について説明する。粘着剤層付偏光板の平面形状が図示例の平面形状に限定されないことは当業者に自明である。また、本発明の実施形態が粘着剤層付偏光板以外の任意の適切な樹脂シートにも適用され得ることは、当業者に自明である。すなわち、本発明の実施形態は、任意の適切な形状を有する任意の適切な樹脂シートの製造に適用され得る。 D. Manufacturing method of resin sheet Hereinafter, a manufacturing method when a polarizing plate with an adhesive layer is adopted as an example of a resin sheet will be described. It is obvious to those skilled in the art that the planar shape of the adhesive layer-attached polarizing plate is not limited to the planar shape of the illustrated example. Furthermore, it is obvious to those skilled in the art that the embodiments of the present invention can be applied to any appropriate resin sheet other than a polarizing plate with an adhesive layer. That is, embodiments of the present invention can be applied to manufacturing any suitable resin sheet having any suitable shape.
D-1.ワークの形成
図3は、本発明の実施形態による製造方法における樹脂シート(ここでは、粘着剤層付偏光板)の端面加工の概要を説明するための概略斜視図である。本図にワークWが示されている。図3に示すように、粘着剤層付偏光板を複数枚重ねることにより、ワークWが形成される。粘着剤層付偏光板は、ワーク形成に際し、代表的には原反ロールから任意の適切なサイズおよび形状に切断されている。具体的には、粘着剤層付偏光板は矩形形状に切断されていてもよく、矩形形状に類似する形状に切断されていてもよく、目的に応じた適切な形状(例えば、円形)に切断されていてもよい。図示例では、粘着剤層付偏光板は矩形形状に切断されており、ワークWは、互いに対向する外周面(切削面)1a、1bおよびそれらと直交する外周面(切削面)1c、1dを有している。切断は、任意の適切な手段により行われる。切断手段の具体例としては、打ち抜き刃(例えば、トムソン刃)による打ち抜き、レーザー照射が挙げられる。1つの実施形態においては、粘着剤層付偏光板の粘着剤層表面にははく離ライナーが仮着されていてもよく、および/または、粘着剤層付偏光板の粘着剤層と反対側の表面には表面保護フィルムが仮着されていてもよい。 D-1. Formation of Workpiece FIG. 3 is a schematic perspective view for explaining the outline of end face processing of a resin sheet (here, a polarizing plate with an adhesive layer) in a manufacturing method according to an embodiment of the present invention. A workpiece W is shown in this figure. As shown in FIG. 3, a workpiece W is formed by stacking a plurality of polarizing plates with adhesive layers. When forming a workpiece, a polarizing plate with an adhesive layer is typically cut from a raw roll into any appropriate size and shape. Specifically, the polarizing plate with an adhesive layer may be cut into a rectangular shape, a shape similar to a rectangular shape, or an appropriate shape (for example, circular) depending on the purpose. may have been done. In the illustrated example, the polarizing plate with an adhesive layer is cut into a rectangular shape, and the workpiece W has outer circumferential surfaces (cut surfaces) 1a and 1b facing each other and outer circumferential surfaces (cut surfaces) 1c and 1d perpendicular thereto. have. Cutting is performed by any suitable means. Specific examples of the cutting means include punching with a punching blade (eg, Thomson blade) and laser irradiation. In one embodiment, a release liner may be temporarily attached to the surface of the adhesive layer of the polarizing plate with an adhesive layer, and/or a release liner may be temporarily attached to the surface of the polarizing plate with an adhesive layer opposite to the adhesive layer. A surface protection film may be temporarily attached to the surface.
図3は、本発明の実施形態による製造方法における樹脂シート(ここでは、粘着剤層付偏光板)の端面加工の概要を説明するための概略斜視図である。本図にワークWが示されている。図3に示すように、粘着剤層付偏光板を複数枚重ねることにより、ワークWが形成される。粘着剤層付偏光板は、ワーク形成に際し、代表的には原反ロールから任意の適切なサイズおよび形状に切断されている。具体的には、粘着剤層付偏光板は矩形形状に切断されていてもよく、矩形形状に類似する形状に切断されていてもよく、目的に応じた適切な形状(例えば、円形)に切断されていてもよい。図示例では、粘着剤層付偏光板は矩形形状に切断されており、ワークWは、互いに対向する外周面(切削面)1a、1bおよびそれらと直交する外周面(切削面)1c、1dを有している。切断は、任意の適切な手段により行われる。切断手段の具体例としては、打ち抜き刃(例えば、トムソン刃)による打ち抜き、レーザー照射が挙げられる。1つの実施形態においては、粘着剤層付偏光板の粘着剤層表面にははく離ライナーが仮着されていてもよく、および/または、粘着剤層付偏光板の粘着剤層と反対側の表面には表面保護フィルムが仮着されていてもよい。 D-1. Formation of Workpiece FIG. 3 is a schematic perspective view for explaining the outline of end face processing of a resin sheet (here, a polarizing plate with an adhesive layer) in a manufacturing method according to an embodiment of the present invention. A workpiece W is shown in this figure. As shown in FIG. 3, a workpiece W is formed by stacking a plurality of polarizing plates with adhesive layers. When forming a workpiece, a polarizing plate with an adhesive layer is typically cut from a raw roll into any appropriate size and shape. Specifically, the polarizing plate with an adhesive layer may be cut into a rectangular shape, a shape similar to a rectangular shape, or an appropriate shape (for example, circular) depending on the purpose. may have been done. In the illustrated example, the polarizing plate with an adhesive layer is cut into a rectangular shape, and the workpiece W has outer circumferential surfaces (cut surfaces) 1a and 1b facing each other and outer circumferential surfaces (cut surfaces) 1c and 1d perpendicular thereto. have. Cutting is performed by any suitable means. Specific examples of the cutting means include punching with a punching blade (eg, Thomson blade) and laser irradiation. In one embodiment, a release liner may be temporarily attached to the surface of the adhesive layer of the polarizing plate with an adhesive layer, and/or a release liner may be temporarily attached to the surface of the polarizing plate with an adhesive layer opposite to the adhesive layer. A surface protection film may be temporarily attached to the surface.
