Method for manufacturing touch panel and molded article

Abstract

An object of the present invention is to provide a method for manufacturing a touch panel. A laminated film is used. The laminated film comprises a resin layer, a protection film-constituent material layer provided on a surface of the resin layer, and a releasing layer provided on a surface of the protection film-constituent material layer. The protection film-constituent material layer is a layer containing fluorine-based substances. The releasing layer is a layer made by using a fluorine-based resin. The method comprises a molding process, a hardening treatment process for providing hardening treatment to the protection film-constituent material layer after the molding process, and a removal process for removing the releasing layer after the molding process. The protection film-constituent material layer is an uncured layer in the course of a molding process.

Claims

1. A method for manufacturing a touch panel by molding a laminated film: wherein the laminated film comprises a resin layer, a protection film-constituent material layer provided on a surface of the resin layer, and a releasing layer provided on a surface of the protection film-constituent material layer; wherein the resin layer, the protection film-constituent material layer, and the releasing layer are laminated together; wherein the protection film-constituent material layer is an uncured layer which is not completely cured, in the course of a molding process; the method comprising: a molding process for forming the laminated film into a predetermined shape, a hardening treatment process for providing hardening treatment to the protection film-constituent material layer after the molding process and getting the protection film-constituent material layer modified to be a protection layer, and a removal process for removing the releasing layer after the molding process; wherein the protection film-constituent material layer is a layer containing fluorine-based substances; and wherein the releasing layer is a layer made by using a fluorine-based resin.

2. The method for manufacturing a touch panel according to claim 1, further comprising a second molding process of forming a wiring film on a surface of an insulative transparent resin layer by molding, the wiring film being provided with a wiring layer of a predetermined pattern.

3. The method for manufacturing a touch panel according to claim 2, wherein: the molding process for forming the laminated film is a first molding process A for forming the laminated film by molding; the second molding process for forming a wiring film is a second molding process B for forming the wiring film by molding; and a third molding process C integrates the molded laminated film body obtained in the molding process A with the molded wiring film body obtained in the molding process B.

4. The method for manufacturing a touch panel according to claim 2, wherein the laminated film and the wiring film define a composite film formed by molding.

5. The method for manufacturing a touch panel according to claim 1, wherein the protection film-constituent material layer contains a composition curable by hardening treatment.

6. The method for manufacturing a touch panel according to claim 1, wherein the protection film-constituent material layer contains a fluorine-based substance and a composition curable by hardening treatment.

7. The method for manufacturing a touch panel according to claim 1, wherein the protection layer has a contact angle to oleic acid equal to or greater than 40.

8. The method for manufacturing a touch panel according to claim 1, wherein the protection layer has a contact angle to water equal to or greater than 70.

9. The method for manufacturing a touch panel according to claim 1, wherein the releasing layer is composed of ethylene tetrafluoro ethylene copolymer and/or tetrafluoroetylene-hexafluoropropylen copolymer.

10. The method for manufacturing a touch panel according to claim 1, wherein the resin layer is composed of one or more resins selected from the group consisting of acrylic resin, methacrylic resin, ester-based resin, cellulose-based resin, olefin-based resin, carbonate-based resin, and ABS resin.

11. The method for manufacturing a touch panel according to claim 1, wherein the removal process is performed after the hardening treatment process.

12. The method for manufacturing a touch panel according to claim 2: wherein the touch panel is an electrostatic capacitive touch panel comprising the laminated film and the wiring film; wherein the touch panel comprises a case body formed of an electrically insulative transparent resin film; wherein the case body comprises a principal surface portion and side surface portions; wherein the principal surface portion comprises a principal surface input region; wherein at least one of the side surface portions comprises a side surface input region; wherein the principal surface portion is provided with the wiring film comprising at least two first electrode rows and at least two second electrode rows; wherein the at least two first electrode rows are arranged in a first direction at predetermined distances; wherein the at least two second electrode rows are arranged in a second direction at predetermined distances; wherein each of the first electrode rows and each of the second electrode rows comprises at least two island-shaped electrodes and inter-electrode wirings electrically connecting the island-shaped electrodes; wherein side surface portion comprising the side surface input region is provided with the wiring film comprising one or more third electrode rows and one or more fourth electrode rows; wherein the third electrode rows are arranged on an extension of the first electrode rows (and/or the second electrode rows), wherein the fourth electrode rows are provided in a direction of the second electrode rows (and/or the first electrode rows); wherein ends of the first electrode rows or ends of the third electrode rows are electrically connected to one ends of first lead wirings in each corresponding manner; wherein the other ends of the first lead wirings are formed on a side surface portion without having the side surface input region; wherein ends of the second electrode rows and ends of the fourth electrode rows are electrically connected to one ends of second leading wirings in each corresponding manner; wherein the other ends of the second lead wirings are formed on the side surface portion without having the side surface input region; and wherein at least one of the first lead wirings and the second lead wirings pass through a ridgeline portion as a boundary between the neighboring side surface portions.

13. The method for manufacturing a touch panel according to claim 12: wherein the first electrode rows are provided on one surface of the principal surface portion; wherein the second electrode rows are provided on the other surface of the principal surface portion; wherein the third electrode rows are provided on a surface where the electrode rows as origins of the third electrode rows are provided; and wherein the fourth electrode rows are provided on a surface where the electrode rows along which the fourth electrode rows are arranged are provided.

14. The method for manufacturing a touch panel according to claim 12: wherein the lead wirings passing through the ridgeline portion are arranged on the inside surface of the case body.

