CN111558741A - Method for producing optical film - Google Patents
Method for producing optical film Download PDFInfo
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- CN111558741A CN111558741A CN202010088117.5A CN202010088117A CN111558741A CN 111558741 A CN111558741 A CN 111558741A CN 202010088117 A CN202010088117 A CN 202010088117A CN 111558741 A CN111558741 A CN 111558741A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 238000005520 cutting process Methods 0.000 claims abstract description 160
- 238000003754 machining Methods 0.000 claims abstract description 36
- 230000002093 peripheral effect Effects 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 13
- 238000010030 laminating Methods 0.000 claims abstract description 5
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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
- B23C5/00—Milling-cutters
- B23C5/02—Milling-cutters characterised by the shape of the cutter
- B23C5/10—Shank-type cutters, i.e. with an integral shaft
- B23C5/1081—Shank-type cutters, i.e. with an integral shaft with permanently fixed cutting inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2210/00—Details of milling cutters
- B23C2210/04—Angles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C2220/00—Details of milling processes
- B23C2220/60—Roughing
- B23C2220/605—Roughing and finishing
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- Milling Processes (AREA)
- Polarising Elements (AREA)
Abstract
The invention provides a method for manufacturing an optical film cut by a plurality of times of end mill machining, and capable of easily judging whether finish machining exists. The method for manufacturing an optical film according to the present invention includes an end mill machining step of forming a workpiece by laminating a plurality of optical films and cutting an outer peripheral surface of the workpiece with an end mill, the end mill machining step including a rough machining step of roughly machining the outer peripheral surface of the workpiece with the end mill and a finish machining step of finishing the roughly machined outer peripheral surface of the workpiece with the end mill, the rough machining step including providing an uncut portion on the outer peripheral surface of the workpiece, the finish machining step including cutting the uncut portion.
Description
Technical Field
The present invention relates to a method for producing an optical film.
Background
In image display devices such as mobile phones and notebook personal computers, various optical films (for example, polarizing plates) are used to realize image display and/or to improve the performance of the image display. In recent years, it has been desired to use an optical laminate for instrument panels, smart watches, and the like of automobiles, and to shape the optical laminate into a desired shape. In such machining, an end face may be cut by an end mill. In this case, the machined surface is subjected to end mill machining several times so as to be rough-cut and then finish-machined.
In the end mill machining, it is assumed that there is a step error in which the product is regarded as a product without being finished after rough cutting and is shifted to the next step. It is difficult to determine whether or not finishing is performed in visual quality inspection, and if a predetermined inspection apparatus is introduced, the process becomes complicated, and it is disadvantageous in terms of cost.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open No. 2007-187781
Patent document 2: japanese patent laid-open publication No. 2018-022140
Disclosure of Invention
Problems to be solved by the invention
The present invention has been made to solve the above-described conventional problems, and a main object thereof is to provide a method for manufacturing an optical film cut by end mill machining several times, which can easily determine whether or not finish machining is performed.
Means for solving the problems
The method for manufacturing an optical film according to the present invention includes an end mill machining step of forming a workpiece by laminating a plurality of optical films and cutting an outer peripheral surface of the workpiece with an end mill, the end mill machining step including a rough machining step of roughly machining the outer peripheral surface of the workpiece with the end mill and a finish machining step of finishing the roughly machined outer peripheral surface of the workpiece with the end mill, the rough machining step including providing an uncut portion on the outer peripheral surface of the workpiece, the finish machining step including cutting the uncut portion.
In one embodiment, the method for manufacturing an optical film includes: in the roughing step, the end mill is brought into contact with the workpiece while being advanced in a direction inclined with respect to the workpiece in a plan view at the start of cutting, and the uncut portion is formed on the workpiece by setting a portion where cutting is started and a portion where cutting is ended to different positions.
In one embodiment, the method for manufacturing an optical film includes: in the roughing step, the end mill is moved away from the workpiece while moving the end mill in a direction inclined with respect to the workpiece in a plan view at the end of cutting.
Effects of the invention
According to the present invention, it is possible to provide a method for manufacturing an optical film cut by end mill machining several times, and to easily determine whether or not finish machining is performed.
Drawings
Fig. 1 is a schematic perspective view for explaining an example of the cutting process of the optical film of the present invention.
Fig. 2 is a schematic perspective view for explaining an example of an end mill used for cutting in the method for producing an optical film according to the present invention.
