# US 9,039,861 B2 · Adhesive optical film, manufacturing method for the same and image display device using the same

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- Number: US 9,039,861 B2
- Document ID: US9039861B2
- Status: Granted
- Kind: B2
- Application number: 13/820,606
- Filed: 2011-07-28
- Published: 2013-06-27
- Granted: 2015-05-26
- Earliest claimed: 2010-09-03
- Assignees: Nitto Denko Corporation
- Applicants: Atsushi Yasui; Yuusuke Toyama; Takaaki Ishii; Masakuni Fujita; Tomoyuki Kimura; Masayuki Satake; Shusaku Goto; Takeharu Kitagawa; Minoru Miyatake; Tomohiro Mori; Takashi Kamijo
- Inventors: Atsushi Yasui; Yuusuke Toyama; Takaaki Ishii; Masakuni Fujita; Tomoyuki Kimura; Masayuki Satake; Shusaku Goto; Takeharu Kitagawa; Minoru Miyatake; Tomohiro Mori; Takashi Kamijo
- Web page: https://patentgrep.com/patent/US9039861B2

## CPC

- G02B 5/3025: {Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state (G02B5/3008, G02B5/3016 take precedence)}
- B05D 5/10: to obtain an adhesive surface
- C09J 7/385: {Acrylic polymers}
- G02B 5/3033: {in the form of a thin sheet or foil, e.g. Polaroid}
- C09K 2323/05: Bonding or intermediate layer characterised by chemical composition, e.g. sealant or spacer
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C09J: ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES (preparation of glue or gelatine C09H)
- C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A pressure-sensitive adhesive optical film of the invention comprises an optical film and a pressure-sensitive adhesive layer provided on the optical film, wherein the pressure-sensitive adhesive layer has a thickness (μm) standard deviation of 0.12 μm or less. The pressure-sensitive adhesive optical film makes it possible to reduce the problem of visible unevenness caused by a pressure-sensitive adhesive layer.

## Claims

### Claim 1

A method for producing a pressure-sensitive adhesive optical film comprising an optical film and a pressure-sensitive adhesive layer provided on the optical film, the method comprising the steps of:
(1A) applying a pressure-sensitive adhesive coating liquid with a viscosity Y (P) to the optical film to form a coating with a thickness X (μm); and
(2A) drying the applied pressure-sensitive adhesive coating liquid to form a pressure-sensitive adhesive layer,
wherein the viscosity Y of the pressure-sensitive adhesive coating liquid and the thickness X of the coating satisfy the relation 0.8X−Y≦68,
wherein the pressure-sensitive adhesive coating liquid has a thickness X (μm) of 60.8 to 250 μm,
wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 20 to 160 P,
wherein the pressure-sensitive adhesive layer has a thickness (μm) standard deviation of 0.12 μm or less, and
wherein the pressure-sensitive adhesive coating liquid is an organic solvent-based pressure-sensitive adhesive containing a (meth)acryl-based polymer having a weight average molecular weight in the range of 1,400,000 to 3,000,000.

### Claim 2

A method for producing a pressure-sensitive adhesive optical film comprising an optical film and a pressure-sensitive adhesive layer provided on the optical film, the method comprising the steps of:
(1B) applying a pressure-sensitive adhesive coating liquid with a viscosity Y (P) to a release film to form a coating with a thickness X (μm);
(2B) drying the applied pressure-sensitive adhesive coating liquid to form a pressure-sensitive adhesive layer; and
(3) bonding the pressure-sensitive adhesive layer, which is formed on the release film, to the optical film,
wherein the viscosity Y of the pressure-sensitive adhesive coating liquid and the thickness X of the coating satisfy the relation 0.8X−Y≦68,
wherein the pressure-sensitive adhesive coating liquid has a thickness X (μm) of 60.8 to 250 μm,
wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 20 to 160 P,
wherein the pressure-sensitive adhesive layer has a thickness (μm) standard deviation of 0.12 μm or less, and
wherein the pressure-sensitive adhesive coating liquid is an organic solvent-based pressure-sensitive adhesive containing a (meth)acryl-based polymer having a weight average molecular weight in the range of 1,400,000 to 3,000,000.