15. A method for manufacturing a molded article by molding a laminated film: wherein the laminated film comprises a resin layer, a protection film-constituent material layer formed on a surface of the resin layer, and a releasing layer formed on a surface of the protection film-constituent material layer; wherein the resin layer, the protection film-constituent material layer, and the releasing layer are laminated together; wherein the protection film-constituent material layer is an uncured layer which is not completely cured in the process of molding; the method comprising: a molding process for forming the laminated film into a predetermined shape; a hardening treatment process for providing hardening treatment to the protection film-constituent material layer after the molding process and getting the protection film-constituent material layer modified to be a protection layer; and a removal process for removing the releasing layer after the molding process; wherein the protection film-constituent material layer contains fluorine-based substances, and wherein the releasing layer is made by using a fluorine-based resin.

16. The method for manufacturing a molded article according to claim 15, wherein the protection film-constituent material layer contains composition curable by hardening treatment.

17. The method for manufacturing a molded article according to claim 15, wherein the protection film-constituent material layer contains fluorine-based substances and composition curable by hardening treatment.

18. The method for manufacturing a molded article according to claim 15, wherein the removal process is performed after hardening treatment process.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a cross sectional view of a laminated film.

(2) FIG. 2 is a cross sectional view of a laminated film shaped molded body.

(3) FIG. 3 is a cross sectional view of the molded body after peel-off of a releasable film.

(4) FIG. 4 is a cross sectional view of the laminated film.

(5) FIG. 5 is a cross sectional view of the laminated film shaped molded body.

(6) FIG. 6 is a cross sectional view of a wiring film (touch panel film).

(7) FIG. 7 is a cross sectional view of a wiring film shaped molded body.

(8) FIG. 8 illustrates a state of an insert-molding.

(9) FIG. 9 is a cross sectional view of a molded body (touch panel precursor) obtained by insert molding.

(10) FIG. 10 is a cross sectional view of a touch panel.

(11) FIG. 11 is a perspective view of the touch panel.

DESCRIPTION OF EMBODIMENTS

(12) An embodiment of the present invention will be described below.

(13) A first invention is directed to a laminated film. The laminated film is a film for obtaining a molded article. The laminated film has a resin layer. Preferably, the resin layer is a transparent resin layer. The resin layer is, for example, an insulative resin layer. The resin layer is, for example, a resin film. The resin layer is, for example, a transparent resin film. The laminated film has a protection film-constituent material layer. The protection film-constituent material layer is provided on one surface (or both surfaces) of the resin layer. The protection film-constituent material layer is an uncured layer, i.e., is not completely cured. The protection film-constituent material layer substantially is not subjected to hardening treatment. For example, the protection film-constituent material layer is an uncured layer. Alternatively, the protection film-constituent material layer is a semi-cured layer. The protection film constituting-material film is not completely cured, and thus is relatively soft. The protection film-constituent material layer contains fluorine-based substances. The laminated film has a releasing layer. The releasing layer is formed on a surface of the protection film-constituent material layer. The releasing layer is a layer made by using a fluorine-based resin. For example, the releasing layer is a film composed of a fluorine-based resin. For example, the releasing layer is a fluorine-based resin film. The resin layer, the protection film-constituent material layer, and the releasing layer are laminated together.

(14) The protection film-constituent material layer is made by applying and drying, for example, a solution (coating) containing the protection film-constituent material. In a process of application and drying, the protection film-constituent material layer has not been completely cured yet. When the protection film-constituent material layer is subjected to hardening treatment, the protection film-constituent material layer is modified to a cured protection layer. The protection film is a completely (almost completely) cured layer. The cured protection layer has a high hardness (preferably, has pencil hardness equal to or greater than 3H). The protection film-constituent material layer contains fluorine-based substances. Preferably, the protection film-constituent material layer contains a composition curable by hardening treatment. Preferably, the protection film-constituent material layer contains fluorine-based substance and a composition curable by hardening treatment. The curable composition is a polymerizable monomer having, for example, a tri- or higher functional group. The fluorine-based substance may be a composition curable by hardening treatment. The composition curable by hardening treatment may be a substance having F. The fluorine-based substance is a fluorine-based resin which is readily obtainable, and the cured composition is a polymerizable monomer having, for example, the tri- or higher functional group. Preferably, the protection film-constituent material layer contains a fluorine-based resin and the polymerizable monomer having, for example, the tri- or higher functional group.

(15) The following materials (substances/compounds) are examples of the protection film-constituent material. The material contains a fluorine-based resin and metal oxide particles modified with, for example, a polyfunctional(meth)acrylic group. The polyfunctional means having tri- or higher functional group. An example of the metal oxide particles modified with the polyfunctional (meth)acrylic group includes metal oxide particles modified with, for example, a polyfunctional methacrylate monomer (e.g., polyfunctional methacrylate monomer resulting from sulfide bonding (RSR: R, R are hydrocarbon groups) between a thiol group of a silane coupling agent (for example, a silane coupling agent having a thiol group) and an acryloyl group and/or methacryloyl group of methacrylate monomer.

(16) Examples of silane coupling agent having a thiol group include (3-mercaptopropyl)trimethoxylsilane, (3-mercaptopropyl)triethoxysilane, (3-mercaptopropyl)methyldimethoxysilane, (3-mercaptopropyl)ethyldimethoxysilane, (1-mercaptomethyl)methyldimethoxysilane, and 11-mercaptoundecyltrimethoxysilane.