ワークの総厚みは、例えば5mm以上であり、好ましくは10mm以上であり、より好ましくは15mm以上であり、さらに好ましくは20mm以上であり、特に好ましくは30mm以上である。本発明の実施形態によれば、切削時にエンドミルに超音波振動を付与することにより(詳細は後述)、分厚いワークであっても不具合なく(代表的には、カッターマークを抑制して)端面加工を行うことができる。その結果、樹脂シート(ここでは、粘着剤層付偏光板)を高効率でかつ簡便に製造することができる。一方で、ワークの総厚みは、好ましくは150mm以下であり、より好ましくは100mm以下である。ワークの総厚みの上限は、主として工作機械の構成上の制約に起因し得る。
The total thickness of the workpiece is, for example, 5 mm or more, preferably 10 mm or more, more preferably 15 mm or more, still more preferably 20 mm or more, and particularly preferably 30 mm or more. According to an embodiment of the present invention, by applying ultrasonic vibration to the end mill during cutting (details will be described later), even thick workpieces can be machined without problems (typically, cutter marks are suppressed). It can be performed. As a result, a resin sheet (here, a polarizing plate with an adhesive layer) can be manufactured easily and with high efficiency. On the other hand, the total thickness of the workpiece is preferably 150 mm or less, more preferably 100 mm or less. The upper limit of the total thickness of the workpiece may be mainly due to constraints on the configuration of the machine tool.
ワークWは、好ましくは、クランプ手段(図示せず)により上下からクランプされている。クランプ手段(例えば、治具)は、軟質材料で構成されてもよく硬質材料で構成されてもよい。軟質材料で構成される場合、その硬度(JIS A)は、好ましくは60°~80°である。硬度が高すぎると、クランプ手段による押し跡が残る場合がある。硬度が低すぎると、治具の変形により位置ずれが生じ、切削精度が不十分となる場合がある。
The workpiece W is preferably clamped from above and below by clamping means (not shown). The clamping means (e.g. jig) may be constructed of soft or hard material. When it is made of a soft material, its hardness (JIS A) is preferably 60° to 80°. If the hardness is too high, pressure marks caused by the clamping means may remain. If the hardness is too low, positional deviation may occur due to deformation of the jig, resulting in insufficient cutting accuracy.
D-2.端面加工
本発明の実施形態においては、切削(端面加工)は、エンドミルを用いて当該エンドミルの上下方向に超音波振動を付与しながら行われる。具体的には、エンドミル20は、工作機械(図示せず)に保持され、エンドミルの回転軸まわりに高速回転されて、回転軸に交差する方向に送り出されながら切削刃をワークWの外周面に当接させ切り込ませて用いられる。すなわち、切削は、代表的には、エンドミルの切削刃をワークWの外周面に当接させ切り込ませることにより行われる。その際に、エンドミルの上下方向(回転軸に平行な方向)に超音波振動が付与される。言い換えれば、エンドミルは、超音波の周波数で上下方向に振動しながら回転軸まわりに高速回転されて、切削に用いられる。 D-2. End Face Processing In the embodiment of the present invention, cutting (end face processing) is performed using an end mill while applying ultrasonic vibrations in the vertical direction of the end mill. Specifically, theend mill 20 is held by a machine tool (not shown), is rotated at high speed around the rotation axis of the end mill, and is fed out in a direction crossing the rotation axis, while cutting the cutting blade onto the outer peripheral surface of the workpiece W. It is used by making abutment and cutting. That is, cutting is typically performed by bringing a cutting blade of an end mill into contact with the outer circumferential surface of the workpiece W to make a cut. At this time, ultrasonic vibrations are applied to the end mill in the vertical direction (direction parallel to the rotation axis). In other words, the end mill is used for cutting by being rotated at high speed around the rotation axis while vibrating in the vertical direction at the ultrasonic frequency.
本発明の実施形態においては、切削(端面加工)は、エンドミルを用いて当該エンドミルの上下方向に超音波振動を付与しながら行われる。具体的には、エンドミル20は、工作機械(図示せず)に保持され、エンドミルの回転軸まわりに高速回転されて、回転軸に交差する方向に送り出されながら切削刃をワークWの外周面に当接させ切り込ませて用いられる。すなわち、切削は、代表的には、エンドミルの切削刃をワークWの外周面に当接させ切り込ませることにより行われる。その際に、エンドミルの上下方向(回転軸に平行な方向)に超音波振動が付与される。言い換えれば、エンドミルは、超音波の周波数で上下方向に振動しながら回転軸まわりに高速回転されて、切削に用いられる。 D-2. End Face Processing In the embodiment of the present invention, cutting (end face processing) is performed using an end mill while applying ultrasonic vibrations in the vertical direction of the end mill. Specifically, the
エンドミルによる切削(端面加工)は、ワークWの外周面全体に対して行ってもよく、外周面の所定の位置に対して行ってもよい。エンドミルによる切削が外周面の所定の位置に対して行われる場合、エンドミルにより切削されなかった部分は、切削されなくてもよく、他の切削手段(例えば、回転砥石等のやすり刃、両頭フライス)により切削されてもよい。好ましくは、エンドミルによる切削(端面加工)は、ワークの外周面全体に対して行われる。好ましくは、エンドミルによる切削全体にわたって、エンドミルに超音波振動が付与される。
Cutting (end face processing) with an end mill may be performed on the entire outer circumferential surface of the workpiece W, or may be performed on a predetermined position on the outer circumferential surface. When cutting with an end mill is performed on a predetermined position on the outer circumferential surface, the portion not cut with the end mill does not need to be cut, and other cutting means (for example, a file blade such as a rotary grindstone, a double-headed milling cutter) are used. It may be cut by. Preferably, cutting (end face processing) with an end mill is performed on the entire outer circumferential surface of the workpiece. Preferably, ultrasonic vibrations are applied to the end mill throughout cutting by the end mill.