Fig. 3(a) is a schematic cross-sectional view when viewed from the axial direction for explaining another example of the cutting means used for the cutting process in the method for producing an optical film according to the present invention, and fig. 3(b) is a schematic perspective view of the cutting means of fig. 3 (a).
Fig. 4(a) to (c) are schematic partial plan views illustrating uncut parts of a work in the method for producing an optical film of the present invention.
Fig. 5(a) and 5(b) are schematic plan views illustrating a rough grinding step in the method for manufacturing an optical film according to an embodiment of the present invention.
Fig. 6(a) and 6(b) are schematic plan views illustrating a cutting process according to an embodiment of the present invention.
Fig. 7(a) and 7(b) are schematic plan views illustrating a cutting process according to an embodiment of the present invention.
Fig. 8 is a schematic plan view illustrating a workpiece according to an embodiment of the present invention.
Fig. 9(a) and 9(b) are schematic plan views illustrating a cutting process according to an embodiment of the present invention.
Fig. 10(a) and 10(b) are schematic plan views illustrating a cutting process according to an embodiment of the present invention.
Description of the reference symbols
1 … workpiece; 20 … end mill.
Detailed Description
Specific embodiments of the present invention will be described below with reference to the drawings, but the present invention is not limited to these embodiments. In addition, the drawings are schematically illustrated for easy observation, and the ratio of the length, width, thickness, and the like, and the angle and the like in the drawings are different from those in reality.
The method for producing an optical film by cutting according to the present invention includes a step of laminating a plurality of optical films to form a workpiece, and a step of end milling the outer peripheral surface of the workpiece by an end mill
< formation of workpiece >)
Fig. 1 is a schematic perspective view for explaining the cutting process, and shows a workpiece 1. As shown in fig. 1, a work 1 is formed by laminating a plurality of optical films. The optical film is typically cut into any suitable shape when the workpiece is formed. Specifically, the optical film may be cut into a rectangular shape, a shape similar to the rectangular shape, or an appropriate shape (for example, a circular shape) suitable for the purpose. In the illustrated example, the optical film is cut into a rectangular shape, and the work 1 has outer peripheral surfaces (cut surfaces) 1a and 1b facing each other and outer peripheral surfaces (cut surfaces) 1c and 1d orthogonal to them. Preferably, the workpiece 1 is clamped from above and below by a clamping unit (not shown). The total thickness of the workpiece is, for example, 8mm to 100mm, preferably 8mm to 50mm, more preferably 8mm to 20mm, still more preferably 9mm to 15mm, most preferably about 10 mm. With such a thickness, damage due to pressing of the clamp unit or impact during cutting can be prevented. Optical films are laminated to give the workpiece such a total thickness. The number of optical films constituting the work may be, for example, 10 to 500 (10 to 300 in one embodiment, 10 to 50 in another embodiment). The clamping unit (e.g., a jig) may be made of a soft material or a hard material. When the resin composition is made of a soft material, the hardness (JIS A) is preferably from 20 to 80 degrees, more preferably from 60 to 80 degrees, and the thickness is, for example, from 0.3mm to 5 mm. When the hardness is too high, an indentation by the clamp unit may remain. If the hardness is too low or too thick, displacement may occur due to deformation of the jig, and the cutting accuracy may be insufficient.
< end milling cutter working procedure >)
Then, in the end mill machining step, the outer peripheral surface of the workpiece 1 is cut by the end mill 20. The cutting is performed by bringing the cutting edge of the end mill into contact with the outer peripheral surface of the workpiece 1. The cutting may be performed over the entire outer peripheral surface of the workpiece, or may be performed only at a predetermined position. Further, in the workpiece having the hole, the cutting edge of the end mill may be brought into contact with the inner peripheral surface of the hole to cut the inner peripheral surface. As the end mill 20, a straight shank end mill (ストレートエンドミル) can be representatively used. In the cutting process, only the end mill may be moved, only the workpiece may be moved, or both the end mill and the workpiece may be moved.