(17) Examples of (meth)acrylate monomer include trimethylolpropane trimethacrylate, trimethylolpropane triacrylate, ethylene oxide-modified trimethylolpropane trimethacrylate, ethylene oxide-modified trimethylolpropane triacrylate, pentaerythritol trimethacrylate, pentaerythritol triacrylate, pentaerythritol tetramethacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexa methacrylate, dipentaerythritol hexa-acrylate, tetramethylolmethane trimethacrylate, tetramethylolmethane triacrylate, tetramethylolmethane tetramethacrylate, tetramethylolmethane tetracrylate, tris-(2-hydroxyethyl)isocyanurate trimethacrylate, tris-(2-hydroxyethyl)isocyanurate triacrylate, urethane methacrylate, and urethane acrylate. Another example of (meth)acrylate monomer includes (meth)acrylate having a polyfunctional group (e.g., tri- or higher functional group). As a matter of course, examples of (meth)acrylate monomer are not limited to the above examples. One or more selected from the above groups are used, as required.

(18) Examples of metal oxide particle include SiO.sub.2, Al.sub.2O.sub.3, ZrO.sub.2, TiO.sub.2, ITO, SnO.sub.2, ZnO, Sb.sub.2O.sub.3, and Sb.sub.2O.sub.5. As a matter of course, examples of the metal oxide particle are not limited to the above examples. The typical metal oxide particle (minute particle) have an OH group on its surface. The metal oxide particle (minute particle) reacts with (meth)acrylate having the polyfunctional group. More specifically, the metal oxide particle (minute particle) is modified with the (meth)acrylate. Further, in addition to the (meth)acrylate having the polyfunctional group, metal oxide particle (minute particle) modified with (meth)acrylate having bifunctional group may be employed.

(19) Examples of the fluorine-based resin include perfluoropolyether acrylate, perfluoropolyether methacrylate, fluorine-containing polysiloxane, and fluorine-containing and cyclic polysiloxane. As a matter of course, examples of the fluorine-based resin are not limited thereto.

(20) The protection film-constituent material is available from, for example, NIDEK CO., LTD., JSR CORPORATION, Nitto Boseki Co., Ltd., DIC CORPORATION, etc. More specifically, Acier (ultraviolet-curing type organic-inorganic composite hard coating agent) produced by NIDEK CO., LTD., is exemplified as a preferable material. As a matter of course, the preferable protection film-constituent material is not limited to the Acier.

(21) The protection film obtained by curing the protection film-constituent material layer preferably has a contact angle (contact angle to oleic acid) equal to or greater than 40. More preferably, the protection film has a contact angle (contact angle to oleic acid) equal to or greater than 60. In other words, there is no specific limit in upper value. However, the preferable upper limit is a value at or below 80.

(22) The protection film obtained by curing the protection film-constituent material layer preferably has a contact angle (contact angle to water) equal to or greater than 70. More preferably, the protection film has a contact angle (contact angle to water) equal to or greater than 80. Further preferably, the protection film has a contact angle (contact angle to water) equal to or greater than 100. There is no specific limit in upper value. However, the preferable upper limit is a value at or below 120.

(23) A preferable constituent material of the releasing layer (film) is ethylene tetrafluoro ethylene copolymer (ETFE). Alternatively, a preferable constituent material of the releasing layer is tetrafluoroetylene-hexafluoropropylen copolymer (FEP). The releasing layer may be also a polymer alloy containing the above described polymer.

(24) Preferably, the resin layer (transparent resin layer (film)/insulative resin layer film) is made of one or more resin selected from the group consisting of, for example, acrylic resin, methacrylic resin, (e.g., polymethyl methacrylate (PMMA)), ester-based resin (e.g., polyethylene-telephthalate (PET) and polyethylene naphthalate (PEN)), cellulose resin (e.g., triacetylcellulose (TAC)), olefin resin (e.g., cycloolefin polymer (COP) and cyclic olefin copolymer (COC)), carbonate resin (e.g., polycarbonate (PC)), and ABS resin.

(25) A second invention is directed to a method for manufacturing a molded article. In the method, the laminated film is subjected to molding in order to manufacture a molded article. The method includes a molding process. The molding process is a process for forming the laminated film into a predetermined shape (e.g., three-dimensional shape) by molding. The method includes a hardening treatment process. In the hardening treatment process, the protection film-constituent material layer is modified to a protection film (a hard protection layer (protection film)). The hardening treatment process is performed after the molding process. The hardening treatment process is, for example, a photo-irradiation process (e.g., an ultraviolet irradiation process). Alternatively, the hardening treatment process is a heating process. Which process is used as a hardening treatment process is determined according to components of the protection film-constituent material. In a case where the protection film-constituent material is the one cured by photo-irradiation, a photo-irradiation process is employed. In a case where the protection film-constituent material is the one cured by heating, a heating process is employed. The method includes a removal process. In the removal process, the releasing layer is removed. The removal process is performed, preferably, after the molding process.

(26) A third invention is directed to a molded article. The molded article is obtained by the method for manufacturing a molded article.