### Claim 3 (depends on 1)

The method for producing a pressure-sensitive adhesive optical film according to claim 1, wherein
the optical film is a polarizing plate comprising a polarizer and a first transparent protective film provided on one side of the polarizer or first and second transparent protective films provided on both sides of the polarizer,
the first transparent protective film has a haze value of 15% or less, and
the pressure-sensitive adhesive layer is provided on a side of the polarizing plate opposite to a side where the first transparent protective film is provided.

### Claim 4 (depends on 3)

The method for producing a pressure-sensitive adhesive optical film according to claim 3, wherein the first transparent protective film has a thickness of 60 μm or less.

### Claim 5 (depends on 3)

The method for producing a pressure-sensitive adhesive optical film according to claim 3, wherein the polarizing plate has first and second transparent protective films on both sides of the polarizer, and at least one of the first and second transparent protective films has a thickness of 60 μm or less.

### Claim 6 (depends on 3)

The method for producing a pressure-sensitive adhesive optical film according to claim 3, wherein the polarizer has a thickness of 10 μm or less.

### Claim 7 (depends on 1)

The method for producing a pressure-sensitive adhesive optical film according to claim 1, wherein the optical film is a retardation plate.

### Claim 8 (depends on 7)

The method for producing a pressure-sensitive adhesive optical film according to claim 7, wherein the retardation plate has a thickness of 60 μm or less.

### Claim 9 (depends on 1)

The method for producing a pressure-sensitive adhesive optical film according to claim 1, wherein the optical film has a haze value of 15% or less.

### Claim 10 (depends on 9)

The method for producing a pressure-sensitive adhesive optical film according to claim 9, wherein the optical film is intended to be bonded to a front face plate or a touch panel.

### Claim 11 (depends on 9)

The method for producing a pressure-sensitive adhesive optical film according to claim 9, wherein the optical film has a thickness of 60 μm or less.

### Claim 12 (depends on 9)

The method for producing a pressure-sensitive adhesive optical film according to claim 9, wherein the optical film is a surface treatment film.

### Claim 13

A method for producing a pressure-sensitive adhesive optical film comprising at least two optical films and at least two pressure-sensitive adhesive layers alternately laminated, the method comprising the steps of:
applying a pressure-sensitive adhesive coating liquid with a viscosity Y (P) to a first one of said at least two optical films to form a first coating with a first thickness X (μm); and
drying the applied pressure-sensitive adhesive coating liquid to form a first one of said at least two pressure-sensitive adhesive layers,
applying the pressure-sensitive adhesive coating liquid with the viscosity Y (P) to a second one of said at least two optical films to form a second coating with a second thickness X (μm); and
drying the applied pressure-sensitive adhesive coating liquid to form a second one of said at least two pressure-sensitive adhesive layers,
wherein the viscosity Y of the pressure-sensitive adhesive coating liquid and the first thickness X of the coating satisfy the relation 0.8X−Y≦68,
wherein the viscosity Y of the pressure-sensitive adhesive coating liquid and the second thickness X of the coating satisfy the relation 0.8X−Y≦68,
wherein the pressure-sensitive adhesive coating liquid has a thickness X (μm) of 60.8 to 250 μm,
wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 20 to 160 P,
wherein at least one of the pressure-sensitive adhesive layers has a thickness (μm) standard deviation of 0.12 μm or less, and
wherein the pressure-sensitive adhesive coating liquid is an organic solvent-based pressure-sensitive adhesive containing a (meth)acryl-based polymer having a weight average molecular weight in the range of 1,400,000 to 3,000,000.

