JP2013182069A - Method of manufacturing polarizer molding, polarizer molding, anti-glare product, and protection product - Google Patents
Method of manufacturing polarizer molding, polarizer molding, anti-glare product, and protection product Download PDFInfo
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Description
本発明は、偏光板成形体の製造方法、偏光板成形体、防眩製品および防護製品に関する。 The present invention relates to a method for producing a polarizing plate molding, a polarizing plate molding, an antiglare product, and a protective product.
熱可塑性樹脂を保護層に有する偏光板を熱曲げして得られる成形体は、例えば、サングラスやスキーゴーグル、ヘルメットシールド、バイザー、保護面、オートバイの風防など、目、顔または体全体の保護材料として耐衝撃性が要求される用途に好んで用いられる。
このように偏光板を熱曲げ加工することによって得る方法は、熱曲げ加工前に偏光性薄膜を予めシートに施すことが可能であるため、加工後に同様の処理を行うよりも生産性が高く好んで用いられる製造方法である。
偏光板を熱曲げ加工する際には、従来保護フィルムを剥した後に曲げ加工を行ったり、偏光板の保護層に用いられる熱可塑性樹脂の曲げ加工温度よりも高い融点を有する保護フィルムを貼り合わせて曲げ加工したりしている。
保護フィルムを剥した後に曲げ加工を行う場合は、成形型に直接偏光板が接触するため、成形型の表面精度を上げる必要があり、また偏光板に異物が付着しないよう留意する必要があり作業性を著しく阻害する。
一方、保護フィルムを貼り合わせて曲げ加工する場合でも、保護フィルムの表面状態や成形型の凹凸を転写しゆず肌などの外観品質上の問題点が発生しやすく、これを防止するために成形型の表面粗さ精度を上げたり、成形型を傷つけないよう注意を要したり、成形型にラバーを貼り付けたりする必要があった。
Molded products obtained by thermally bending a polarizing plate having a thermoplastic resin as a protective layer are, for example, sunglasses, ski goggles, helmet shields, visors, protective surfaces, motorcycle windshields, etc. It is preferably used for applications that require impact resistance.
The method obtained by hot bending the polarizing plate in this way is more preferable than performing the same treatment after processing because the polarizing thin film can be applied to the sheet in advance before the heat bending. It is a manufacturing method used in this.
When heat-bending a polarizing plate, the conventional protective film is peeled off and then bent, or a protective film having a melting point higher than the bending temperature of the thermoplastic resin used for the protective layer of the polarizing plate is bonded. Or bending.
When bending after removing the protective film, the polarizing plate is in direct contact with the mold, so it is necessary to increase the surface accuracy of the mold, and care must be taken to prevent foreign matter from adhering to the polarizing plate. Significantly inhibits sex.
On the other hand, even when the protective film is bonded and bent, the surface condition of the protective film and the unevenness of the mold are transferred, and it is easy to cause problems in appearance quality such as the skin, and the mold is used to prevent this. Therefore, it was necessary to increase the surface roughness accuracy of the mold, to take care not to damage the mold, and to attach rubber to the mold.
これらを改善するため、ポリカーボネート製偏光板の熱曲げ加工については、特許文献１には融点の異なる２枚の保護フィルムを用いること、特許文献２には特定の融解ピークを有する保護フィルムを用いることが示されている。しかしながら、これらはポリカーボネート製偏光板についてのみこれら不具合を改善出来るが、他の樹脂を用いた偏光板についての方法は示されていない。さらに特許文献１記載の方法では、片側に２枚の保護フィルムを用いる必要があるため不経済であること、生産時の工程が煩雑になること、また貼り合わせ界面が片面２箇所ずつとなるため保護フィルムが１枚の場合と比べゴミやエアの噛み込みが起こりやすくなることなどの新たな不具合が生じやすい。また、特許文献２では、特定の融解ピークを有する保護フィルムの生産が必要となる。
また、これら特許文献には、曲率半径が８５ｍｍ以下のより深い形状に曲げ加工する方法が示されていない。これ以上深い形状に曲げ加工を行う場合には、例えば一度浅い形状に成型した後にさらに深い形状の成形型を用いて曲げ加工を行うなど、２回以上の曲げ加工を行い深い形状に曲げ加工することが考えられるが、２度目以降の曲げ加工を行う際に１度目の曲げ加工にて周囲に生じたマスキングのシワが転写する場合がある。この周囲のシワを防止するための方法として、偏光板周囲をクランプした後に１回で曲げ加工を行う方法が考えられるが、偏光板に用いる熱可塑性樹脂の樹脂特性により干渉縞が発生する場合がある。
以上より、外観および生産性が良好であり、偏光板に用いる熱可塑性樹脂の種類に寄らず保護フィルムを貼り合わせた偏光板を所望の形状に熱曲げ加工を行うことが出来る偏光板成形体の製造方法はいままで示されていないのが現状である。
In order to improve these, regarding the heat bending process of the polarizing plate made of polycarbonate, Patent Document 1 uses two protective films having different melting points, and Patent Document 2 uses a protective film having a specific melting peak. It is shown. However, they can improve these problems only for polycarbonate polarizing plates, but no method for polarizing plates using other resins is shown. Furthermore, in the method described in Patent Document 1, it is necessary to use two protective films on one side, which is uneconomical, the production process becomes complicated, and the bonding interface becomes two places on one side. Compared with the case of a single protective film, new problems such as dust and air biting are more likely to occur. In Patent Document 2, it is necessary to produce a protective film having a specific melting peak.
Moreover, these patent documents do not show a method of bending into a deeper shape having a radius of curvature of 85 mm or less. When bending into a deeper shape than this, for example, after forming into a shallow shape once, using a deeper shape mold, bending is performed twice or more times into a deep shape. However, when performing the second and subsequent bending processes, masking wrinkles generated around the first bending process may be transferred. As a method for preventing the surrounding wrinkles, a method of bending once after clamping the periphery of the polarizing plate can be considered, but interference fringes may occur due to the resin characteristics of the thermoplastic resin used for the polarizing plate. is there.