(27) A fourth invention is directed to a method for manufacturing a touch panel. In the method, the laminated film is subjected to molding, thereby manufacturing a touch panel. The method includes a molding process. In the molding process, the laminated film is formed into a predetermined shape by molding. The method includes a hardening treatment process. In the hardening treatment process, the protection film-constituent material layer is modified to a protection film (hard protection layer (hard protection film)). The hardening treatment process is performed, preferably, after the molding process. The hardening treatment process is, for example, a photo-irradiation process (e.g., ultraviolet irradiation process). Alternatively, the hardening treatment process is a heating process. Which hardening treatment process is employed is decided according to the components of the protection film-constituent material. In a case where the protection film-constituent material is the one which cures by photo-irradiation, a photo-irradiation process is employed. In a case where the protection film-constituent material is the one which cures by heating, a heating process is employed. The method includes a removal process. In the removal process, the releasing layer is removed. The removal process is performed, preferably, after the molding process.

(28) Preferably, the method further includes a molding process for forming a wiring film by molding. The wiring film has a structure that a wire layer of a predetermined pattern is provided on a surface of an insulative transparent resin layer.

(29) Preferably, the molding process includes a molding process A, a molding process B, and a molding process C. In the molding process A, the laminated film is formed by molding. In the molding process B, the wiring film is formed by molding. In the molding process C, a molded body obtained in the molding process A is formed into one piece with a molded body obtained in the molding process B.

(30) There is a case where the laminated film is not formed independently from the wiring film in the molding process. For example, it is possible to form a composite film by laminating the laminated film and the wiring film together by molding.

(31) The method for manufacturing a touch panel will be described below in the next embodiment. First, a wiring film is prepared. The wiring film (touch panel film) has the following structure. A plurality of first electrode rows arranged on at least one surface of a transparent electrical insulative resin film, the first electrode rows formed of a plurality of island-shaped electrodes being arranged in a first direction via inter-electrode wirings, are formed in a second direction approximately orthogonal to the first direction at designated intervals. A plurality of second electrode rows formed of a plurality of island-shaped electrodes arranged in the second direction via inter-electrode wirings is formed in the first direction at designated intervals. Ends of the plurality of first electrode rows and the plurality of second electrode rows are provided with the island-shaped electrodes, respectively. A lead wiring is connected to each of the island-shaped electrodes. The touch panel film having the above structure is initially preheated. Accordingly, there is obtained a box shaped touch panel film preforming body including a principal surface portion at a crossing position between the first direction and the second direction, at least two side surface portions which are approximately orthogonal to the first direction and continuous to the principal surface portion, and at least two side surface portions which are approximately orthogonal to the second direction and continuous to the principal surface portion, wherein the touch panel film preforming body includes therein a first hollow portion defined by the principal surface portion and at least four side surface portions. On the other hand, the laminated film is initially preheated. Alternatively, a laminated film made of the laminated film and a film (design film) laminated together is initially preheated. The design film is a film on which a design (characters, signs, drawings, etc.) is provided. Accordingly, a box shaped design film preforming body including the hollow portion defined by the at least four side surface portions and the principal surface portion can be obtained. The touch panel film preforming body is set in a first mold, and the design film preforming body is set in a second mold (positioned opposite to the first mold). An insert molding is performed to inject a transparent resin into a space between the touch panel film preforming body and the design film performing body. Accordingly, the touch panel film preforming body and the design film performing body are formed into one piece. This enables obtainment of a box shaped body (touch panel precursor) including a hollow portion having a shape similar to the first hollow portion. The touch panel precursor is exposed to light (e.g., ultra violet rays). This makes the protection film-constituent material layer being cured. As a result, a protection film is formed. Subsequent peeling-off of the releasing layer (releasable film) provides a touch panel of which protection film is exposed to the outside. In thus obtained touch panel, the plurality of first electrode rows and the plurality of second electrode rows are formed on the principal surface portion. When viewing from a direction perpendicular to a surface of the film made of the insulative transparent resin, the island-shaped electrodes of the first electrode rows and the island-shaped electrodes of the second electrode rows are separated from each other and are arranged alternatively, two-dimensionally into a lattice shape. A plurality of third electrode rows including a plurality of island-shaped electrodes connected via the inter-electrode wirings is arranged in a third direction approximately orthogonal to the first direction and the second direction. The plurality of third electrode rows are formed in at least one of the second direction in one or both of the two side surface portions approximately orthogonal to the first direction and the first direction in one side surface portion of the two side surface portions approximately orthogonal to the second direction. A principal surface input region of which position is designated on the principal surface portion by an electric conductive indicator is provided. Also, a side surface input region of which position is designated by the indicator is provided on at least one of the at least two side surface portions approximately orthogonal to the first direction and/or at least one of the at least two side surface portions approximately orthogonal to the second direction. At least the island-shaped electrodes and the inter-electrode wirings among the island-shaped electrodes, the inter-electrode wirings, and the lead wirings are formed into a net shape by using conductor thin lines.

(32) A fifth invention is directed to a touch panel. The touch panel is obtained by the method for manufacturing a touch panel.