### Claim 14

A method for producing a pressure-sensitive adhesive optical film comprising at least two optical films and at least two pressure-sensitive adhesive layers alternately laminated, the method comprising the steps of:
applying a pressure-sensitive adhesive coating liquid with a viscosity Y (P) to a release film to form a coating with a thickness X (μm);
drying the applied pressure-sensitive adhesive coating liquid to form a pressure-sensitive adhesive layer; and
bonding the pressure-sensitive adhesive layer, which is formed on the release film, to at least one of the at least two optical films,
wherein the viscosity Y of the pressure-sensitive adhesive coating liquid and the thickness X of the coating satisfy the relation 0.8X−Y≦68,
wherein the pressure-sensitive adhesive coating liquid has a thickness X (μm) of 60.8 to 250 μm,
wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 20 to 160 P,
wherein at least one of the pressure-sensitive adhesive layer has a thickness (μm) standard deviation of 0.12 μm or less, and
wherein the pressure-sensitive adhesive coating liquid is an organic solvent-based pressure-sensitive adhesive containing a (meth)acryl-based polymer having a weight average molecular weight in the range of 1,400,000 to 3,000,000.

### Claim 15 (depends on 13)

The method for producing a pressure-sensitive adhesive optical film according to claim 13, wherein each of the at least two pressure-sensitive adhesive layers has a thickness (μm) standard deviation of 0.12 μm or less.

### Claim 16 (depends on 13)

The method for producing a pressure-sensitive adhesive optical film according to claim 13, wherein one of the optical films is a polarizing plate comprising a polarizer and a first transparent protective film provided on one side of the polarizer or first and second transparent protective films provided on both sides of the polarizer,
the first transparent protective film has a haze value of 15% or less, and
the pressure-sensitive adhesive layer is provided on a side of the polarizing plate opposite to a side where the first transparent protective film is provided.

### Claim 17 (depends on 16)

The method for producing a pressure-sensitive adhesive optical film according to claim 16, wherein the first transparent protective film has a thickness of 60 μm or less.

### Claim 18 (depends on 16)

The method for producing a pressure-sensitive adhesive optical film according to claim 16, wherein the polarizing plate has first and second transparent protective films on both sides of the polarizer, and at least one of the first and second transparent protective films has a thickness of 60 μm or less.

### Claim 19 (depends on 16)

The method for producing a pressure-sensitive adhesive optical film according to claim 16, wherein the polarizer has a thickness of 10 μm or less.

### Claim 20 (depends on 13)

The method for producing a pressure-sensitive adhesive optical film according to claim 13, wherein one of the optical films is a polarizing plate comprising a polarizer and a first transparent protective film provided on one side of the polarizer or first and second transparent protective films provided on both sides of the polarizer,
the first transparent protective film has a haze value of 15% or less,
the pressure-sensitive adhesive layer is provided on a side of the polarizing plate opposite to a side where the first transparent protective film is provided, and
at least one of the other optical film or films is a retardation plate.

### Claim 21 (depends on 20)

The method for producing a pressure-sensitive adhesive optical film according to claim 20, wherein the retardation plate has a thickness of 60 μm or less.

### Claim 22 (depends on 2)

The method for producing a pressure-sensitive adhesive optical film according to claim 2, wherein
the optical film is a polarizing plate comprising a polarizer and a first transparent protective film provided on one side of the polarizer or first and second transparent protective films provided on both sides of the polarizer,
the first transparent protective film has a haze value of 15% or less, and
the pressure-sensitive adhesive layer is provided on a side of the polarizing plate opposite to a side where the first transparent protective film is provided.

### Claim 23 (depends on 22)

The method for producing a pressure-sensitive adhesive optical film according to claim 22, wherein the first transparent protective film has a thickness of 60 μm or less.

### Claim 24 (depends on 22)

The method for producing a pressure-sensitive adhesive optical film according to claim 22, wherein the polarizing plate has first and second transparent protective films on both sides of the polarizer, and at least one of the first and second transparent protective films has a thickness of 60 μm or less.