As described above, a polarizing plate molded body having good appearance and productivity, and capable of performing a heat bending process on a polarizing plate to which a protective film is bonded regardless of the type of thermoplastic resin used for the polarizing plate. The manufacturing method has not been shown so far.
本発明は、上記に顧みてなされたものであり、偏光板に保護フィルムを貼り合わせたままで熱曲げ加工しても良好な外観を有する偏光板成形体の製造方法を提供することである。 The present invention has been made in view of the above, and it is an object of the present invention to provide a method for producing a polarizing plate molded body having a good appearance even when heat-bending with a protective film bonded to a polarizing plate.
上記課題は、下記［１］〜［７］に記載の本発明により達成される。
［１］ 偏光性薄膜の両面に熱可塑性樹脂シートを貼り合わせた厚さ１ｍｍ以下の偏光板の少なくとも片面に保護フィルムを貼り合わせる工程、
裁断または打ち抜きにより形状加工する工程、
加熱しながら前記保護フィルムを貼り合わせた偏光板を金属製の成形型に密着させ、賦形させることにより曲率半径が８５ｍｍ以下となるように曲げ加工する工程、を含む偏光板成形体の製造方法であって、
前記曲げ加工工程が、周囲を保持せずに目的の偏光板成形体形状よりも曲率半径の大きな成形型で１次の曲げ加工を行い、１次の曲げ加工を行った成形体をさらに曲率半径の小さな異なる成形型で２次の曲げ加工を行うことで偏光板成形体の曲げ加工を行う方法であり、
前記保護フィルムの１３０℃の最大引張強度が０．９５Ｎ以下の保護フィルムを用いる、
偏光板成形体の製造方法。
［２］ 前記保護フィルムの１４０℃の最大引張強度が０．０５Ｎ以上の保護フィルムを用いる、［１］に記載の偏光板成形体の製造方法。
［３］ 前記保護フィルムの１０５℃の最大引張強度が１．7Ｎ以下の保護フィルムを用
いる、［１］または［２］に記載の偏光板成形体の製造方法。
［４］ 前記曲げ加工回数を２回以上行う、［１］から［３］のいずれか１項に記載の偏光板成形体の製造方法。
［５］ 前記偏光板の両面に前記保護フィルムを貼り合わせる工程を有する、［１］から［４］のいずれか１項に記載の偏光板成形体の製造方法。
［６］ ［１］から［５］のいずれか１項に記載の製造方法によって製造される偏光板成形体。
［７］ ［６］に記載の偏光板成形体を用いて製造される防眩製品または防護製品。
The said subject is achieved by this invention as described in following [1]-[7].
[1] A step of bonding a protective film to at least one side of a polarizing plate having a thickness of 1 mm or less in which a thermoplastic resin sheet is bonded to both surfaces of a polarizing thin film;
A process of shape processing by cutting or punching,
A method for producing a polarizing plate molded body, comprising: a step of closely bonding a polarizing plate having the protective film bonded thereto while heating to a metal mold and bending the polarizing plate so that the radius of curvature is 85 mm or less. Because
In the bending process, a primary bending process is performed with a mold having a larger radius of curvature than the shape of the objective polarizing plate without holding the periphery, and the molded body subjected to the primary bending process is further subjected to a radius of curvature. Is a method of bending a polarizing plate molded body by performing secondary bending with a small different mold,
A protective film having a maximum tensile strength at 130 ° C. of 0.95 N or less is used.
Manufacturing method of polarizing plate molding.
[2] The method for producing a polarizing plate molded article according to [1], wherein a protective film having a maximum tensile strength at 140 ° C. of 0.05 N or more is used.
[3] The method for producing a polarizing plate molding according to [1] or [2], wherein a protective film having a maximum tensile strength at 105 ° C. of 1.7 N or less is used.
[4] The method for producing a polarizing plate molded article according to any one of [1] to [3], wherein the bending process is performed twice or more.
[5] The method for producing a polarizing plate molded body according to any one of [1] to [4], including a step of bonding the protective film to both surfaces of the polarizing plate.
[6] A polarizing plate molded body produced by the production method according to any one of [1] to [5].
[7] An antiglare product or a protective product produced using the polarizing plate molding according to [6].
本発明によれば、偏光板の熱曲げ加工において、曲げ加工時の成形型の温度に応じて適切な保護フィルムを貼り合わせることにより、成形型からの転写やゴミやエアの噛み込みが少なく外観良好であり、生産性にも優れた偏光板成形体の製造方法を提供することができる。 According to the present invention, in the heat bending process of the polarizing plate, by attaching an appropriate protective film according to the temperature of the mold during the bending process, the appearance from the transfer from the mold and the biting of dust and air is reduced. It is possible to provide a method for producing a molded polarizing plate that is good and excellent in productivity.
本発明は、 偏光性薄膜の両面に熱可塑性樹脂シートを貼り合わせた厚さ１ｍｍ以下の偏光板の少なくとも片面に保護フィルムを貼り合わせる工程、
裁断または打ち抜きにより形状加工する工程、
加熱しながら前記保護フィルムを貼り合わせた偏光板を金属製の成形型に密着させ、賦形させることにより曲率半径が８５ｍｍ以下となるように曲げ加工する工程、を含む偏光板成形体の製造方法であって、
前記曲げ加工工程が、周囲を保持せずに目的の偏光板成形体形状よりも曲率半径の大きな成形型で１次の曲げ加工を行い、１次の曲げ加工を行った成形体をさらに曲率半径の小さな異なる成形型で２次の曲げ加工を行うことで偏光板成形体の曲げ加工を行う方法であ
り、
前記保護フィルムの１３０℃の最大引張強度が０．９５Ｎ以下の保護フィルムを用いる、
偏光板成形体の製造方法であり、
前記保護フィルムを貼り合わせたままで熱曲げ加工しても、成形型からの転写や、ゴミやエアの噛み込みなどの外観不具合が少なく、生産性にも優れた偏光板成形体の製造方法を提供することができる。
The present invention includes a step of bonding a protective film to at least one side of a polarizing plate having a thickness of 1 mm or less in which a thermoplastic resin sheet is bonded to both sides of a polarizing thin film,
A process of shape processing by cutting or punching,
A method for producing a polarizing plate molded body, comprising: a step of closely bonding a polarizing plate having the protective film bonded thereto while heating to a metal mold and bending the polarizing plate so that the radius of curvature is 85 mm or less. Because
In the bending process, a primary bending process is performed with a mold having a larger radius of curvature than the shape of the objective polarizing plate without holding the periphery, and the molded body subjected to the primary bending process is further subjected to a radius of curvature. Is a method of bending a polarizing plate molded body by performing secondary bending with a small different mold,
A protective film having a maximum tensile strength at 130 ° C. of 0.95 N or less is used.