As shown in fig. 2 and 3, the end mill 20 includes a rotation shaft 21 extending along the stacking direction (vertical direction) of the workpieces 1, and a cutting edge 22 having the outermost diameter of the main body configured to rotate about the rotation shaft 21. The cutting edge 22 may be formed to have an outermost diameter twisted along the rotation axis 21 (may have a predetermined twist angle) as shown in fig. 2, or may be formed to extend in a direction substantially parallel to the rotation axis 21 (the twist angle may be 0 °) as shown in fig. 3. "0 °" means substantially 0 °, and includes a case where the rotation is at a slight angle due to a machining error or the like. When the cutting edge has a predetermined twist angle, the twist angle is preferably 70 ° or less, more preferably 65 ° or less, and still more preferably 45 ° or less. The cutting edge 22 includes a cutting edge 22a, a cutting surface 22b, and a relief surface 22 c. The number of cutting edges 22 may be set as appropriate as long as a desired number of contacts, which will be described later, can be obtained. The number of blades in fig. 2 is 3, and the number of blades in fig. 3 is 2, but the number of blades may be 1, 4, or 5 or more. Preferably, the number of blades is 2. With this configuration, the rigidity of the blade is ensured, and the cutting scraps can be discharged satisfactorily by ensuring the dimples (ポケット). In one embodiment, an end mill with a twist angle of 0 ° is used.
In the end mill machining step, a rough machining step of roughly machining the outer peripheral surface of the workpiece with an end mill is performed, and the outer peripheral surface of the roughly machined workpiece is further finished with the end mill. The rough cutting step and the finish cutting step are performed to improve cutting accuracy, and in the rough cutting step, for example, the outer peripheral surface of the workpiece is cut with a thickness of 0.1mm to 0.5mm, and in the finish cutting step, for example, the outer peripheral surface of the workpiece after the rough cutting is cut with a thickness of 0.01mm to 0.2 mm. In the rough cutting step and the finish cutting step, the surface to be ground may be cut several times by an end mill.
< roughing step >
In the present invention, in the rough cutting step, an uncut portion is provided on the outer peripheral surface of the workpiece. Fig. 4(a) to (c) are schematic partial plan views illustrating uncut portions of the workpiece. The uncut portion 11 refers to a portion where cutting by the end mill is not performed. Typically, the uncut portion 11 is formed as a convex portion formed on the outer peripheral surface of the workpiece 1 as shown in fig. 4(a) to (c).
The uncut portion is cut by a finishing process as a subsequent step. According to the present invention, by providing an uncut portion in the rough cutting step, it is possible to easily determine whether or not the workpiece is a finished product (or semi-finished product) based on the presence or absence of the uncut portion. That is, the workpiece or the optical film having no uncut portion can be judged as a normal product obtained by the finish machining, and the workpiece or the optical film having an uncut portion can be judged as a defective product not subjected to the finish machining or a semi-finished product to be subjected to the finish machining.
The shape of the uncut portion 11 can be dictated by the path of travel of the end mill. In one embodiment, the uncut portion is formed by setting a portion where cutting starts and a portion where cutting ends to different positions on the workpiece. More specifically, as shown in a travel trajectory t of the end mill shown in fig. 5(a), cutting by the end mill is started, and the end mill is caused to travel so as to finish cutting before reaching a cutting start point a and retreat from the workpiece, thereby forming an uncut portion 11 shown in fig. 5 (b).
The shape of the uncut portion 11 is not particularly limited, and the shapes shown in fig. 4(a) to (c) are exemplified. The width of the uncut portion (width w in FIG. 4) is preferably 0.1mm to 30mm, more preferably 0.5mm to 10mm, and still more preferably 1mm to 2 mm. The height of the uncut portion (height h in FIG. 4) is preferably 0.05mm to 1mm, more preferably 0.1mm to 0.5 mm.
In one embodiment, the end mill used in the roughing step has an outer diameter of 10mm or less, preferably 3mm to 9mm, and more preferably 4mm to 6 mm. In the present specification, the term "outer diameter of the end mill" means 2 times the distance from the rotation axis to one cutting edge.
The conditions for the cutting process in the rough cutting step may be set as appropriate according to the desired shape. For example, the end mill rotation speed is preferably 1000rpm to 60000rpm, more preferably 10000rpm to 40000 rpm. The feed rate of the end mill is preferably 500mm/min to 10000 mm/min, more preferably 500mm/min to 2500 mm/min. In this specification, the speed of the end mill refers to the relative speed with respect to the workpiece.