エンドミルによる切削(端面加工)は、目的に応じた任意の適切な様式で行われる。例えば、外周面に沿って一筆書きの要領で切削してもよく;対向する一対の外周面を切削した後、対向するもう一対の外周面を切削してもよい。エンドミルによるワーク外周面の切削回数は、1回削り、2回削り、3回削りまたはそれ以上であり得る。
Cutting (end face processing) with an end mill is performed in any appropriate manner depending on the purpose. For example, cutting may be performed in a single stroke along the outer circumferential surface; after cutting a pair of opposing outer circumferential surfaces, another pair of opposing outer circumferential surfaces may be cut. The number of times the end mill cuts the outer peripheral surface of the workpiece may be one time, two times, three times, or more.
本発明の実施形態においては、上記のように、エンドミルによる切削は、エンドミルの上下方向(回転軸に平行な方向)に超音波振動を付与しながら行われる。超音波振動を付与しながら切削を行うことにより、分厚いワークであってもカッターマークを抑制することができる。その結果、切削端面の表面粗さを小さくすることができる。これに伴い、樹脂シートが積層体である場合に層間はがれ(デラミネーション)を顕著に抑制することができる。また、樹脂シートが光学フィルム(特に、偏光子)を含む場合にクラックを顕著に抑制することができる。さらに、樹脂シートが粘着剤層および/または接着剤層を含む場合に糊欠けおよび刃汚れを顕著に抑制することができる。なお、糊欠けとは、粘着剤層または接着剤層の端部が欠落する現象をいい;刃汚れとは、切削刃に粘着剤層の粘着剤または接着剤層の接着剤が付着して切削性能(加工性能)が許容範囲を超えて低下する現象をいう。
In the embodiment of the present invention, as described above, cutting with the end mill is performed while applying ultrasonic vibration in the vertical direction of the end mill (direction parallel to the rotation axis). By performing cutting while applying ultrasonic vibration, cutter marks can be suppressed even on thick workpieces. As a result, the surface roughness of the cut end surface can be reduced. Accordingly, when the resin sheet is a laminate, interlayer peeling (delamination) can be significantly suppressed. Moreover, when the resin sheet includes an optical film (particularly a polarizer), cracks can be significantly suppressed. Furthermore, when the resin sheet includes a pressure-sensitive adhesive layer and/or an adhesive layer, adhesive chipping and blade staining can be significantly suppressed. In addition, adhesive chipping refers to the phenomenon in which the adhesive layer or the edge of the adhesive layer is missing; blade staining refers to the phenomenon in which the adhesive in the adhesive layer or the adhesive in the adhesive layer adheres to the cutting blade, causing cutting. A phenomenon in which performance (processing performance) deteriorates beyond the allowable range.
エンドミルに超音波振動を付与する方式としては、任意の適切な方式が採用され得る。1つの実施形態においては、いわゆる超音波スピンドルにエンドミルを取り付けることにより、エンドミルに超音波振動を付与することができる。超音波スピンドルは硬質材料(代表的には、セラミックス、サファイア、石英ガラス)の切削工具として周知であるところ、本発明者らは、この切削技術を非常に薄く柔らかい樹脂シート(特に、偏光子等の光学フィルム)に適用することにより、上記のような優れた効果が得られることを見出した。すなわち、本発明の実施形態により得られる効果は、予期せぬ優れた効果である。
Any suitable method may be adopted as a method for applying ultrasonic vibration to the end mill. In one embodiment, ultrasonic vibrations can be applied to the end mill by attaching the end mill to a so-called ultrasonic spindle. Ultrasonic spindles are well known as cutting tools for hard materials (typically ceramics, sapphire, and quartz glass), but the present inventors have applied this cutting technology to very thin and soft resin sheets (especially polarizers, etc.). It has been found that the above-mentioned excellent effects can be obtained by applying the present invention to an optical film (optical film). That is, the effects obtained by the embodiments of the present invention are unexpectedly excellent effects.
エンドミルに付与される超音波振動の振動数(周波数)は、好ましくは30kHz~50kHzであり、より好ましくは32kHz~48kHzであり、さらに好ましくは34kHz~46kHzであり、特に好ましくは36kHz~44kHzであり、とりわけ好ましくは38kHz~42kHzである。当該振動数がこのような範囲であれば、樹脂シートが光学フィルム(特に、偏光子)と粘着剤層および/または接着剤層とを含む場合に、層間はがれ(デラミネーション)、クラック、糊欠けおよび刃汚れをさらに良好に抑制することができる。
The frequency (frequency) of the ultrasonic vibration applied to the end mill is preferably 30 kHz to 50 kHz, more preferably 32 kHz to 48 kHz, still more preferably 34 kHz to 46 kHz, particularly preferably 36 kHz to 44 kHz. , particularly preferably from 38 kHz to 42 kHz. If the frequency is in this range, interlayer peeling (delamination), cracks, and adhesive chipping may occur when the resin sheet includes an optical film (particularly a polarizer) and an adhesive layer and/or an adhesive layer. And blade fouling can be suppressed even better.