It is a manufacturing method of a polarizing plate molding,
Providing a method for producing a polarizing plate molded body with excellent productivity, with few appearance defects such as transfer from a mold and entrapment of dust and air even when heat-bending with the protective film attached can do.
まず、本発明の偏光性薄膜の両面に熱可塑性樹脂シートを貼り合わせた厚さ１ｍｍ以下の偏光板の少なくとも片面に保護フィルムを貼り合わせる工程としては、例えば、圧着ロールを用いて偏光板の両面に保護フィルムを圧着する方法が挙げられる。
次に、裁断または打ち抜きにより形状加工する工程としては、ギロチン、シャーリング、カッター、パネルソー、糸鋸、帯鋸、鋏、ＮＣルーター、トムソン刃、ダイカッターなどを用いて、所望の形状や大きさに加工する方法が挙げられる。特に、所望の形状に短時間で打ち抜くことが可能かつ断面の仕上がりも良好となるトムソン刃を用いることが好ましい。
First, as a step of bonding a protective film to at least one surface of a polarizing plate having a thickness of 1 mm or less in which a thermoplastic resin sheet is bonded to both surfaces of the polarizing thin film of the present invention, for example, both surfaces of the polarizing plate using a pressure roll. And a method of pressure-bonding a protective film.
Next, as a process of shape processing by cutting or punching, it is processed into a desired shape and size using guillotine, shearing, cutter, panel saw, yarn saw, band saw, scissors, NC router, Thomson blade, die cutter, etc. A method is mentioned. In particular, it is preferable to use a Thomson blade that can be punched into a desired shape in a short time and has a good cross-sectional finish.
本発明の製造方法では、保護フィルムを貼り合わせた１ｍｍ以下の偏光板を曲率半径が８５ｍｍ以下になるように曲げ加工を行うために、目的の偏光板成形体形状よりも曲率半径の大きな成形型で１次の曲げ加工を行い、１次の曲げ加工を行った成形体をさらに曲率半径の小さな異なる成形型で２次の曲げ加工を行うことで偏光板成形体の曲げ加工を行うことができる。曲率半径８５ｍｍ以下になるように１回で曲げ加工を行おうとすると、偏光板成形体に折れやシワが入るため好ましくない。段階的に３回以上の曲げ加工を行ってもよい。 In the production method of the present invention, in order to bend a polarizing plate of 1 mm or less bonded with a protective film so that the radius of curvature is 85 mm or less, a mold having a larger radius of curvature than the shape of the target polarizing plate molded body The polarizing plate molded body can be bent by performing a primary bending process and performing a secondary bending process on the molded body subjected to the primary bending process with a mold having a different curvature radius. . It is not preferable to perform the bending process once so that the curvature radius is 85 mm or less, because folds and wrinkles are formed in the polarizing plate molded body. You may perform a bending process 3 times or more in steps.
本発明の製造方法に用いる保護フィルムは、ＪＩＳＫ６２５１のダンベル状１号形（引張試験部の幅が１０ｍｍ）に打ち抜いた後、１３０℃にて引張長さ５０ｍｍの引張試験を行った際の最大引張強度が０．９５Ｎ以下であることが好ましい。また、ＪＩＳＫ６２５１のダンベル状１号形に打ち抜いた後に１４０℃にて引張長さ５０ｍｍの引張試験を行った際の最大引張強度が０．０５Ｎ以上であることが好ましい。ＪＩＳＫ６２５１のダンベル状１号形に打ち抜いた後に１３０℃にて引張長さ８０ｍｍの引張試験を行った際の最大引張強度が０．５Ｎ以下であることがさらに好ましい。
特に金型温度が１３０℃以下で熱曲げ加工を行う場合には、ＪＩＳＫ６２５１のダンベル状１号形に打ち抜いた後に１０５℃にて引張長さ５０ｍｍの引っ張り試験を行った際の最大引張強度が１．７Ｎ以下であることが好ましい。
このような最大引張強度を有する保護フィルムを用いることにより、熱曲げ加工温度で溶融するなどの不具合が生じることのない実用上問題ない耐熱性を有し、かつ、熱曲げ加工温度で適度な柔軟性を有するため、成形型の表面肌や真空孔または成形型に付着したゴミなどの転写を抑えたり、２回目以降の曲げ加工でそれ以前の曲げ加工にて保護フィルムに生じたシワなどの不具合が偏光板成形体へ転写することも抑えたりすることができる。
この範囲を逸脱した場合、曲げ加工温度による保護フィルムの柔軟性が不十分であったりするため良好な外観の成形体が得られなかったり、曲げ加工温度により保護フィルムが裂けたり、成形型や成形体への溶着が起こったりするため好ましくない。
The protective film used in the production method of the present invention is the maximum tensile strength when a tensile test with a tensile length of 50 mm is performed at 130 ° C. after punching into JIS K6251 dumbbell-shaped No. 1 (width of the tensile test part is 10 mm). The strength is preferably 0.95 N or less. Further, it is preferable that the maximum tensile strength when a tensile test with a tensile length of 50 mm is performed at 140 ° C. after punching into JISK6251 dumbbell-shaped No. 1 is 0.05 N or more. It is more preferable that the maximum tensile strength when a tensile test with a tensile length of 80 mm is performed at 130 ° C. after punching into dumbbell-shaped No. 1 of JIS K6251 is 0.5 N or less.