In one embodiment, the end mill is brought into contact with the workpiece while being advanced in a direction inclined with respect to the workpiece in a plan view at the start of cutting. In the present specification, the "direction inclined with respect to the workpiece" at the start of cutting means a direction in which an angle x (angle x in fig. 6) formed with a side a of the workpiece including the cutting start point a or a tangent B of the workpiece at the cutting start point a is 60 ° or less rearward in the advancing direction of the end mill after the start of cutting with reference to the cutting start point a. The "direction inclined with respect to the workpiece" means a direction excluding a direction perpendicular to the workpiece or a direction close to the perpendicular direction, that is, a direction in which the angle x is 0 °. In the present specification, the angle x is referred to as a travel angle x of the end mill at the start of cutting. When the cutting start point a is located on a straight line, the travel angle x of the end mill at the time of the cutting start is defined by the side a of the workpiece including the cutting start point a and the travel locus of the end mill (fig. 6), and when the cutting start point a is located on a curved line, the travel angle x of the end mill at the time of the cutting start is defined by the tangent line B of the workpiece at the cutting start point a and the travel locus of the end mill (fig. 7). In the present specification, the "cutting start point a" refers to a portion where the end mill starts to run to cut the outer periphery of a workpiece having a predetermined thickness.
In one embodiment, in the rough cutting step, the end mill is brought into contact with the workpiece while being advanced in a direction inclined with respect to the workpiece in a plan view at the start of cutting, and the uncut portion is formed on the workpiece by setting a portion at which cutting is started and a portion at which cutting is ended to different positions.
Fig. 6(a) and 6(b) are schematic plan views illustrating a cutting process according to an embodiment of the present invention. Fig. 7(a) and 7(b) are schematic plan views illustrating cutting processing according to another embodiment of the present invention. In fig. 6(a) and 6(b) and fig. 7(a) and 7(b), the movement of the end mill (relative movement with respect to the workpiece 1) at the start of cutting is shown as a travel trajectory ts in a plan view. In fig. 6(a) and (b), the workpiece 1 is substantially rectangular. In fig. 7(a) and (b), the profile of the workpiece 1 includes a curve. The travel path ts of the end mill at the start of cutting may be curved as shown in fig. 6(a) and 7(a), or may be linear as shown in fig. 6(b) and 7 (b). As described above, the travel angle x of the end mill at the start of cutting is 60 ° or less, preferably 0 ° or more and 60 ° or less, more preferably 0 ° or more and 45 ° or less, still more preferably 0 ° or more and 40 ° or less, and particularly preferably 0 ° or more and 35 ° or less. As described above, the travel angle x may be 0 °, for example, in the case where the profile of the workpiece 1 includes a curve, the travel angle x may be set to 0 °. In one embodiment, in the case where the workpiece 1 is substantially rectangular, the travel angle x may be set to an angle greater than 0 °. By bringing the end mill into contact with the workpiece while the end mill is being advanced in a direction inclined with respect to the workpiece, it is possible to prevent the occurrence of an unnecessary recess at the cutting start point. The travel angle x of the end mill at the start of cutting is preferably as close to 0 °, and in one embodiment, the travel angle x is 5 ° or less (preferably 3 ° or less, more preferably 1 ° or less, and still more preferably 0.5 ° or less).
In one embodiment, the travel trajectory ts of the end mill at the start of cutting is curved. The effect of the present invention described above is more remarkable by making the travel trajectory ts of the end mill at the start of cutting into a curved shape. When the travel locus ts is curved, the travel angle x of the end mill at the start of cutting is defined by a tangent line us of the travel locus ts at the start point a of cutting, the edge a of the workpiece, or a tangent line B at the start point a of cutting. In one embodiment, the end mill and the workpiece are brought into close contact with each other while rotating the workpiece in a plane, and the end mill is relatively moved with respect to the workpiece along a curved path ts. When the end mill and the workpiece are brought close to each other, the workpiece may be brought close to a fixed end mill, the end mill and the workpiece may be brought close to each other by linearly moving the end mill, or both the end mill and the workpiece may be brought close to each other by linearly moving the end mill and the workpiece.
When the travel locus ts of the end mill at the start of cutting is curved, the curvature radius of the travel locus ts is preferably 1/2% or more of the outer diameter of the end mill, more preferably larger than the outer diameter of the end mill, still more preferably 110% or more of the outer diameter of the end mill, particularly preferably 130% or more of the outer diameter of the end mill, and most preferably 150% or more of the outer diameter of the end mill. By setting the range as described above, it is possible to prevent the occurrence of an unnecessary recess at the cutting start point a. When the travel locus ts of the end mill at the start of cutting is curved, the curvature radius of the travel locus ts is preferably 4mm or more, more preferably 6mm or more, and still more preferably 7.5mm or more.