エンドミルに付与される超音波振動の振幅は、好ましくは0.5μm~30μmであり、より好ましくは1μm~20μmであり、さらに好ましくは3μm~15μmであり、特に好ましくは5μm~10μmである。当該振幅がこのような範囲であれば、樹脂シートが光学フィルム(特に、偏光子)と粘着剤層および/または接着剤層とを含む場合に、層間はがれ(デラミネーション)、クラック、糊欠けおよび刃汚れをさらに良好に抑制することができる。
The amplitude of the ultrasonic vibration applied to the end mill is preferably 0.5 μm to 30 μm, more preferably 1 μm to 20 μm, even more preferably 3 μm to 15 μm, and particularly preferably 5 μm to 10 μm. If the amplitude is within this range, interlayer peeling (delamination), cracks, adhesive chipping, and Blade staining can be suppressed even better.
エンドミルによる端面加工の条件は、樹脂シートの種類、所望の形状等に応じて適切に設定され得る。例えば、エンドミルの回転速度(回転数)は、好ましくは100rpm~50,000rpmであり、より好ましくは200rpm~40,000rpmであり、さらに好ましくは300rpm~30,000rpmである。また例えば、エンドミルの送り速度は、好ましくは10mm/分~5,000mm/分であり、より好ましくは20mm/分~3,000mm/分であり、さらに好ましくは25mm/分~1000mm/分である。エンドミルの回転速度および送り速度がこのような範囲であれば、上記の超音波振動を付与することによる効果との相乗的な効果により、分厚いワークであっても不具合なく(代表的には、カッターマークを抑制して)端面加工を行うことができる。
The conditions for end face processing using an end mill can be appropriately set depending on the type of resin sheet, desired shape, etc. For example, the rotational speed (number of rotations) of the end mill is preferably 100 rpm to 50,000 rpm, more preferably 200 rpm to 40,000 rpm, and still more preferably 300 rpm to 30,000 rpm. For example, the feed speed of the end mill is preferably 10 mm/min to 5,000 mm/min, more preferably 20 mm/min to 3,000 mm/min, and even more preferably 25 mm/min to 1000 mm/min. . If the rotational speed and feed rate of the end mill are within this range, the synergistic effect with the effect of applying ultrasonic vibration as described above will allow even thick workpieces to be processed without any problems (typically, the cutter It is possible to perform end face processing (while suppressing marks).
エンドミルは、上記のとおり、工作機械に片持ち状態で保持されてもよく、両持ち状態で保持されてもよい。エンドミルへの超音波振動の付与を考慮すると、片持ち状態で保持することが好ましい。
As mentioned above, the end mill may be held on the machine tool in a cantilevered state, or may be held in a both-end supported state. Considering the application of ultrasonic vibration to the end mill, it is preferable to hold it in a cantilevered state.
本発明の実施形態の製造方法により得られる樹脂シートの端面の表面粗さは、例えば算術平均高さSaを指標とすることができる。算術平均高さSaは、エンドミルの切削刃のねじれ角に依存して変化し得る。例えばねじれ角が30°である場合には、算術平均高さSaは、好ましくは0.30μm~0.65μmであり、より好ましくは0.35μm~0.55μmである。例えばねじれ角が50°である場合には、算術平均高さSaは、好ましくは0.30μm~1.00μmであり、より好ましくは0.40μm~0.80μmである。ねじれ角によらず、ワーク中央部および下部(厚み方向に3分割したときの中央の部分および一番下の部分)に含まれる樹脂シートの算術平均高さSaは、超音波振動を付与しない場合に得られる算術平均高さSaを1.00としたとき、好ましくは0.50~0.85であり、より好ましくは0.55~0.80である。なお、算術平均高さSaは、例えばISO 25178に準じて測定され得る。
The surface roughness of the end face of the resin sheet obtained by the manufacturing method of the embodiment of the present invention can be expressed using, for example, the arithmetic mean height Sa. The arithmetic mean height Sa may vary depending on the helix angle of the cutting blade of the end mill. For example, when the twist angle is 30°, the arithmetic mean height Sa is preferably 0.30 μm to 0.65 μm, more preferably 0.35 μm to 0.55 μm. For example, when the twist angle is 50°, the arithmetic mean height Sa is preferably 0.30 μm to 1.00 μm, more preferably 0.40 μm to 0.80 μm. Regardless of the torsion angle, the arithmetic mean height Sa of the resin sheet included in the center and lower part of the workpiece (the middle part and the bottom part when divided into three parts in the thickness direction) is the same when no ultrasonic vibration is applied. When the arithmetic mean height Sa obtained is 1.00, it is preferably 0.50 to 0.85, more preferably 0.55 to 0.80. Note that the arithmetic mean height Sa may be measured according to ISO 25178, for example.
以下、実施例により本発明を具体的に説明するが、本発明はこれらの実施例には限定されない。実施例における評価項目は以下のとおりである。
Hereinafter, the present invention will be specifically explained with reference to Examples, but the present invention is not limited to these Examples. Evaluation items in Examples are as follows.