(33) Preferably, the touch panel is an electrostatic capacitive type touch panel. The electrostatic capacitive type touch panel has a shape of a case body including a principal surface portion and side surface portions. The case body is molded by using the laminated film and the wiring film. The case body is provided with the protection film at least on its outer surface. The side surface portions are continuous to the principal surface portion. Each of the side surface portions is approximately orthogonal to the principal surface portion. For example, there are more than four side surface portions which are approximately orthogonal to the principal surface portion. At least one side surface portion among the side surface portions is approximately orthogonal to the first direction in the principal surface portion. At least one side surface portion among the side surface portions is approximately orthogonal to the second direction in the principal surface portion. The principal surface portion includes a principal surface input region. At least one side surface portion of the more than four side surface portions includes a side surface input region. The principal surface portion is provided with at least two first electrode rows and at least two second electrode rows. The at least two first electrode rows are provided at designated intervals. The at least two first electrode rows are provided along the first direction. The at least two second electrode rows are provided at designated intervals. The at least two second electrode rows are provided along the second direction. Each of the first electrode rows and the second electrode rows is composed of more than two island-shaped electrodes and the inter-electrode wirings electrically connected to the island-shaped electrodes. The side surface portion including the side surface input region is provided with one or more third electrode rows and one or more fourth electrode rows. The third electrode rows are arranged on an extension of the first electrode rows (and/or the second electrode rows). The fourth electrode rows are arranged along a direction of the second electrode rows (and/or the first electrode rows). One ends of the first lead wirings are electrically connected to ends of the first electrode rows or ends of the third electrode rows. The other ends of the first lead wirings are formed on a side surface portion which does not include the side surface input region. One ends of the second lead wirings are electrically connected to the ends of the second electrode rows and ends of the fourth electrode rows. The other ends of the second lead wirings are formed on a side surface portion which does not include the side surface input region. At least one of the first lead wirings and the second lead wirings pass through a ridgeline portion which is a boundary between side surface portions adjacent to each other.

(34) Preferably, the first electrode rows are provided on one surface of the principal surface portion. Preferably, the second electrode rows are provided on the other surface of the principal surface portion. Preferably, the third electrode rows are provided on a surface where the electrode rows as origins of the third electrode rows are provided. Preferably, the fourth electrode rows are provided on a surface where the electrode rows along which the fourth electrode rows are arranged are provided.

(35) The first electrode rows and the second electrode rows are provided on one surface of the principal surface portion. The electrically insulative spacers are interposed at crossings between the first electrode rows and the second electrode rows. The third electrode rows and the fourth electrode rows are provided on one surface of the side surface portion. The electrically insulative spacers are interposed at crossings between the third electrode rows and the fourth electrode rows.

(36) Preferably, the lead wirings which pass through the ridge line portion are positioned on an inner surface of the case body.

(37) A sixth invention is directed to a display device. The display device includes the touch panel.

(38) A seventh invention is directed to an information processor. The information processor includes the display device.

(39) More specific embodiments will be described below. However, the present invention is not limited to the following embodiments. In so far as the features of the present invention are not impaired, various modifications and applications will be encompassed within the scope of the present invention.

Embodiment (A)

(40) An embodiment (A) of the present invention is illustrated in FIG. 1 to FIG. 3. FIG. 1 is a cross sectional view of a laminated film. FIG. 2 is a cross sectional view of a molded body obtained by forming a laminated film of FIG. 1 into a predetermined shape by molding. FIG. 3 is a cross sectional view of a molded body from which a releasable film has been peeled off.

(41) In FIG. 1 to FIG. 3, 1 denotes a base material (resin film/transparent resin film/insulative transparent resin film). The base material 1 has a thickness of a range, for example, between 50 and 2000 m. A preferable thickness of the base material 1 is of a range between 50 and 500 m. It is sufficient for the base material 1 to have an insulation property equivalent to the insulation property required in the conventional touch panel. It is sufficient for the base material 1 to have transparency equivalent to the transparency required in the conventional touch panel. In the present embodiment, the film used here is a PMMA film (Technolloy S001G#125, having a thickness of 125 m, manufactured by Sumitomo Chemical Company).

(42) 2 denotes a protection film constituting-material film. The protection film constituting-material film 2 has a thickness of a range between 1 and 100 m. A preferable thickness of the protection film constituting-material film 2 was of a range between 1 and 30 m. The protection film constituting-material film 2 is cured by hardening treatment (e.g., heating and/or photo-irradiation). Thus cured film is a protection film. In a process of FIG. 1, the hardening treatment has not been performed yet. Application of a coating containing a protection film-constituent material (e.g., resin material) to a surface of the film 1 formed the protection film constituting-material film 2. Any coating method can be employed, as required, for example, from meyer bar coating, bar coater coating, air knife coating, gravure coating, offset printing, flexo printing, and screen printing. After the application, drying treatment (e.g., hot-air drying at a temperature of 80 C. for 1 minute) was performed. The protection film constituting-material film 2 was dried and solidified but was not subjected to hardening treatment. Since the protection film constituting-material film 2 has not been subjected to the hardening treatment, the protection film constituting-material film 2 was still uncured. Even if the protection film constituting-material film 2 would have been cured under natural conditions, the protection film constituting-material film 2 had not been in a completely cured state. In this case, the protection film constituting-material film 2 was in a semi-cured state at the most. The protection film constituting-material film 2 which is not completely cured is relatively soft. Therefore, the base material 1 provided with the protection film constituting-material film 2 can be rolled up. A film (cured film/protection film) obtained by causing the protection film constituting-material film 2 to be subjected to hardening treatment is a fluorine-based resin film. In the present embodiment, a thickness of the protection film constituting-material film 2 was 9 m. In the present embodiment, the protection film constituting-material film 2 was an ultra violet irradiation curable type film. For example, the protection film constituting-material film 2 was of a type of film being cured as the polymerization reaction by ultraviolet irradiation improved.