The speed of the end mill when the end mill is brought into contact with the workpiece is preferably slower than the feed speed of the end mill during cutting (when the face of the workpiece to be cut is cut by the end mill). By slowing down the speed of the end mill at the start of cutting, the workpiece can be prevented from wobbling. In one embodiment, the speed of the end mill when it is brought into contact with the workpiece is preferably 400mm/min to 1200mm/min, more preferably 500mm/min to 900 mm/min. In one embodiment, for example, when cutting the inner peripheral surface of a hole in a workpiece having the hole, the speed of the end mill when bringing the end mill into contact with the workpiece is preferably 30mm/min to 1200mm/min, and more preferably 50mm/min to 1000 mm/min.
The shape of the workpiece (i.e., the optical film) can be any appropriate shape. Examples of the shape of the workpiece include a substantially polygonal shape, a substantially circular shape, and a substantially elliptical shape, in addition to a substantially rectangular shape as shown in fig. 6. The shape of the workpiece may be a shape in which a straight line and a curved line are appropriately combined, or a shape in which a plurality of curved lines having different curvatures are combined. The workpiece may not be a pure rectangle, polygon, circle, ellipse, or the like, but may be a shape obtained by adding a special-shaped portion to the shape. In this specification, for example, a rectangle to which an irregularly shaped portion is added is included in "substantially rectangular". Examples of the irregular portion include a convex portion, a hole, and the like, in addition to the concave portion shown in fig. 6. The workpiece may have a shape in which corners of a rectangle are curved.
The cutting method described above (specifically, the travel path of the end mill at the start of cutting and the travel path of the end mill at the end of cutting, which will be described later) can also be applied to cutting the inner peripheral surface of the hole 11 in a workpiece 1' having the hole 11 as shown in fig. 8.
In one embodiment, the end mill is moved away from the workpiece while moving the end mill in a direction inclined with respect to the workpiece in a plan view at the end of cutting. In the present specification, the "direction inclined with respect to the workpiece" at the end of cutting means a direction in which an angle y (angle y in fig. 9) formed by the edge a of the workpiece including the cutting end point B or the tangent line B' of the workpiece at the cutting end point B in front of the end mill before the end of cutting in the traveling direction of the end mill with respect to the cutting end point B is 60 ° or less. As described above, the "direction inclined with respect to the workpiece" means a direction excluding a direction perpendicular to the workpiece or a direction close to perpendicular, that is, a direction in which the angle y is 0 °. In the present specification, the angle y is referred to as a travel angle y of the end mill at the end of cutting. When the cutting end point B is located on a straight line, the travel angle y of the end mill at the end of cutting is defined by the edge a of the workpiece including the cutting end point B and the travel locus of the end mill (fig. 9), and when the cutting end point B is located on a curved line, the travel angle y of the end mill at the end of cutting is defined by the tangent line B' of the workpiece at the cutting end point B and the travel locus of the end mill (fig. 10).
Fig. 9(a) and 9(b) are schematic plan views illustrating a cutting process according to an embodiment of the present invention. Fig. 10(a) and 10(b) are schematic plan views illustrating cutting processing according to another embodiment of the present invention. In fig. 9(a) and 9(b) and fig. 10(a) and 10(b), the movement of the end mill (relative movement with respect to the workpiece 1) at the end of cutting is represented as a travel locus te in a plan view. In fig. 9(a) and (b), the workpiece 1 is substantially rectangular. In fig. 10(a) and (b), the profile of the workpiece 1 includes a curve. The travel path te of the end mill at the end of cutting may be curved as shown in fig. 9(a) and 10(a), or may be linear as shown in fig. 9(b) and 10 (b). As described above, the travel angle y of the end mill at the end of cutting is 60 ° or less, preferably 0 ° or more and 60 ° or less, more preferably 0 ° or more and 45 ° or less, still more preferably 0 ° or more and 40 ° or less, and particularly preferably 0 ° or more and 35 ° or less. As described above, the travel angle y may be 0 °, for example, in the case where the profile of the workpiece 1 includes a curve, the travel angle y may be set to 0 °. In one embodiment, in the case where the workpiece 1 is substantially rectangular, the travel angle y may be set to an angle greater than 0 °. In the present specification, the "cutting end point b" refers to a portion where an end mill, which travels so as to cut the outer periphery of a workpiece having a predetermined thickness, changes its traveling direction to a direction away from the workpiece and ends the cutting. In one embodiment, the distance between the "cutting start point a" and the "cutting end point b" corresponds to the width w of the uncut portion.
