Film application method

• US 10,486,408 B2
• Filed: 06/08/2016
• Issued: 11/26/2019
• Est. Priority Date: 06/15/2015
• Status: Active Grant

• Current Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Original Assignee: Sharp Kabushiki Kaisha (Hon Hai Precision Industry Co., Ltd.)
• Inventors: Yamada, Nobuaki
• Primary Examiner(s): Osele, Mark A
• Assistant Examiner(s): Harm, Nickolas R
• Application Number:
  US15/579,728
• Publication Number:
  US 20180178502A1
• Time in Patent Office: 1,266 Days
• Field of Search: 156714, 156719, 156767
• CPC Class Codes: A47L 25/005 using adhesive or tacky surfaces to remove dirt, e.g. lint removers
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/44 Number of layers variable across the laminate
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2307/40 having particular optical properties light or UV resistant B32B2307/71
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/536 Hardness
• CPC Class Codes: B32B 2307/584 Scratch resistance
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 2457/202 LCD, i.e. liquid crystal displays
• CPC Class Codes: B32B 2551/00 Optical elements
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/325 comprising polycycloolefins
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 3/08 : characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 38/10 : Removing layers, or parts of layers, mechanically or chemically
• CPC Class Codes: B32B 38/18 : Handling of layers or the laminate
• CPC Class Codes: B32B 43/006 : Delaminating
• CPC Class Codes: B32B 7/04 : Interconnection of layers
• CPC Class Codes: B32B 7/06 : permitting easy separation
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C09J 5/02 : involving pretreatment of the surfaces to be joined
• CPC Class Codes: G02B 1/11 : Anti-reflection coatings
• CPC Class Codes: G02B 1/14 : Protective coatings, e.g. hard coatings
• CPC Class Codes: G02B 5/3083 : Birefringent or phase retarding elements G02B5/3008, G02B5/3016 take precedence; systems for polarisation control G02B27/286; manufacturing phase modulating patterns by lithographic processes G03F7/001
• CPC Class Codes: G02F 1/1303 : Apparatus specially adapted to the manufacture of LCDs
• CPC Class Codes: G02F 1/133331 : Cover glasses
• CPC Class Codes: G02F 1/133528 : Polarisers
• CPC Class Codes: G02F 1/133541 : Circular polarisers
• CPC Class Codes: Y10T 156/1168 : Gripping and pulling work apart during delaminating
• CPC Class Codes: Y10T 156/1195 : Delaminating from release surface
• CPC Class Codes: Y10T 156/1994 : Means for delaminating from release surface

Abstract

The present invention provides a film application method that can prevent entry of foreign substances and air bubbles between the film and the application target even when the film is applied in a general environment in which foreign substances such as dust are floating. The film application method is a film application method that applies a functional film to a substrate, the method including the steps of: (1) applying a first adhesive layer to the substrate, with a foreign-substance-removing unit including the first adhesive layer and a first film being overlaid onto a main unit including a second film, a second adhesive layer, and the functional film; and (2) while peeling off both the foreign-substance-removing unit and the second film, with one end of the functional film fixed to the substrate, by pulling ends of the foreign-substance-removing unit and the second film adjacent to the fixed end of the functional film through between the substrate and the functional film, applying the second adhesive layer exposed by removal of the second film to the surface of the substrate exposed by removal of the foreign-substance-removing unit.

Claims

1. A film application method that applies a functional film to a substrate, the method comprising the steps of:

(1) applying a first adhesive layer to the substrate, with a foreign-substance-removing unit including the first adhesive layer and a first film being overlaid onto a main unit including a second film, a second adhesive layer, and the functional film; and

(2) while peeling off both the foreign-substance-removing unit and the second film, with one end of the functional film fixed to the substrate, by pulling ends of the foreign-substance-removing unit and the second film adjacent to the fixed end of the functional film through between the substrate and the functional film, applying the second adhesive layer exposed by removal of the second film to the surface of the substrate exposed by removal of the foreign-substance-removing unit,

wherein in the step (1), the foreign-substance-removing unit and the main unit are combined with each other, and

wherein in the step (2), the foreign-substance-removing unit and the main unit are separated by injection of a gas between the foreign-substance-removing unit and the main unit, and the ends of the foreign-substance-removing unit and the second film adjacent to a temporary fixing member are pulled out.