(1)算術平均高さSa
実施例および比較例で得られた粘着剤層付偏光板の外周端面の表面粗さについて、ISO 25178に準じて算術平均高さSaを測定した。 (1) Arithmetic mean height Sa
Regarding the surface roughness of the outer peripheral end face of the adhesive layer-attached polarizing plates obtained in Examples and Comparative Examples, the arithmetic mean height Sa was measured according to ISO 25178.
実施例および比較例で得られた粘着剤層付偏光板の外周端面の表面粗さについて、ISO 25178に準じて算術平均高さSaを測定した。 (1) Arithmetic mean height Sa
Regarding the surface roughness of the outer peripheral end face of the adhesive layer-attached polarizing plates obtained in Examples and Comparative Examples, the arithmetic mean height Sa was measured according to ISO 25178.
(2)層間はがれ
実施例および比較例で得られた粘着剤層付偏光板における各層の剥がれの発生状態を光学顕微鏡(倍率10倍)により観察し、各層の剥がれの大きさ(μm)の評価を行った。結果を表1に示す。 (2) Peeling between layers The state of peeling of each layer in the polarizing plates with adhesive layers obtained in Examples and Comparative Examples was observed using an optical microscope (10x magnification), and the size (μm) of peeling of each layer was evaluated. I did it. The results are shown in Table 1.
実施例および比較例で得られた粘着剤層付偏光板における各層の剥がれの発生状態を光学顕微鏡(倍率10倍)により観察し、各層の剥がれの大きさ(μm)の評価を行った。結果を表1に示す。 (2) Peeling between layers The state of peeling of each layer in the polarizing plates with adhesive layers obtained in Examples and Comparative Examples was observed using an optical microscope (10x magnification), and the size (μm) of peeling of each layer was evaluated. I did it. The results are shown in Table 1.
(3)クラック
実施例および比較例で得られた粘着剤層付偏光板を、粘着剤層を介してガラス板(厚み1.1mm)に貼り付け、試験サンプルとした。この試験サンプルのクラックの発生状態を光学顕微鏡(倍率10倍)により観察し、クラックの長さ(μm)の評価を行った。結果を表1に示す。 (3) Cracks The adhesive layer-attached polarizing plates obtained in Examples and Comparative Examples were attached to a glass plate (thickness: 1.1 mm) via the adhesive layer to form test samples. The state of crack occurrence in this test sample was observed using an optical microscope (10x magnification), and the length (μm) of the crack was evaluated. The results are shown in Table 1.
実施例および比較例で得られた粘着剤層付偏光板を、粘着剤層を介してガラス板(厚み1.1mm)に貼り付け、試験サンプルとした。この試験サンプルのクラックの発生状態を光学顕微鏡(倍率10倍)により観察し、クラックの長さ(μm)の評価を行った。結果を表1に示す。 (3) Cracks The adhesive layer-attached polarizing plates obtained in Examples and Comparative Examples were attached to a glass plate (thickness: 1.1 mm) via the adhesive layer to form test samples. The state of crack occurrence in this test sample was observed using an optical microscope (10x magnification), and the length (μm) of the crack was evaluated. The results are shown in Table 1.
(4)糊欠け
実施例および比較例で得られた粘着剤層付偏光板における粘着剤層の粘着剤の糊欠け(粘着剤層の欠落)の発生状態を光学顕微鏡(倍率10倍)により観察し、糊欠けの大きさ(μm)の評価を行った。結果を表1に示す。 (4) Adhesive chipping The occurrence of adhesive chipping (missing of the adhesive layer) in the adhesive layer of the adhesive layer-attached polarizing plate obtained in the Examples and Comparative Examples was observed using an optical microscope (10x magnification). Then, the size (μm) of adhesive chipping was evaluated. The results are shown in Table 1.
実施例および比較例で得られた粘着剤層付偏光板における粘着剤層の粘着剤の糊欠け(粘着剤層の欠落)の発生状態を光学顕微鏡(倍率10倍)により観察し、糊欠けの大きさ(μm)の評価を行った。結果を表1に示す。 (4) Adhesive chipping The occurrence of adhesive chipping (missing of the adhesive layer) in the adhesive layer of the adhesive layer-attached polarizing plate obtained in the Examples and Comparative Examples was observed using an optical microscope (10x magnification). Then, the size (μm) of adhesive chipping was evaluated. The results are shown in Table 1.
(5)カッターマーク
実施例および比較例で得られた粘着剤層付偏光板の端面の状態をレーザー顕微鏡(倍率20倍)で観察した。端面の観察は、ワークの上部、中央部および下部の3つの領域の粘着剤層付偏光板について行った。なお、上部はワークを厚み方向に3分割したときの一番上の部分であり、中央部は上から2番目の部分であり、下部は一番下の部分である。 (5) Cutter mark The state of the end face of the adhesive layer-attached polarizing plate obtained in the Examples and Comparative Examples was observed using a laser microscope (20x magnification). The end faces of the polarizing plate with the adhesive layer were observed in three areas: the upper part, the center part, and the lower part of the workpiece. Note that the upper part is the top part when the workpiece is divided into three parts in the thickness direction, the center part is the second part from the top, and the lower part is the bottom part.
実施例および比較例で得られた粘着剤層付偏光板の端面の状態をレーザー顕微鏡(倍率20倍)で観察した。端面の観察は、ワークの上部、中央部および下部の3つの領域の粘着剤層付偏光板について行った。なお、上部はワークを厚み方向に3分割したときの一番上の部分であり、中央部は上から2番目の部分であり、下部は一番下の部分である。 (5) Cutter mark The state of the end face of the adhesive layer-attached polarizing plate obtained in the Examples and Comparative Examples was observed using a laser microscope (20x magnification). The end faces of the polarizing plate with the adhesive layer were observed in three areas: the upper part, the center part, and the lower part of the workpiece. Note that the upper part is the top part when the workpiece is divided into three parts in the thickness direction, the center part is the second part from the top, and the lower part is the bottom part.