(43) 3 denotes a releasable film. The releasable film 3 has a thickness of a range between, for example, 5 and 50 m. The releasable film 3 was provided on a surface of the protection film constituting-material film 2 before the protection film constituting-material film 2 was dried and solidified. A roll laminator was used for lamination. This enabled the releasable film 3 to closely cover the protection film constituting-material film 2. The releasable film 3 is a fluorine-based resin film. The releasable film 3 can be formed by applying a fluorine-based resin containing-coating to a film surface (a surface touching the protection film constituting-material film 2). For example, the releasable film 3 may be formed by applying a FEP containing coating or an ETFE containing coating. In this case, the protection film-constituent material and the FEP containing coating (ETFE containing coating) may be formed by a simultaneous multilayer-lamination application method. Even with the simultaneous multilayer-lamination application method, strictly speaking, the protection film constituting-material film (lower layer) 2 is formed prior to the releasable film (upper layer) 3 for sure.

(44) In a case where the fluorine-based resin containing-coating is applied to the releasable film, the film itself is not necessarily being composed of a fluorine-based resin film. In this case, a resin film publicly known as a releasable film can be used. For example, a film made of materials used in the above mentioned resin layer (transparent resin layer, insulative resin layer) can be used.

(45) 4 denotes a laminated film. The laminated film 4 is a laminated material composed of the film 1, the protection film constituting-material film 2, and the releasable film 3.

(46) The laminated film 4 was formed by molding (by, for example, heat-molding).

(47) After formation of the laminated film 4, a molded article (see, FIG. 2) 5 was taken out from a mold.

(48) Thus taken out molded article 5 was subjected to ultraviolet irradiation. An ultraviolet irradiation apparatus used here was a Light Hammer (H valve) manufactured by Fusion UV Systems, Japan. The accumulative light intensity of ultraviolet irradiation was 900 mJ/cm.sup.2. Accordingly, the protection film constituting-material film 2 was completely cured. In other words, the protection film constituting-material film 2 was modified to be a cured film (protection film) 6.

(49) Subsequently, the releasable film 3 was peeled off (see, FIG. 3).

(50) After the peeling-off of the releasable film 3, features of the resulting product were checked. A result thereof is shown in Table-1.

(51) In Table-1, in the laminated film 4 of example 1, a hard coating agent (Acier produced by NIDEK CO., LTD.) composing the fluorine-based resin was employed for the protection film constituting-material film 2, and an ethylene tetrafluoro ethylene copolymer (ETFE) film (AFLEX 12N, having a thickness of 12 m, produced by ASAHI GLASS CO., LTD.) was employed for the releasable film 3.

(52) In the laminated film 4 of example 2, materials identical to those of example 1 were employed, except that a thickness of the releasable film (ETFE film) 3 was 25 m.

(53) In the laminated film 4 of example 3, materials identical to those of example 1 were employed, except that a thickness of the releasable film (ETFE film) 3 was 50 m.

(54) In the laminated film 4 of example 4, materials identical to those of example 1 were employed, except that a tetrafluoroetylene-hexafluoropropylen copolymer (FEP) film (TOYOFLON12FLS, having a thickness of 12.5 m, produced by TORAY INDUSTRIES, INC.) was employed for the releasable film 3.

(55) In the laminated film 4 of example 5, materials identical to those of example 2 were employed, except that a hard coating agent (RL-1563 produced by SANYU REC CO., LTD.) composing fluorine-based resin was employed for the protection film constituting-material film 2.

(56) In the laminated film 4 of example 6, materials identical to those of example 1 were employed, except that a film obtained by applying releasable agent (containing a perfluoro group) to a PET (PET100SG-2 produced by PANAC Corporation) film was employed for the releasable film 3.

(57) In the laminated film 4 of example 7, materials identical to those of example 1 were employed, except that a film obtained by applying releasable agent (fluoroethylene-vinyl ether-based) to a PET (PET100SG-2 produced by PANAC Corporation) film was employed for the releasable film 3.

(58) In the laminated film 4 of comparison example 1, materials identical to those of example 1 were employed, except that the releasable film 3 was not provided. Before molding, the protection film constituting-material film 2 was subjected to ultraviolet irradiation, instead, to be formed into a completely cured film.

(59) In the laminated film 4 of comparison example 2, materials identical to those of example 1 were employed, except that the releasable film 3 was a PET film (Lumilar25T60, having a thickness of 25 m, produced by TORAY INDUSTRIES, INC.).

(60) In the laminated film 4 of comparison example 3, materials identical to those of example 1 were employed, except that the releasable film 3 was a polymethylpentene (PMP) film (Opyuran50X44B, having a thickness of 50 m, produced by Mitsui Chemicals, Inc.).

(61) In the laminated film 4 of comparison example 4, materials identical to those of example 1 were employed, except that the releasable film 3 was a polypropylene (PP) film (Torayfan40BO2500, having a thickness of 40 m, produced by TORAY INDUSTRIES, INC.).

(62) In the laminated film 4 of comparison example 5, materials identical to those of example 7 were employed, except that no releasable film 3 was provided. Before molding, the protection film constituting-material film 2 was subjected to ultraviolet irradiation, instead, to be completely cured.

(63) In the laminated film 4 of comparison example 6, materials identical to those of example 7 were employed, except that the releasable film 3 was a polymethylpentene (PMP) film (Opyuran50X44B, having a thickness of 50 m, produced by Mitsui Chemicals, Inc.).

(64) How to evaluate features (items to be evaluated) of Table-1 is described below.