2. The film application method according to claim 1,

wherein in the step (2), a pressing roller is rotated to apply the functional film to the substrate.

3. A film application method that applies a functional film to a substrate, the method comprising the steps of:

(1) applying a first adhesive layer to the substrate, with a foreign-substance-removing unit including the first adhesive layer and a first film being overlaid onto a main unit including a second film, a second adhesive layer, and the functional film; and

(2) while peeling off both the foreign-substance-removing unit and the second film, with one end of the functional film fixed to the substrate, by pulling ends of the foreign-substance-removing unit and the second film adjacent to the fixed end of the functional film through between the substrate and the functional film, applying the second adhesive layer exposed by removal of the second film to the surface of the substrate exposed by removal of the foreign-substance-removing unit,

wherein in the step (2), the method utilizes a pulling jig that includes a first plate, a second plate, and a shaft about which the first plate and the second plate are rotatable, and

both the foreign-substance-removing unit and the second film are peeled off by arranging the pulling jig between the foreign-substance-removing unit and the main unit, applying the first plate to the foreign-substance-removing unit and the second plate to the main unit, and pulling out the pulling jig while rotating the first plate and the second plate.

4. The film application method according to claim 3,

wherein the step (1) includes overlaying the main unit separated from the foreign-substance-removing unit onto the foreign-substance-removing unit applied to the substrate.

5. The film application method according to claim 4,

wherein at least one of the foreign-substance-removing unit and the second film is provided with a mark for alignment of the foreign-substance-removing unit and the main unit.

6. The film application method according to claim 3,

wherein in the step (2), a pressing roller is rotated to apply the functional film to the substrate.

7. A film application method that applies a functional film to a substrate, the method comprising the steps of:

(1) applying a first adhesive layer to the substrate, with a foreign-substance-removing unit including the first adhesive layer and a first film being overlaid onto a main unit including a second film, a second adhesive layer, and the functional film; and

(2) while peeling off both the foreign-substance-removing unit and the second film, with one end of the functional film fixed to the substrate, by pulling ends of the foreign-substance-removing unit and the second film adjacent to the fixed end of the functional film through between the substrate and the functional film, applying the second adhesive layer exposed by removal of the second film to the surface of the substrate exposed by removal of the foreign-substance-removing unit,

wherein in the step (1), the foreign-substance-removing unit and the main unit are combined with each other, and

wherein in the step (1), the main unit and the foreign-substance-removing unit are bonded by a pulling film,

the pulling film is more strongly bonded with the main unit and the foreign-substance-removing unit at a first end than at a second end, and

in the step (2), the second end of the pulling film is separated from the foreign-substance-removing unit and the main unit and pulled out through between the substrate and the functional film, such that the foreign-substance-removing unit and the second film that are bonded with the first end of the pulling film are pulled out together with the pulling film.

8. The film application method according to claim 7,

wherein in the step (2), a pressing roller is rotated to apply the functional film to the substrate.

9. A film application method that applies a functional film to a substrate, the method comprising the steps of:

(1) applying a first adhesive layer to the substrate, with a foreign-substance-removing unit including the first adhesive layer and a first film being overlaid onto a main unit including a second film, a second adhesive layer, and the functional film; and

(2) while peeling off both the foreign-substance-removing unit and the second film, with one end of the functional film fixed to the substrate, by pulling ends of the foreign-substance-removing unit and the second film adjacent to the fixed end of the functional film through between the substrate and the functional film, applying the second adhesive layer exposed by removal of the second film to the surface of the substrate exposed by removal of the foreign-substance-removing unit,

wherein in the step (2), a peel-off roller is rotated to wind at least one of the foreign-substance-removing unit, the second film, and the pulling film around the roller.

10. The film application method according to claim 9,

wherein in the step (2), a pressing roller is rotated to apply the functional film to the substrate.

11. The film application method according to claim 9,

wherein the step (1) includes overlaying the main unit separated from the foreign-substance-removing unit onto the foreign-substance-removing unit applied to the substrate.

12. The film application method according to claim 11,

wherein at least one of the foreign-substance-removing unit and the second film is provided with a mark for alignment of the foreign-substance-removing unit and the main unit.