In particular, when heat bending is performed at a mold temperature of 130 ° C. or less, the maximum tensile strength when a tensile test is performed at 105 ° C. and a tensile length of 50 mm after punching into JISK6251 dumbbell-shaped No. 1 is 1. 0.7N or less is preferable.
By using such a protective film having the maximum tensile strength, there is no problem in practical use, such as melting at the hot bending temperature, and there is no problem in practical use, and an appropriate flexibility at the hot bending temperature. Because of its properties, it suppresses the transfer of dust on the surface of the mold, vacuum holes, or mold, and wrinkles that occur on the protective film in the second and subsequent bending processes. Can be suppressed from being transferred to the polarizing plate molding.
If the temperature deviates from this range, the protective film may not be sufficiently flexible due to the bending temperature, so that a molded article with a good appearance cannot be obtained, or the protective film may be torn due to the bending temperature, or the mold or molding It is not preferable because welding to the body occurs.
また、前記保護フィルムは、偏光板の少なくとも片面に貼着させることで、打ち抜きや裁断時の繊維状のバリ（髭）発生が起こりにくく、バリが原因となるラインの汚染や、バリの除去作業を行う必要がない上、保護フィルムを貼り合わせる回数が１回で済むため、生産性にも優れる。好ましくは、偏光板の両面に貼着させることにより、偏光板を保護することができる。 In addition, the protective film is adhered to at least one surface of the polarizing plate so that fibrous burrs are not easily generated at the time of punching or cutting. In addition, since the number of times of attaching the protective film is one, the productivity is excellent. Preferably, the polarizing plate can be protected by being attached to both surfaces of the polarizing plate.
保護フィルムの組成としては、特に限定されるものではないが、不十分な加熱でも成形型に密着させることが出来る十分な伸び性を有する熱可塑性樹脂を用いることが好ましい。
例えば、ポリプロピレンやポリエチレン、エチレン−プロピレン共重合体、エチレン−α−オレフィン共重合体、プロピレン−α−オレフィン共重合体、エチレン−酢酸ビニル共重合体などのポリオレフィン樹脂、ポリ塩化ビニル樹脂、さらにはこれらの混合物を用いることが例として挙げられる。
前記の引張強度を満たすことができればこれらに限らず、いずれの熱可塑性樹脂を用いても良い。
このような、保護フィルムとしては、例えば、保護フィルムＵＣＦ−ＭＰＧＬ（ＹＵＳＡＮＧ社製）、ＤＩＦＡＲＥＮ Ｋ８０２０（ＤＩＣ社製）、ＭＬ−９５１０（日立化成社製）などが挙げられる。
Although it does not specifically limit as a composition of a protective film, It is preferable to use the thermoplastic resin which has sufficient extensibility which can be made to contact | adhere to a shaping | molding die even with inadequate heating.
For example, polyolefin resins such as polypropylene, polyethylene, ethylene-propylene copolymer, ethylene-α-olefin copolymer, propylene-α-olefin copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride resin, An example is the use of these mixtures.
Any thermoplastic resin can be used without limitation to these as long as the above-described tensile strength can be satisfied.
Examples of such a protective film include a protective film UCF-MPGL (manufactured by YUSANG), DIFAREN K8020 (manufactured by DIC), ML-9510 (manufactured by Hitachi Chemical Co., Ltd.), and the like.
加熱しながら曲げ加工する工程としては、予め所望の形状にかたどられた成形型に密着させ、加熱による賦形を行うことによって得られる。
成形型に密着させる方法としては、特に限定されないが、真空吸引、雄型と雌型によるプレス、圧空などの方法から選ばれる。
なお、雄型と雌型によるプレスを行った後に真空吸引を行うなど、これらの方法を組み合わせた方法を用いても良い。加熱しながら曲げ加工する際の加熱方法についても曲げ加工に適した温度に制御できる方法であれば特に限定されるものではなく、成形型に密着させた状態で加熱炉を通しても良いし、加熱した成形型を用いても良い。
成形型として用いる金型としては、アルミニウム、鉄、銅、ステンレス合金などに代表される合金など、加熱と圧力に耐えうる材質であれば何を用いても良い。また、成形型の表面精度は特に限定されず、中心線表面粗さ（Ｒａ）が概ね３０μｍ程度以下であれば問題ない。
The step of bending while heating can be obtained by bringing the mold into close contact with a mold previously formed into a desired shape and shaping by heating.
The method for closely contacting the forming die is not particularly limited, and is selected from methods such as vacuum suction, pressing with a male die and a female die, and compressed air.
Note that a method combining these methods may be used, for example, vacuum suction is performed after the male die and the female die are pressed. The heating method for bending while heating is not particularly limited as long as it can be controlled to a temperature suitable for bending, and may be passed through a heating furnace in close contact with the mold or heated. A mold may be used.
As the mold used as the molding die, any material that can withstand heat and pressure, such as an alloy typified by aluminum, iron, copper, and a stainless alloy, may be used. The surface accuracy of the mold is not particularly limited, and there is no problem if the center line surface roughness (Ra) is about 30 μm or less.
熱曲げ加工前に用いる偏光板は、曲げ加工時のシワ入り防止や、曲げ加工時の気泡発生の抑制、偏光性能を有する偏光性薄膜の色調変化を抑制するなどの目的で、あらかじめ予備乾燥または予備加熱して用いてもよい。
保護フィルムが溶融したり、得られる成形体の寸法変化やシワ入りによる外観不良が発生したりする可能性があるため、予備乾燥または予備加熱を行う場合は曲げ加工温度よりも１０℃高い温度よりも低いことが好ましい。
さらには、用いる偏光板の保護層として用いられる熱可塑性樹脂シートの樹脂のガラス転移点以下に留めることがより好ましい。予備乾燥のみに限っては、長時間保護フィルムが高温下にさらされるため、曲げ加工温度の３０℃以下で行うことが特に好ましい。
The polarizing plate used before the heat bending process is pre-dried or pre-dried for the purpose of preventing wrinkling at the time of bending process, suppressing the generation of bubbles at the time of bending process, suppressing the color tone change of the polarizing thin film having polarization performance, etc. You may preheat and use.