<実施例1>
常法により、視認側から順に表面保護フィルム(60μm)/シクロオレフィン系保護フィルム(47μm)/偏光子(5μm)/シクロオレフィン系保護フィルム(24μm)/粘着剤層(20μm)/はく離ライナーの構成を有する粘着剤層付偏光板を作製した。なお、表面保護フィルムとしては、PET基材(50μm)/粘着剤層(10μm)の構成を有する表面保護フィルムを用いた。この粘着剤層付偏光板を5.7インチサイズ(縦140mmおよび横65mm程度)に打ち抜いた。ここで、偏光子の吸収軸方向は横方向(短辺方向)となるように打ち抜きを行った。打ち抜いた粘着剤層付偏光板を複数枚重ねてワークとした。ワークの総厚みは16mmであった。得られたワークをクランプ(治具)で挟んだ状態で、エンドミルにより端面加工を行った。エンドミルの外径は2mm、刃数は2枚、ねじれ角は30°であった。端面加工は、ワークの外周全体を一筆書きの要領で、粗加工および仕上げ加工の2回の加工を行った。粗加工および仕上げ加工のいずれにおいても、エンドミルに超音波振動を付与しながら切削を行った。超音波振動の振動数は39kHz、振幅は5μmであった。粗加工の削り量は0.05mmであり、仕上げ加工の削り量は0.005mmであった。さらに、粗加工および仕上げ加工のいずれにおいても、エンドミルの送り速度は50mm/分、回転数は2,500rpmであった。得られた粘着剤層付偏光板について、上記(1)~(5)の評価を行った。(1)~(4)の結果を表1に、(5)の結果(SEM画像)を図4に示す。 <Example 1>
By a conventional method, the composition of the surface protection film (60 μm) / cycloolefin protective film (47 μm) / polarizer (5 μm) / cycloolefin protective film (24 μm) / adhesive layer (20 μm) / release liner in order from the viewing side. A polarizing plate with an adhesive layer was produced. In addition, as the surface protection film, a surface protection film having a structure of PET base material (50 μm)/adhesive layer (10 μm) was used. This adhesive layer-attached polarizing plate was punched out to a size of 5.7 inches (approximately 140 mm in length and 65 mm in width). Here, punching was performed so that the absorption axis direction of the polarizer was in the horizontal direction (short side direction). A workpiece was made by stacking several punched polarizing plates with adhesive layers. The total thickness of the workpiece was 16 mm. While the obtained workpiece was held between clamps (jigs), end face processing was performed using an end mill. The end mill had an outer diameter of 2 mm, a number of blades of 2, and a helix angle of 30°. For edge processing, the entire outer periphery of the workpiece was processed in a single stroke, and the processing was performed twice: rough processing and finishing processing. In both rough machining and finishing machining, cutting was performed while applying ultrasonic vibration to the end mill. The frequency of the ultrasonic vibration was 39 kHz, and the amplitude was 5 μm. The amount of scraping in the rough machining was 0.05 mm, and the amount of scraping in the finishing machining was 0.005 mm. Furthermore, in both rough machining and finishing machining, the feed rate of the end mill was 50 mm/min, and the rotation speed was 2,500 rpm. The obtained polarizing plate with an adhesive layer was evaluated as described in (1) to (5) above. The results of (1) to (4) are shown in Table 1, and the results of (5) (SEM image) are shown in FIG.
常法により、視認側から順に表面保護フィルム(60μm)/シクロオレフィン系保護フィルム(47μm)/偏光子(5μm)/シクロオレフィン系保護フィルム(24μm)/粘着剤層(20μm)/はく離ライナーの構成を有する粘着剤層付偏光板を作製した。なお、表面保護フィルムとしては、PET基材(50μm)/粘着剤層(10μm)の構成を有する表面保護フィルムを用いた。この粘着剤層付偏光板を5.7インチサイズ(縦140mmおよび横65mm程度)に打ち抜いた。ここで、偏光子の吸収軸方向は横方向(短辺方向)となるように打ち抜きを行った。打ち抜いた粘着剤層付偏光板を複数枚重ねてワークとした。ワークの総厚みは16mmであった。得られたワークをクランプ(治具)で挟んだ状態で、エンドミルにより端面加工を行った。エンドミルの外径は2mm、刃数は2枚、ねじれ角は30°であった。端面加工は、ワークの外周全体を一筆書きの要領で、粗加工および仕上げ加工の2回の加工を行った。粗加工および仕上げ加工のいずれにおいても、エンドミルに超音波振動を付与しながら切削を行った。超音波振動の振動数は39kHz、振幅は5μmであった。粗加工の削り量は0.05mmであり、仕上げ加工の削り量は0.005mmであった。さらに、粗加工および仕上げ加工のいずれにおいても、エンドミルの送り速度は50mm/分、回転数は2,500rpmであった。得られた粘着剤層付偏光板について、上記(1)~(5)の評価を行った。(1)~(4)の結果を表1に、(5)の結果(SEM画像)を図4に示す。 <Example 1>
By a conventional method, the composition of the surface protection film (60 μm) / cycloolefin protective film (47 μm) / polarizer (5 μm) / cycloolefin protective film (24 μm) / adhesive layer (20 μm) / release liner in order from the viewing side. A polarizing plate with an adhesive layer was produced. In addition, as the surface protection film, a surface protection film having a structure of PET base material (50 μm)/adhesive layer (10 μm) was used. This adhesive layer-attached polarizing plate was punched out to a size of 5.7 inches (approximately 140 mm in length and 65 mm in width). Here, punching was performed so that the absorption axis direction of the polarizer was in the horizontal direction (short side direction). A workpiece was made by stacking several punched polarizing plates with adhesive layers. The total thickness of the workpiece was 16 mm. While the obtained workpiece was held between clamps (jigs), end face processing was performed using an end mill. The end mill had an outer diameter of 2 mm, a number of blades of 2, and a helix angle of 30°. For edge processing, the entire outer periphery of the workpiece was processed in a single stroke, and the processing was performed twice: rough processing and finishing processing. In both rough machining and finishing machining, cutting was performed while applying ultrasonic vibration to the end mill. The frequency of the ultrasonic vibration was 39 kHz, and the amplitude was 5 μm. The amount of scraping in the rough machining was 0.05 mm, and the amount of scraping in the finishing machining was 0.005 mm. Furthermore, in both rough machining and finishing machining, the feed rate of the end mill was 50 mm/min, and the rotation speed was 2,500 rpm. The obtained polarizing plate with an adhesive layer was evaluated as described in (1) to (5) above. The results of (1) to (4) are shown in Table 1, and the results of (5) (SEM image) are shown in FIG.