Preferably, the travel locus te of the end mill at the end of cutting is curved. The aforementioned effect is further remarkable by making the travel locus te of the end mill at the end of cutting into a curved shape. When the travel locus te is curved, the travel angle y of the end mill at the end of cutting is defined by the tangent ue of the travel locus te at the end point B of cutting, the edge a of the workpiece, or the tangent B' at the end point B of cutting. In one embodiment, the end mill and the workpiece are separated from each other while rotating the workpiece in a plane, and the end mill is caused to travel relative to the workpiece along a curved travel locus te. When the end mill and the workpiece are separated from each other, the workpiece may be separated from the fixed end mill, the end mill may be linearly moved to separate the end mill from the workpiece, or both the end mill and the workpiece may be linearly moved to separate the end mill from the workpiece.
When the travel locus te of the end mill at the end of cutting is curved, the curvature radius of the travel locus te is preferably 1/2% or more of the outer diameter of the end mill, more preferably larger than the outer diameter of the end mill, still more preferably 110% or more of the outer diameter of the end mill, particularly preferably 130% or more of the outer diameter of the end mill, and most preferably 150% or more of the outer diameter of the end mill. By setting the range as described above, it is possible to prevent the occurrence of an unnecessary step and fuzz at the cutting end point b. When the travel locus te of the end mill at the end of cutting is curved, the curvature radius of the travel locus te is preferably 4mm or more, more preferably 6mm or more, and still more preferably 7.5mm or more.
The speed of the end mill when the end mill is moved away from the workpiece is preferably slower than the feed speed of the end mill during cutting (when the face of the workpiece to be cut is cut by the end mill). By slowing down the speed of the end mill at the end of cutting, the workpiece can be prevented from wobbling. In one embodiment, the speed of the end mill when it is moved away from the workpiece is preferably 400mm/min to 1200mm/min, more preferably 500mm/min to 900 mm/min. In one embodiment, for example, when cutting the inner peripheral surface of a hole in a workpiece having the hole, the speed of the end mill when the end mill is moved away from the workpiece is preferably 30mm/min to 1200mm/min, and more preferably 50mm/min to 1000 mm/min.
< finishing >
After the rough-cutting step, the outer peripheral surface of the roughly-cut workpiece is finished by cutting with an end mill. In the finish machining, the outer peripheral surface of the workpiece including the uncut portion is cut.
In one embodiment, the end mill used for finishing has an outer diameter of 10mm or less, preferably 3mm to 9mm, and more preferably 4mm to 6 mm.
The conditions for the cutting process in the finishing process may be set as appropriate according to the desired shape. For example, the end mill rotation speed is preferably 1000rpm to 60000rpm, more preferably 10000rpm to 40000 rpm. The feed rate of the end mill is preferably 500mm/min to 10000 mm/min, more preferably 500mm/min to 2500 mm/min.
In the finish machining, as described above, the end mill may be brought into contact with the workpiece while being advanced in a direction inclined with respect to the workpiece in a plan view at the start of cutting. Further, the end mill may be moved away from the workpiece while being moved in a direction inclined with respect to the workpiece in a plan view at the end of cutting. In the finish machining, the cutting start point and the cutting end point may be the same position, or the cutting start point and the cutting end point may be different positions, and the front in the traveling direction of the end mill relative to the cutting start point may be set as the cutting end point. Preferably, the cutting start point and the cutting end point are set at different positions, and the cutting end point b is set forward in the direction of travel of the end mill relative to the cutting start point. Thus, if the cutting is completed by overlapping the travel paths of the end mill during the cutting process, it is possible to favorably prevent the occurrence of an unnecessary step and fuzz at the end of the cutting.
< optical film >
In one embodiment, the optical film includes a polarizer.
The optical film including the polarizer may be a polarizer alone, or may be a film including a polarizer and other layers. Examples of the other layers include a protective layer for protecting the polarizer, and a layer composed of an arbitrary appropriate optical functional layer. In one embodiment, a polarizing plate is used as the optical film including a polarizer. The polarizing plate may have a polarizer and a protective layer disposed on at least one side of the polarizer. As the film including the polarizer, a laminate of a polarizing plate and a surface protective film and/or a separator may be used. The surface protective film or the separator is releasably laminated on the polarizing plate with any suitable adhesive. In the present specification, the "surface protective film" refers to a film that temporarily protects a polarizing plate, and is different from a protective layer (a layer that protects a polarizer) provided in a polarizing plate.