(65) [Contact Angle (Contact Angle to Purified Water and Contact Angle to Oleic Acid)]

(66) Purified water (or oleic acid) was dropped (by dropping amount of 2.0 l) on a surface of a protection film (completely cured film). A contact angle to purified water (or oleic acid) was measured. CA-VE Type Automatic Contact Angle Meter (manufactured by Kyowa Interface Science Co., LTD.) was used for the measurement of contact angle. Room temperature at the time of measurement was in a range between 20 C. and 25 C. Humidity at the time of measurement was in a range between 20 and 60% RH. (1/2) Method was employed for measurement. Stain-proof performance of protection film was evaluated by using the contact angle. An oleic acid is considered as oil composition of a finger print, and a contact angle to the oleic acid is regarded as a lipophilic parameter.

(67) It is desirable that a surface of the protection film has water repellency and oil repellency. It is further desirable that both of a contact angle to water and a contact angle to oleic acid show high angles. Preferable contact angle to water is a value equal to or greater than 70. Preferable contact angle to oleic acid is a value equal to or greater than 40. With such degree of values, both of aqueous stain and oleic stain hardly stick to the surface of the protection film.

(68) [Sticking Resistance of Solvent Ink (Wiping Easiness of Solvent Ink)]

(69) Here, a degree of oil soluble stain resistance (removal easiness of the sticking oil soluble stain) is evaluated in this item. That is, stain resistance of the protection film is evaluated.

(70) An oily magic pen (Mackie Care, superfine (red) manufactured by ZEBRA CO., LTD.) was employed. Writing was performed on a surface of the protection film by the oily magic pen.

(71) A case where ink was strongly repelled to form a water drop and thus could be readily wiped out was indicated by .

(72) A case where ink was repelled and thus could be readily wiped out was indicated by .

(73) A case where ink was not repelled but could be wiped out was indicated by .

(74) A case where ink could not be wiped out was indicated by x.

(75) [Pencil Hardness of Protection Film]

(76) A pencil hardness of completely hardened protection film was checked according to JIS-K5600-5-4 (scratch hardness (Pencil Method)).

(77) [Scratch Resistance of Protection Film]

(78) Gakushin friction fastness tester AB-301 (manufactured by TESTER SANGYO CO., LTD.) and a friction block (steel wool of #0000) were employed. While a load of 1000 g was applied to a surface of the protection film, a to-and-fro motion was repeated for 10 times at 120 mm/s (speed) for 120 mm (distance).

(79) A case where no scratch was made was indicated by .

(80) A case where 1 to 3 scratches were made was indicated by .

(81) A case where more than 11 scratches were made was indicated by .

(82) [Vacuum Molding Property]

(83) In a case where the laminated film 4 was subjected to vacuum forming (heating at a temperature of 400 C. for 20 seconds),

(84) if the laminated film 4 could be formed into a deep drawing shape, it was indicated by ;

(85) if the laminated film 4 could be formed into a shallow drawing shape, it was indicated by ;

(86) if the laminated film 4 was formed into a mere simple curving shape, it was indicated by ; and

(87) if the laminated film 4 was broken to fail to obtain a resulting product, it was indicated by x.

(88) TABLE-US-00001 TABLE 1 contact angle () solvent ink pencil wear-resistance total water oleic acid sticking resistance hardness feature moldability evaluation example 1 103.0 60.4 4H example 2 103.8 61.6 4H example 3 104.4 62.0 4H example 4 107.2 73.0 4H example 5 116.6 72.6 3H example 6 97.8 54.6 4H example 7 100.2 48.2 3H comparison 106.6 67.2 3H X X example 1 comparison 70.2 19.8 X 3H X example 2 comparison 100.2 51.8 X X example 3 comparison 104.8 18.4 X 2H X example 4 comparison 112.4 72.8 2H X X example 5 comparison 105.4 54.2 X 2H X X example 6

(89) Table-1 shows that a feature of the cured film (protection film) 6 differs largely according to a combination of the protection film constituting-material film 2 and the releasable film 3. Table-1 shows excellent moldability in a case where a ETFE film or a FEP film is employed as the releasable film 3 with respect to the protection film constituting-material film 2. Further, Table-1 shows that contaminant such as oil hardly sticks to the protection film. Table-1 further shows that the contaminant can be removed with ease even if contaminant sticks to the protection film. In other words, Table-1 shows that the protection film is excellent in contamination resistance. Table-1 still further shows that the protection film is hardly scratched since it is hard.

(90) A resin without containing fluorine (PET, PP, PMP, etc.) is not desirable to be employed as the releasable film 3 since stain resistance does not appear. According to the embodiment of the present invention, while placing the protection film constituting-material film 2 in a state of being not polymerized or cured completely, the surface of the film 2 was covered with the releasable film 3 (laminating film), and subsequently, the protection film constituting-material film 2 covered by the releasable film 3 was completely cured (polymerized and cured). If it was desired to cause the protection film 6 to have a preferable feature (e.g., mechanical properties (pencil hardness, scratch resistance, etc.) and antifouling property (water repellency and oil repellency)), it was needed to cause the F (fluorine) for generating stain resistance to exist on the surface of the protection film 6 after the removal of the releasable film 3. Therefore, it was known that existence of F in the releasable film 3 was essential.

(91) In each example, in order to enhance affinity between the protection film constituting-material film 2 and the releasable film 3 and to cause F to exist in the protection film constituting-material film 2, a releasable film containing F is employed. This enables simultaneous appearance of mechanical properties and antifouling property.