Since the protective film may melt or the appearance of the molded product may change due to dimensional changes or wrinkles, when pre-drying or pre-heating is performed, the temperature is higher by 10 ° C than the bending temperature. Is preferably low.
Furthermore, it is more preferable to keep below the glass transition point of the resin of the thermoplastic resin sheet used as a protective layer of the polarizing plate to be used. Only for preliminary drying, the protective film is exposed to a high temperature for a long time, and therefore it is particularly preferable to carry out at a bending temperature of 30 ° C. or less.
偏光性能を有する偏光板は、例えば、ポリビニルアルコールを二色性色素で染色、延伸、ホウ酸処理を施すことによって得られる偏光性薄膜の両面に、熱可塑性樹脂フィルムまたはシートを接着剤により貼り合わせられる方法により作製することができる。
この熱可塑性樹脂は、例えばトリアセチルセルロースに代表されるセルロース系樹脂や、ポリカーボネート樹脂、アクリル樹脂、ポリアミド樹脂、ポリエステル樹脂、環状オレフィン樹脂に代表されるポリオレフィン系樹脂、あるいはこれらの混合物を用いてもよい。これらの樹脂は、複屈折率×厚みで求められるリタデーションの値が４００ｎｍ以下あるいは１３００ｎｍ以上にあらかじめ調整しておくことが好ましく、２００ｎｍ以下あるいは２０００ｎｍであることが特に好ましい。リタデーションの値を高くする方法としては、例えばシートを加熱し一軸延伸する方法や、リタデーションの値を低くする方法としては、例えば溶液キャスト法によりを用いたり、押出法によりＴダイより出てきた樹脂をなるべく延伸しないように冷却する方法などを用いたりすることができる。
A polarizing plate having polarizing performance is obtained by, for example, bonding a thermoplastic resin film or sheet with an adhesive on both surfaces of a polarizing thin film obtained by dyeing polyvinyl alcohol with a dichroic dye, stretching, and boric acid treatment. It can be produced by a method.
The thermoplastic resin may be, for example, a cellulose resin represented by triacetyl cellulose, a polycarbonate resin, an acrylic resin, a polyamide resin, a polyester resin, a polyolefin resin represented by a cyclic olefin resin, or a mixture thereof. Good. In these resins, the retardation value obtained by birefringence × thickness is preferably adjusted in advance to 400 nm or less or 1300 nm or more, and particularly preferably 200 nm or less or 2000 nm. As a method for increasing the retardation value, for example, a method of heating a sheet and uniaxially stretching, and as a method for decreasing a retardation value, for example, a solution cast method or a resin that has come out of a T die by an extrusion method is used. The method of cooling so that it may extend | stretch as much as possible can be used.
本発明で用いられる偏光性薄膜は、例えば、ポリビニルアルコールに、ヨウ素や二色性
染料などに代表される二色性色素を染色し、ホウ素化合物などで架橋することによって得ることができる。染色する際に用いられる二色性色素の耐熱性によっては、曲げ加工を行う温度で色調変化が起こるが、例えば曲げ加工前に加熱を行い軟化させた後に賦形を行う方法よりも、本発明の製造方法は低い温度で熱曲げ加工を行うことが出来るため色調変化が起こりにくい。
The polarizing thin film used in the present invention can be obtained, for example, by staining polyvinyl alcohol with a dichroic dye typified by iodine or a dichroic dye and crosslinking with a boron compound or the like. Depending on the heat resistance of the dichroic dye used for dyeing, the color tone changes at the temperature at which bending is performed.For example, the present invention is more effective than the method of shaping after heating and softening before bending. In this manufacturing method, since the heat bending process can be performed at a low temperature, the color tone hardly changes.
また、本発明の製造方法は、偏光板の表面に、あらかじめ紫外線硬化型樹脂を塗布した後に紫外線で処理することによって得られる表面層を有する偏光板の熱曲げ加工に適している。この表面層は耐擦傷性、防曇性、フォトクロミック性などを有していても良い。
本発明の製造方法を用いることにより、周囲を保持して成形する方法と比較して、塗膜のクラックなどの外観欠点が起こりにくい。同様の理由から、反射防止コート、表面印刷、染色による着色などの処理を行った後に同様の製造方法を適用させても良い。
Moreover, the manufacturing method of this invention is suitable for the heat bending process of the polarizing plate which has a surface layer obtained by apply | coating an ultraviolet curable resin previously to the surface of a polarizing plate, and processing with an ultraviolet-ray. This surface layer may have scratch resistance, antifogging properties, photochromic properties, and the like.
By using the production method of the present invention, appearance defects such as cracks in the coating film are less likely to occur as compared with a method of molding while holding the periphery. For the same reason, the same manufacturing method may be applied after processing such as antireflection coating, surface printing, and coloring by dyeing.
本発明の偏光性薄膜の保護層として用いられる熱可塑性樹脂シートの樹脂には、用途によって着色剤、離型剤、酸化防止剤、光安定剤、紫外線吸収剤、蛍光増白剤、エステル交換防止剤、帯電防止剤などの各種添加剤を適宜配合しても良い。 The resin of the thermoplastic resin sheet used as the protective layer of the polarizing thin film of the present invention includes a colorant, a release agent, an antioxidant, a light stabilizer, an ultraviolet absorber, a fluorescent whitening agent, and a transesterification prevention depending on applications. Various additives such as an agent and an antistatic agent may be appropriately blended.