### Claim 25 (depends on 22)

The method for producing a pressure-sensitive adhesive optical film according to claim 22, wherein the polarizer has a thickness of 10 μm or less.

### Claim 26 (depends on 2)

The method for producing a pressure-sensitive adhesive optical film according to claim 2, wherein the optical film is a retardation plate.

### Claim 27 (depends on 26)

The method for producing a pressure-sensitive adhesive optical film according to claim 26, wherein the retardation plate has a thickness of 60 μm or less.

### Claim 28 (depends on 2)

The method for producing a pressure-sensitive adhesive optical film according to claim 2, wherein the optical film has a haze value of 15% or less.

### Claim 29 (depends on 28)

The method for producing a pressure-sensitive adhesive optical film according to claim 28, wherein the optical film is intended to be bonded to a front face plate or a touch panel.

### Claim 30 (depends on 28)

The method for producing a pressure-sensitive adhesive optical film according to claim 28, wherein the optical film has a thickness of 60 μm or less.

### Claim 31 (depends on 28)

The method for producing a pressure-sensitive adhesive optical film according to claim 28, wherein the optical film is a surface treatment film.

### Claim 32 (depends on 2)

The method for producing a pressure-sensitive adhesive optical film according to claim 2, wherein the pressure-sensitive adhesive coating liquid has a thickness X (μm) of 20 to 250 μm.

### Claim 33 (depends on 14)

The method for producing a pressure-sensitive adhesive optical film according to claim 14, wherein each of the at least two pressure-sensitive adhesive layers has a thickness (μm) standard deviation of 0.12 μm or less.

### Claim 34 (depends on 14)

The method for producing a pressure-sensitive adhesive optical film according to claim 14, wherein one of the optical films is a polarizing plate comprising a polarizer and a first transparent protective film provided on one side of the polarizer or first and second transparent protective films provided on both sides of the polarizer,
the first transparent protective film has a haze value of 15% or less, and
the pressure-sensitive adhesive layer is provided on a side of the polarizing plate opposite to a side where the first transparent protective film is provided.

### Claim 35 (depends on 34)

The method for producing a pressure-sensitive adhesive optical film according to claim 34, wherein the first transparent protective film has a thickness of 60 μm or less.

### Claim 36 (depends on 34)

The method for producing a pressure-sensitive adhesive optical film according to claim 34, wherein the polarizing plate has first and second transparent protective films on both sides of the polarizer, and at least one of the first and second transparent protective films has a thickness of 60 μm or less.

### Claim 37 (depends on 34)

The method for producing a pressure-sensitive adhesive optical film according to claim 34, wherein the polarizer has a thickness of 10 μm or less.

### Claim 38 (depends on 14)

The method for producing a pressure-sensitive adhesive optical film according to claim 14, wherein one of the optical films is a polarizing plate comprising a polarizer and a first transparent protective film provided on one side of the polarizer or first and second transparent protective films provided on both sides of the polarizer,
the first transparent protective film has a haze value of 15% or less,
the pressure-sensitive adhesive layer is provided on a side of the polarizing plate opposite to a side where the first transparent protective film is provided, and
at least one of the other optical film or films is a retardation plate.

### Claim 39 (depends on 38)

The method for producing a pressure-sensitive adhesive optical film according to claim 38, wherein the retardation plate has a thickness of 60 μm or less.

### Claim 40 (depends on 1)

The method for producing a pressure-sensitive adhesive optical film according to claim 1, wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 20 to 140 P.

### Claim 41 (depends on 1)

The method for producing a pressure-sensitive adhesive optical film according to claim 1, wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 40 to 140 P.

### Claim 42 (depends on 13)

The method for producing a pressure-sensitive adhesive optical film according to claim 13, wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 20 to 140 P.

### Claim 43 (depends on 13)

The method for producing a pressure-sensitive adhesive optical film according to claim 13, wherein the pressure-sensitive adhesive coating liquid has a viscosity Y (P) of 40 to 140 P.