(92) When compared with PP having a SP value (solubility parameter: ) of 8.1, PET having a SP value of 11, poly(vinylidene fluoride) having a SP value of 11, PTFE having a SP value of 6.2, FEP having a SP value of 6.5, and ETFE having a SP value of 7.1, it is considered that a fluorine-based resin having a SP value of 6.57.1 is suitable as the releasable film 3.

Embodiment (B)

(93) An embodiment (B) is illustrated in FIG. 4 to FIG. 11. FIG. 4 is a cross sectional view of a laminated film (in some cases, it is referred to as a design film) obtained by laminating a design film on the laminated film of FIG. 1. FIG. 5 is a cross sectional view of a molded body obtained by forming the laminated film of FIG. 4 into a predetermined shape by molding. FIG. 6 is a cross sectional view of a wiring film (touch panel film). FIG. 7 is a cross sectional view of a molded body obtained by forming a wiring film (touch panel film) into a predetermined shape by molding. FIG. 8 is a cross sectional view illustrating a state of a molding process in which the molded body of FIG. 5 and the molded body of FIG. 7 are formed into one piece. FIG. 9 is a cross sectional view of a molded body (touch panel precursor) taken out from a mold. FIG. 9 illustrates a state of ultraviolet irradiation (hardening treatment of a protection film constituting-material film). FIG. 10 is a cross sectional view of a touch panel from which the releasable film 3 has been peeled off. FIG. 11 is a perspective view of a touch panel.

(94) The laminated film of FIG. 4 corresponds to those of examples 1 to 7 in the first embodiment.

(95) 10 denotes a design film. The design film 10 is laminated on the other side (a side where the protection film constituting-material film 2 is not provided) of the base material (resin film/transparent resin film/insulative transparent resin film) 1.

(96) The laminated film 11 of FIG. 4 was formed by molding (by heat-molding or, in some cases, vacuum forming, pneumatic molding, or press molding is performed simultaneously with the heat-molding). Reference characters 1 to 6 means components identical to those of the embodiment (A). A design film molded body 12 was obtained by molding (see, FIG. 5).

(97) The design film molded body 12 includes four side surface portions having a design print layer (decorative film) formed at a peripheral region and a principal surface portion where no design print layer (decorative film) is formed, and defines a hollow portion by the four side surface portions and the principal surface portion. The design film molded body 12 has a case shape (box shape).

(98) 13 denotes a wiring film (touch panel film). 14 denotes an insulative transparent resin layer (film). The above exemplified resins are used, as required. Specifically, a stretchable resin is employed. Examples of the stretchable resin include PET and PMMA. The film 14 has a thickness of a range, for example, between 10 and 500 m. Preferable thickness of the film 14 is in a range between 50 and 300 m. Wirings 15 and 16, each having a predetermined pattern, are formed on both of a front surface and a rear surface (an upper surface and a lower surface) of the film 14 in each corresponding manner. The patterns of the wirings 15 and 16 are as described above. An electrostatic capacity can be detected via the wirings 15 and 16. The wiring film 13 can be produced by using a transparent electric conductive film Exclear (produced by FUJIFILM Holdings Corporation) applied with, for example, optical silver halide photography technology. Each wiring is made of conductor thin line. Each wiring is composed of, for example, net-shaped electrode, inter-electrode wiring, lead wiring, etc. The wirings 15 and 16 may be formed with a transparent electric conductive material such as ITO and carbon nanotube. Meanwhile, a design film similar to the design film 10 may be laminated with the wirings 15 and 16.

(99) A wiring film 13 (see, FIG. 6) was formed by molding (by heat-molding or, in some cases, vacuum forming, pneumatic molding, or press molding is performed simultaneously with the heat-molding). Accordingly, a touch panel film-shaped molded body 17 (see, FIG. 7) was obtained. The touch panel film molded body 17 has a shape similar to that of the design film molded body 12.

(100) The design film molded body 12 (see, FIG. 5) and the touch panel film molded body 17 (see, FIG. 7) were used to form a touch panel precursor by insert molding. The touch panel film molded body 17 was set in a convex mold 18a. The design film molded body 12 was set in a concave mold 18b. The convex mold 18a and the concave mold 18b were matched (closed). Subsequently, a fluidized resin material for molding (transparent resin 19) was injected into a space between the design film molded body 12 and the touch panel film molded body 17. After cooling, the mold was opened. Then, a molded body obtained by insert molding (a molded body obtained by integrating the design film molded body 12 and the touch panel film molded body 17/touch panel precursor) 20 (see, FIG. 9) was taken out. Subsequently, thus taken out integrated molded body was subjected to ultraviolet irradiation (see, FIG. 9). Accordingly, the protection film constituting-material film 2 was completely cured and modified to be the cured film (protection film) 6. Then, the releasable film 3 was peeled off. This causes the protection film 6 to be exposed to the outside. As a result, a touch panel 21 was obtained (see, FIG. 10 and FIG. 11).

REFERENCE CHARACTER LIST

(101) 1 base material (resin film)

(102) 2 protection film constituting-material film

(103) 3 releasable film

(104) 4 laminated film

(105) 5 molded article

(106) 6 cured film (protection film)

(107) 10 design film

(108) 11 laminated film

(109) 12 design film molded body

(110) 13 wiring film (touch panel film)

(111) 14 insulative transparent resin layer (film)

(112) 15, 16 wiring

(113) 17 touch panel film molded body

(114) 18a convex mold

(115) 18b concave mold

(116) 20 molded body obtained by insert molding (touch panel precursor)

(117) 21 touch panel