本発明の製造方法によって得られる成形体は、サングラス、ゴーグル、眼鏡、ヘルメットシールド、防護面、水中眼鏡、防毒マスク用透視板、オートバイ用風防、自動車のサンルーフ、船舶の窓板、各種監視カメラ用カバーなどに代表される、防眩製品または防護製品に用いることができる。 The molded product obtained by the production method of the present invention is sunglasses, goggles, glasses, helmet shield, protective surface, underwater glasses, gas mask see-through plate, motorcycle windshield, automobile sunroof, ship window plate, and various surveillance cameras. It can be used for an antiglare product or a protective product represented by a cover or the like.
次に、本発明の具体的な実施例および比較例について説明する。
＜実施例１＞
＜保護フィルムの貼り合わせ工程＞
偏光板として、ポリビニルアルコール製偏光性薄膜の両面にポリカーボネート樹脂シートを接着剤により貼り合わせられた厚み０．８５ｍｍのポリカーボネート樹脂製偏光板（住友ベークライト社製、ＰＤＨ１４０１）の両面に、保護フィルムＵＣＦ−ＭＰＧＬ（ＹＵＳＡＮＧ社製）（厚み６０μｍ）をゴム製の圧着ロールで圧着した。
＜偏光板成形体の作製＞
保護フィルムが両面に圧着された偏光板を、トムソン刃を用いて直径７８ｍｍの円状に打ち抜きを行った。
その後、成形機ＣＰＬ３２（レマ社製）を用いて成形型の雰囲気温度１５３℃で、表面温度１４５℃、中央１箇所に真空孔を有し、中心線表面粗さ（Ｒａ）が１０μｍであり、曲率半径が８８ｍｍであるアルミニウム製の球面状の雌型に真空度０．０９ＭＰａにて５分間真空吸引させた後、さらに上記成形機にて、雰囲気温度１５３℃で、成形型の表面温度１４５℃、中央１箇所に真空孔を有し、中心線表面粗さ（Ｒａ）が１０μｍであり、曲率半径が６６ｍｍであるアルミニウム製の球面状の雌型に真空度０．０９ＭＰａにて５分間真空吸引させることにより、偏光板成形体を得た。
＜保護フィルムの加熱時引張強度測定＞
まず、貼り合わせに用いた保護フィルム；ＵＣＦ−ＭＰＧＬ（ＹＵＳＡＮＧ社製、厚み６０μｍ）をトムソン刃にてＪＩＳＫ６２５１のダンベル状１号形に打ち抜いた。次に、このダンベル状試験片をあらかじめ掴み治具間の距離を８０ｍｍに調整したオートグラフＡＧＳ−Ｊ（島津製作所社製）に取り付け、オートグラフ用恒温槽ＴＣＨ−２２０Ｔ（島津製作所社製）を用いて１３０℃まで昇温させた。試験片の温度を安定させるため昇温後２分間経った後に、引張速度５０ｍｍ／分にて引張距離５０ｍｍにて引張試験を行った。この試験により得られた１３０℃での最大引張強度は０．１２Ｎであった。また１４０℃でも引張強度を上記同様に測定し、０．０９Ｎであった。
Next, specific examples and comparative examples of the present invention will be described.
<Example 1>
<Protection film bonding process>
As a polarizing plate, a protective film UCF- is applied to both surfaces of a 0.85 mm thick polycarbonate resin polarizing plate (Sumitomo Bakelite Co., Ltd., PDH1401) in which a polycarbonate resin sheet is bonded to both surfaces of a polyvinyl alcohol polarizing thin film with an adhesive. MPGL (manufactured by YUSANG) (thickness 60 μm) was pressure-bonded with a rubber pressure-bonding roll.
<Production of polarizing plate molding>
A polarizing plate having a protective film bonded on both sides was punched into a circular shape having a diameter of 78 mm using a Thomson blade.
Then, using a molding machine CPL32 (manufactured by Rema), the molding die has an atmosphere temperature of 153 ° C., a surface temperature of 145 ° C., a vacuum hole in one central location, and a center line surface roughness (Ra) of 10 μm. The aluminum spherical female mold having a curvature radius of 88 mm was vacuum-sucked for 5 minutes at a degree of vacuum of 0.09 MPa, and then the molding machine was operated at an ambient temperature of 153 ° C. and a mold mold surface temperature of 145 ° C. , Vacuum suction at a vacuum degree of 0.09 MPa for 5 minutes in a spherical female die made of aluminum having a vacuum hole at one central location, a centerline surface roughness (Ra) of 10 μm, and a radius of curvature of 66 mm By doing so, a polarizing plate molded body was obtained.
<Measurement of tensile strength during heating of protective film>
First, the protective film used for bonding; UCF-MPGL (manufactured by YUSANG, thickness 60 μm) was punched into a JISK6251 dumbbell shape No. 1 with a Thomson blade. Next, this dumbbell-shaped test piece was previously grasped and attached to an autograph AGS-J (manufactured by Shimadzu Corporation) whose distance between jigs was adjusted to 80 mm, and an autograph thermostatic chamber TCH-220T (manufactured by Shimadzu Corporation) was attached. The temperature was raised to 130 ° C. In order to stabilize the temperature of the test piece, 2 minutes after the temperature increase, a tensile test was performed at a tensile distance of 50 mm at a tensile speed of 50 mm / min. The maximum tensile strength at 130 ° C. obtained by this test was 0.12 N. The tensile strength was also measured at 140 ° C. in the same manner as described above, and was 0.09N.