<比較例1>
超音波振動を付与することなくエンドミルによる切削(端面加工)を行ったこと以外は実施例1と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例1と同様の評価を行った。結果を表1および図4に示す。 <Comparative example 1>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 4.
超音波振動を付与することなくエンドミルによる切削(端面加工)を行ったこと以外は実施例1と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例1と同様の評価を行った。結果を表1および図4に示す。 <Comparative example 1>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 4.
<実施例2>
エンドミルの切削刃のねじれ角を40°としたこと以外は実施例1と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について上記(2)~(4)の評価を行った。の評価を行った。結果を表1に示す。 <Example 2>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1 except that the helix angle of the cutting blade of the end mill was 40°. The obtained polarizing plate with an adhesive layer was evaluated as described in (2) to (4) above. was evaluated. The results are shown in Table 1.
エンドミルの切削刃のねじれ角を40°としたこと以外は実施例1と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について上記(2)~(4)の評価を行った。の評価を行った。結果を表1に示す。 <Example 2>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1 except that the helix angle of the cutting blade of the end mill was 40°. The obtained polarizing plate with an adhesive layer was evaluated as described in (2) to (4) above. was evaluated. The results are shown in Table 1.
<比較例2>
超音波振動を付与することなくエンドミルによる切削(端面加工)を行ったこと以外は実施例2と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例2と同様の評価を行った。結果を表1に示す。 <Comparative example 2>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 2, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 2. The results are shown in Table 1.
超音波振動を付与することなくエンドミルによる切削(端面加工)を行ったこと以外は実施例2と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例2と同様の評価を行った。結果を表1に示す。 <Comparative example 2>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 2, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 2. The results are shown in Table 1.
<実施例3>
エンドミルの切削刃のねじれ角を50°としたこと以外は実施例1と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例1と同様の評価を行った。結果を表1および図5に示す。 <Example 3>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1 except that the helix angle of the cutting blade of the end mill was 50°. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 5.
エンドミルの切削刃のねじれ角を50°としたこと以外は実施例1と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例1と同様の評価を行った。結果を表1および図5に示す。 <Example 3>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 1 except that the helix angle of the cutting blade of the end mill was 50°. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 5.
<比較例3>
超音波振動を付与することなくエンドミルによる切削(端面加工)を行ったこと以外は実施例3と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例1と同様の評価を行った。結果を表1および図5に示す。 <Comparative example 3>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 3, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 5.
超音波振動を付与することなくエンドミルによる切削(端面加工)を行ったこと以外は実施例3と同様にして、粘着剤層付偏光板を得た。得られた粘着剤層付偏光板について、実施例1と同様の評価を行った。結果を表1および図5に示す。 <Comparative example 3>
A polarizing plate with an adhesive layer was obtained in the same manner as in Example 3, except that cutting with an end mill (end face processing) was performed without applying ultrasonic vibration. The obtained polarizing plate with an adhesive layer was evaluated in the same manner as in Example 1. The results are shown in Table 1 and FIG. 5.
<評価>
表1ならびに図4および図5から明らかなように、本発明の実施例によれば、分厚いワークであってもカッターマークを抑制して切削でき、その結果、切削端面の表面粗さを小さくすることができることがわかる。特に、ワークの中央部および下部においてその効果が顕著であることがわかる。さらに、本発明の実施例によれば、クラック、糊欠けおよび刃汚れが顕著に抑制されていることがわかる。 <Evaluation>
As is clear from Table 1 and FIGS. 4 and 5, according to the embodiment of the present invention, even thick workpieces can be cut while suppressing cutter marks, and as a result, the surface roughness of the cut end surface is reduced. It turns out that you can do it. It can be seen that the effect is particularly remarkable in the center and lower parts of the workpiece. Furthermore, according to the examples of the present invention, it can be seen that cracks, adhesive chips, and blade stains are significantly suppressed.