The polarizer is typically obtained by subjecting a resin film (e.g., a polyvinyl alcohol resin film) to various treatments such as a swelling treatment, a stretching treatment, a dyeing treatment with a dichroic material (e.g., iodine, an organic dye, etc.), a crosslinking treatment, a washing treatment, and a drying treatment. Generally, a polarizer obtained through a stretching process has a characteristic of easily generating cracks, and according to the present invention, an optical film including the polarizer can be cut while preventing cracks.
The thickness of the optical film including the polarizer is not particularly limited, and an appropriate thickness, for example, 20 μm to 200 μm may be adopted according to the purpose. The thickness of the polarizer is not particularly limited, and may be appropriately selected according to the purpose. The thickness of the polarizer is typically about 1 μm to 80 μm, preferably 3 μm to 40 μm.
The size of the optical film including the polarizer is not particularly limited, and may be set to an appropriate size according to the purpose. In one embodiment, the optical film including the polarizer has a rectangular shape including a side parallel to an absorption axis of the polarizer, a length of the side parallel to the absorption axis of the polarizer is 10mm to 400mm, and a length of the other side is 10mm to 500 mm. In the present specification, the term "parallel" includes a case where the two directions are substantially parallel to each other, specifically, a case where an angle formed by the two directions is 0 ° to 5 °.
Industrial applicability
The optical film obtained by cutting according to the production method of the present invention can be used for liquid crystal image display devices, organic EL image display devices, and the like. The optical film obtained by cutting may be used for a rectangular image display unit represented by the Personal Computer (PC) and a tablet terminal, and/or a special-shaped image display unit represented by an instrument panel and a smart watch of an automobile.
Claims (3)
1. A method for manufacturing an optical film by cutting, comprising:
laminating a plurality of optical films to form a workpiece; and
an end mill machining step of cutting the outer peripheral surface of the workpiece with an end mill,
the end mill machining step includes a rough-cutting step of roughly cutting the outer peripheral surface of the workpiece with an end mill, and a finish-cutting step of finish-cutting the roughly-cut outer peripheral surface of the workpiece with the end mill,
the rough-cutting process includes providing an uncut portion on an outer peripheral surface of the work,
the finishing includes cutting the uncut portion.
2. The method of manufacturing a cut optical film according to claim 1, comprising:
in the roughing step, the end mill is brought into contact with the workpiece while being advanced in a direction inclined with respect to the workpiece in a plan view at the start of cutting,
the uncut portion is formed on the workpiece by setting a cutting start portion and a cutting end portion to different positions.
3. The method of manufacturing an optical film by cutting according to claim 1 or 2, comprising:
when the cutting is completed, the end mill is moved away from the workpiece while being moved in a direction inclined with respect to the workpiece in a plan view.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2019024585A JP7278091B2 (en) | 2019-02-14 | 2019-02-14 | Method for manufacturing optical film |
| JP2019-024585 | 2019-02-14 |
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| CN111558741A true CN111558741A (en) | 2020-08-21 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202010088117.5A Pending CN111558741A (en) | 2019-02-14 | 2020-02-12 | Method for producing optical film |
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| JP (1) | JP7278091B2 (en) |
| CN (1) | CN111558741A (en) |
Cited By (2)
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| CN116097927A (en) * | 2020-09-14 | 2023-05-09 | 日东电工株式会社 | Polarizing plate, polarizing plate with retardation layer, and image display device comprising the polarizing plate or the polarizing plate with retardation layer |
| CN116748577A (en) * | 2022-03-14 | 2023-09-15 | 日东电工株式会社 | Composite cutting tool and method for manufacturing resin sheet using the same |
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| JP6968854B2 (en) * | 2019-09-19 | 2021-11-17 | 住友化学株式会社 | Polarizing plate manufacturing method and polarizing plate |
| JP7203879B2 (en) * | 2021-03-25 | 2023-01-13 | 日東電工株式会社 | Method for manufacturing polarizing plate and polarizing plate |
| JP2024018610A (en) * | 2022-07-29 | 2024-02-08 | 日東電工株式会社 | Method for manufacturing cut film |
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Also Published As
| Publication number | Publication date |
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| JP2020134582A (en) | 2020-08-31 |
| JP7278091B2 (en) | 2023-05-19 |
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