得られた偏光板成形体を用いて以下の評価を行った。
＜外観評価＞
得られた偏光板成形体の保護フィルムを剥し、成形体の表面肌について目視で確認を行った。評価基準は下記の通りとした。
Ａ：成形体の外観に不具合が無い場合
Ｂ：成形体の外観（シワ、ゆず肌状、凹凸）に不具合がある、保護フィルムの溶融
がある場合
＜干渉縞評価＞
得られた偏光板成形体の保護フィルムを剥し、検査用蛍光灯照明ボックスの上に、ＴＡＣ偏光板を１枚置き、さらに成形体の凸面側を下になるよう、成形体の吸収軸方向とＴＡＣ偏光板の吸収軸方向とが直交するように置き、干渉縞がないかを目視で確認した。評価基準は下記の通りとした。
Ａ：部分的な透過や干渉縞が目視でほとんど確認できない場合
Ｂ：部分的な透過や干渉縞が目視で明らかに確認できる場合
＜形状評価＞
得られた成形体の保護フィルムを剥がし、カーブ計（カートン光学社製）を用い、吸収軸方向および透過軸方向の曲がり度合いを測定した。評価基準は以下の通りとした。なお、この測定値で８Ｒは曲率半径６６ｍｍ、７Ｒは曲率半径７５ｍｍである。
Ａ：吸収軸方向および透過軸方向の曲がり度合いが７Ｒ以上の場合
Ｂ：吸収軸方向または透過軸方向の曲がり度合いが７Ｒ未満の場合
The following evaluation was performed using the obtained polarizing plate molding.
<Appearance evaluation>
The protective film of the obtained polarizing plate molded body was peeled off, and the surface skin of the molded body was confirmed visually. The evaluation criteria were as follows.
A: When there is no defect in the appearance of the molded body B: There is a defect in the appearance (wrinkle, yuzu skin shape, unevenness) of the molded body, melting of the protective film
If there is <interference fringe evaluation>
The protective film of the obtained polarizing plate molding is peeled off, one TAC polarizing plate is placed on the fluorescent lamp lighting box for inspection, and the absorption axis direction of the molding is set so that the convex side of the molding is down. The TAC polarizing plate was placed so as to be orthogonal to the absorption axis direction, and it was visually confirmed whether there was any interference fringe. The evaluation criteria were as follows.
A: When partial transmission and interference fringes can hardly be visually confirmed B: When partial transmission and interference fringes can be clearly confirmed visually <shape evaluation>
The protective film of the obtained molded body was peeled off, and the degree of bending in the absorption axis direction and the transmission axis direction was measured using a curve meter (manufactured by Carton Optical Co., Ltd.). The evaluation criteria were as follows. In this measured value, 8R has a radius of curvature of 66 mm, and 7R has a radius of curvature of 75 mm.
A: When the bending degree in the absorption axis direction and the transmission axis direction is 7R or more B: When the bending degree in the absorption axis direction or the transmission axis direction is less than 7R
＜実施例２＞
保護フィルムとして、Ｋ８０２０（ＤＩＣ社製、厚み６０μｍ）を用いたこと以外は実施例１と同様に偏光板成形体を作製した。なお、この保護フィルムの前記引張試験の最大引張強度は、１３０℃では０．４７Ｎ、１４０℃では０．３３Ｎであった。
得られた偏光板成形体を、実施例１と同様の方法にて評価した。
＜実施例３＞
保護フィルムとして、ＭＬ−９５１０（日立化成社製、厚み４０μｍ）を用いたこと以外は実施例１と同様に偏光板成形体を作製した。なお、この保護フィルムの前記引張試験の最大引張強度は、１３０℃では０．８６Ｎ、１４０℃では０．５７Ｎであった。
得られた偏光板成形体を、実施例１と同様の方法にて評価した。
<Example 2>
A polarizing plate molded body was produced in the same manner as in Example 1 except that K8020 (manufactured by DIC, thickness 60 μm) was used as the protective film. The maximum tensile strength of the protective film in the tensile test was 0.47 N at 130 ° C. and 0.33 N at 140 ° C.
The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
<Example 3>
A polarizing plate molded body was produced in the same manner as in Example 1 except that ML-9510 (manufactured by Hitachi Chemical Co., Ltd., thickness 40 μm) was used as the protective film. The maximum tensile strength of the protective film in the tensile test was 0.86 N at 130 ° C. and 0.57 N at 140 ° C.
The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
＜実施例４＞
偏光板として、厚み０．４５ｍｍである、０．０８ｍｍ厚みのトリアセチルセルロース樹脂層を片面に、もう一方の面に０．３３ｍｍ厚みのポリカーボネート樹脂層を保護層に有する偏光板（住友ベークライト社製、ＴＰＤ１３８１）を用い、雰囲気温度１４８℃で、成形型の表面温度１４０℃、トリアセチルセルロース樹脂層が成形体の凸面側になるように２回の曲げ加工を行ったこと以外は実施例１と同様に偏光板成形体を作製した。なお、この保護フィルムの前記引張試験の最大引張強度は、１２５℃では０．１３Ｎ、１３５℃では０．１０Ｎであった。
得られた偏光板成形体を、実施例１と同様の方法にて評価した。
＜実施例５＞
成形機ＣＰＬ３２（レマ社製）を用いて成形型の雰囲気温度１５３℃で、表面温度１４５℃、中央１箇所に真空孔を有し、中心線表面粗さ（Ｒａ）が１０μｍであり、曲率半径が８８ｍｍであるアルミニウム製の球面状の雌型に真空度０．０９ＭＰａにて５分間真空吸引させた後、上記成形機にて成形型の雰囲気温度１５３℃で、表面温度１４５℃、中央１箇所に真空孔を有し、中心線表面粗さ（Ｒａ）が１０μｍであり、曲率半径が７６ｍｍであるアルミニウム製の球面状の雌型に真空度０．０９ＭＰａにて５分間真空吸引させ、さらに上記成形機にて、雰囲気温度１５３℃で、成形型の表面温度１４５℃、中央１箇所に真空孔を有し、中心線表面粗さ（Ｒａ）が１０μｍであり、曲率半径が６６ｍｍである
アルミニウム製の球面状の雌型に真空度０．０９ＭＰａにて５分間真空吸引させることにより、３回の曲げ加工で偏光板成形体を得たこと以外は実施例１と同様に偏光板成形体を得た。得られた偏光板成形体を、実施例１と同様の方法にて評価した。
<Example 4>
As a polarizing plate, a polarizing plate (manufactured by Sumitomo Bakelite Co., Ltd.) having a triacetyl cellulose resin layer having a thickness of 0.45 mm on one side and a polycarbonate resin layer having a thickness of 0.33 mm on the other side as a protective layer. And TPD1381), except that the atmosphere temperature was 148 ° C., the surface temperature of the mold was 140 ° C., and the bending process was performed twice so that the triacetyl cellulose resin layer was on the convex side of the molded body. Similarly, a polarizing plate molded body was produced. The maximum tensile strength of the protective film in the tensile test was 0.13 N at 125 ° C. and 0.10 N at 135 ° C.