表1ならびに図4および図5から明らかなように、本発明の実施例によれば、分厚いワークであってもカッターマークを抑制して切削でき、その結果、切削端面の表面粗さを小さくすることができることがわかる。特に、ワークの中央部および下部においてその効果が顕著であることがわかる。さらに、本発明の実施例によれば、クラック、糊欠けおよび刃汚れが顕著に抑制されていることがわかる。 <Evaluation>
As is clear from Table 1 and FIGS. 4 and 5, according to the embodiment of the present invention, even thick workpieces can be cut while suppressing cutter marks, and as a result, the surface roughness of the cut end surface is reduced. It turns out that you can do it. It can be seen that the effect is particularly remarkable in the center and lower parts of the workpiece. Furthermore, according to the examples of the present invention, it can be seen that cracks, adhesive chips, and blade stains are significantly suppressed.
本発明の実施形態による製造方法により得られる樹脂シートは、広範囲な用途に用いられ得る。樹脂シートは例えば光学フィルムであり得る。
The resin sheet obtained by the manufacturing method according to the embodiment of the present invention can be used in a wide range of applications. The resin sheet can be, for example, an optical film.
W ワーク
20 エンドミル
21 回転軸
22 本体
23 切削刃
23a 刃先
23b すくい面
23c 逃がし面
W Work 20 End mill 21 Rotating shaft 22 Main body 23 Cutting blade 23a Cutting edge 23b Rake surface 23c Relief surface
20 エンドミル
21 回転軸
22 本体
23 切削刃
23a 刃先
23b すくい面
23c 逃がし面
Claims (9)
- 樹脂シートを複数枚重ねてワークを形成すること、および
該ワークの外周面をエンドミルで切削すること、を含み、
該エンドミルによる切削が、該エンドミルの上下方向に超音波振動を付与しながら行われる、
樹脂シートの製造方法。 Including stacking a plurality of resin sheets to form a workpiece, and cutting the outer peripheral surface of the workpiece with an end mill,
Cutting with the end mill is performed while applying ultrasonic vibrations in the vertical direction of the end mill.
Method for manufacturing resin sheets. - 前記超音波振動の振動数が30kHz~50kHzである、請求項1に記載の製造方法。 The manufacturing method according to claim 1, wherein the frequency of the ultrasonic vibration is 30 kHz to 50 kHz.
- 前記超音波振動の振幅が0.5μm~30μmである、請求項1または2に記載の製造方法。 The manufacturing method according to claim 1 or 2, wherein the amplitude of the ultrasonic vibration is 0.5 μm to 30 μm.
- 前記エンドミルのねじれ角が65°以下である、請求項1から3のいずれかに記載の製造方法。 The manufacturing method according to any one of claims 1 to 3, wherein the end mill has a helix angle of 65° or less.
- 前記ワークの厚みが5mm以上である、請求項1から4のいずれかに記載の製造方法。 The manufacturing method according to any one of claims 1 to 4, wherein the workpiece has a thickness of 5 mm or more.
- 前記樹脂シートが積層体である、請求項1から5のいずれかに記載の製造方法。 The manufacturing method according to any one of claims 1 to 5, wherein the resin sheet is a laminate.
- 前記樹脂シートが光学フィルムを含む、請求項6に記載の製造方法。 The manufacturing method according to claim 6, wherein the resin sheet includes an optical film.
- 前記光学フィルムが偏光子を含む、請求項7に記載の製造方法。 The manufacturing method according to claim 7, wherein the optical film includes a polarizer.
- 前記樹脂シートが接着剤層および/または粘着剤層を含む、請求項6から8のいずれかに記載の製造方法。
The manufacturing method according to any one of claims 6 to 8, wherein the resin sheet includes an adhesive layer and/or a pressure-sensitive adhesive layer.
Applications Claiming Priority (2)
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JP2022039606A JP2023134212A (en) | 2022-03-14 | 2022-03-14 | Method for manufacturing resin sheet |
JP2022-039606 | 2022-03-14 |
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WO2023176342A1 true WO2023176342A1 (en) | 2023-09-21 |
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PCT/JP2023/006408 WO2023176342A1 (en) | 2022-03-14 | 2023-02-22 | Production method for resin sheet |
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JP (1) | JP2023134212A (en) |
TW (1) | TW202335765A (en) |
WO (1) | WO2023176342A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH04129610A (en) * | 1990-09-20 | 1992-04-30 | Toyo Electric Mfg Co Ltd | Milling machine with ultrasonic vibration |
JP2009214286A (en) * | 2008-03-11 | 2009-09-24 | Fuji Kogyo Kk | Ultrasonic vibration machining unit device and working method for fiber-reinforced resin and the like using the same, large-sized boring machine and multi-articulated robot and working method for fiber-reinforced resin and the like using them |
JP2020134709A (en) * | 2019-02-20 | 2020-08-31 | 日東電工株式会社 | Method for manufacturing cut optical laminate having adhesive layer |
-
2022
- 2022-03-14 JP JP2022039606A patent/JP2023134212A/en active Pending
-
2023
- 2023-02-22 WO PCT/JP2023/006408 patent/WO2023176342A1/en unknown
- 2023-03-08 TW TW112108563A patent/TW202335765A/en unknown
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH04129610A (en) * | 1990-09-20 | 1992-04-30 | Toyo Electric Mfg Co Ltd | Milling machine with ultrasonic vibration |
JP2009214286A (en) * | 2008-03-11 | 2009-09-24 | Fuji Kogyo Kk | Ultrasonic vibration machining unit device and working method for fiber-reinforced resin and the like using the same, large-sized boring machine and multi-articulated robot and working method for fiber-reinforced resin and the like using them |
JP2020134709A (en) * | 2019-02-20 | 2020-08-31 | 日東電工株式会社 | Method for manufacturing cut optical laminate having adhesive layer |
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TW202335765A (en) | 2023-09-16 |
JP2023134212A (en) | 2023-09-27 |
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