Adhesive film and method of manufacturing the same and display device including the adhesive film

1. A method of manufacturing an adhesive film comprising:

preparing a transparent adhesion layer in a state having a storage modulus of about 10 3 Pa to about 10 6 Pa at room temperature;

disposing a film mask including a light-transmitting region and a light-shielding region on the transparent adhesion layer in the state having a storage modulus of about 10 3 Pa to about 10 6 Pa at room temperature;

applying ultraviolet (UV) light to the transparent adhesion layer in the state having a storage modulus of about 10 3 Pa to about 10 6 Pa at room temperature through the film mask to precure an area of the transparent adhesion layer corresponding to the light-transmitting region of the film mask into a state having a storage modulus of no less than about 10 6 Pa; and

only cutting within the precured area of the transparent adhesion layer in the state having a storage modulus of no less than about 10 6 Pa.

2. The method of claim 1 , wherein the film mask comprises a light-blocking printed layer and a release layer formed on the transparent adhesion layer, and wherein the light-blocking printed layer is formed on all areas of the transparent adhesion layer except for a place corresponding to the area where the transparent adhesion layer is to be cured.

3. The method of claim 2 , wherein the place corresponding to the area where the transparent adhesion layer is to be cured is formed with a closed curved line.

4. The method of claim 1 , wherein the preparing of the transparent adhesion layer comprises: laminating the optically clear adhesive in the state having a storage modulus of about 10 3 Pa to about 10 6 Pa at room temperature.

5. The method of claim 4 , wherein the optically clear adhesive comprises:

an acrylic copolymer obtained from a composition including a solution-polymerizable acryl compound and a reaction initiator, and

an ultraviolet (UV) curable compound.

6. The method of claim 5 , wherein the solution-polymerizable acryl compound comprises at least one selected from the group consisting of an acrylic acid, 2-ethylhexyl acrylate, 2-methylbutyl acrylate, isooctyl acrylate, lauryl acrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, octyl acrylate, decyl acrylate, and isodecyl acrylate.

7. The method of claim 6 , wherein the solution-polymerizable acryl compound comprises:

about 30 to about 60 wt % of butyl acrylate,

about 30 to about 60 wt % of 2-ethylhexyl acrylate, and

about 0.1 to about 40 wt % of acrylic acid.

8. The method of claim 5 , wherein the reaction initiator comprises at least one selected from the group consisting of benzoylperoxide, acetyl peroxide, dilauryl peroxide, hydrogen peroxide, potassium persulfonate, and 2,2′-azobisisobutyronitrile.

9. The method of claim 5 , wherein the ultraviolet (UV) curable compound comprises at least one selected from the group consisting of caprolactone acrylate, 1,6-hexanediol diacrylate, trimethylolpropane triacrylate, pentaerythritol triacrylate, lauryl acrylate, urethane acrylate, epoxy acrylate, polyester acrylate, and silicon acrylate.

10. The method of claim 9 , wherein the ultraviolet (UV) curable compound comprises about 5 to about 50 wt % of trimethylolpropane triacrylate, about 5 to about 50 wt % of multi-functional urethane acrylate, and about 5 to about 50 wt % of 1,6-hexadiol diacrylate.

11. The method of claim 5 , wherein the optically clear adhesive further comprises a photoinitiator.

12. The method of claim 5 , wherein the acrylic copolymer and the ultraviolet (UV) curable compound are included at a weight ratio of about 70:30 to about 95.5:0.5.

13. The method of claim 1 , wherein the disposing of the film mask, the precuring of the transparent adhesion layer, and the cutting of the precured area of the transparent adhesion layer in the state having a storage modulus of no less than about 10 6 Pa are performed in an in-line process.