The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
<Example 5>
Using a molding machine CPL32 (manufactured by Rema), the mold has an atmosphere temperature of 153 ° C., a surface temperature of 145 ° C., a vacuum hole in one central location, a center line surface roughness (Ra) of 10 μm, and a radius of curvature. Was vacuum-sucked at a vacuum degree of 0.09 MPa for 5 minutes in an aluminum spherical female mold having a thickness of 88 mm, and the molding machine was operated at an ambient temperature of 153 ° C., a surface temperature of 145 ° C., and one center And vacuum suction at a vacuum degree of 0.09 MPa for 5 minutes to an aluminum spherical female mold having a center hole surface roughness (Ra) of 10 μm and a radius of curvature of 76 mm. In a molding machine, the atmosphere temperature is 153 ° C., the mold surface temperature is 145 ° C., a vacuum hole is provided at one central location, the center line surface roughness (Ra) is 10 μm, and the radius of curvature is 66 mm. A spherical female mold By vacuum suction for 5 minutes at empty of 0.09 MPa, was obtained in the same manner as in polarizing plate molded article as in Example 1 except that to obtain a polarizing plate shaped body 3 times bending. The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
＜実施例６＞
偏光板として、厚み０．４５ｍｍである、０．０８ｍｍ厚みのトリアセチルセルロース樹脂層を片面に、もう一方の面に０．３３ｍｍ厚みのポリカーボネート樹脂層を保護層に有する偏光板（住友ベークライト社製、ＴＰＤ１３８１）を用い、トリアセチルセルロース樹脂層の面に保護フィルムとしてＵＣＦ−ＭＰＧＬ（厚み６０μｍ）を、ポリカーボネート樹脂層の面に保護フィルムとしてＫ８０２０（厚み６０μｍ）を用いたこと以外は実施例３と同様に偏光板成形体を作製した。なお、保護フィルム；Ｋ８０２０の前記引張試験の最大引張強度は、１２５℃では０．６３Ｎ、１３５℃では０．３９Ｎであった。
得られた偏光板成形体を、実施例１と同様の方法にて評価した。
＜実施例７＞
まず、ポリビニルアルコールフィルム（クラレビニロン＃７５００、クラレ社製）を水槽中で延伸しながら、Ｃ．Ｉ．ダイレクトブラック１７を溶解した水溶液にて染色、ホウ酸で処理したのち、水洗、乾燥を行うことにより偏光性薄膜を得た。一方、偏光性薄膜の保護層として、ポリカーボネート樹脂（ユーピロンＥ−２０００ＦＮ、三菱エンジニアプラスチック社製）を６０重量部、ポリエステル樹脂（スカイグリーンＪ−２００３、ＳＫケミカル社製）を４０重量部とをミキサーで混合し、ベント式単軸押出機により押出成形を行い得られた０．５ｍｍ厚みのシートを１．９倍に一軸延伸して０．３３ｍｍの樹脂シートを得た。前記偏光性薄膜の両面にウレタン系接着剤を用いて前記樹脂シートを貼り合わせ、厚み０．７ｍｍの偏光板を得た。この偏光板を用い、成形型の雰囲気温度１２８℃表面温度１２０℃で２回の曲げ加工を行ったこと以外は実施例１と同様に偏光板成形体を得た。ここで用いた保護フィルム（ＵＣＦ−ＭＰＧＬ）（厚み６０μｍ）の前記引張試験の最大引張強度は、１０５℃では０．８５Ｎ、１１５℃では０．２３Ｎであった。得られた偏光板成形体を、実施例１と同様の方法にて評価した。
<Example 6>
As a polarizing plate, a polarizing plate (manufactured by Sumitomo Bakelite Co., Ltd.) having a triacetyl cellulose resin layer having a thickness of 0.45 mm on one side and a polycarbonate resin layer having a thickness of 0.33 mm on the other side as a protective layer. , TPD1381) and UCF-MPGL (thickness 60 μm) as the protective film on the surface of the triacetyl cellulose resin layer, and K8020 (thickness 60 μm) as the protective film on the surface of the polycarbonate resin layer. Similarly, a polarizing plate molded body was produced. The maximum tensile strength of the protective film; K8020 in the tensile test was 0.63 N at 125 ° C. and 0.39 N at 135 ° C.
The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
<Example 7>
First, while stretching a polyvinyl alcohol film (Kuraray Vinylon # 7500, manufactured by Kuraray Co., Ltd.) in a water tank, C.I. I. After dyeing with an aqueous solution in which direct black 17 was dissolved and treating with boric acid, the polarizing thin film was obtained by washing with water and drying. On the other hand, as a protective layer for the polarizing thin film, 60 parts by weight of polycarbonate resin (Iupilon E-2000FN, manufactured by Mitsubishi Engineer Plastics Co., Ltd.) and 40 parts by weight of polyester resin (Sky Green J-2003, manufactured by SK Chemical Co., Ltd.) are mixed. Then, a 0.5 mm thick sheet obtained by extrusion molding with a vent type single screw extruder was uniaxially stretched 1.9 times to obtain a 0.33 mm resin sheet. The resin sheet was bonded to both surfaces of the polarizing thin film using a urethane-based adhesive to obtain a polarizing plate having a thickness of 0.7 mm. Using this polarizing plate, a polarizing plate molded body was obtained in the same manner as in Example 1 except that the bending process was performed twice at a mold atmosphere temperature of 128 ° C. and a surface temperature of 120 ° C. The maximum tensile strength of the protective film (UCF-MPGL) (thickness 60 μm) used here was 0.85 N at 105 ° C. and 0.23 N at 115 ° C. The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
＜実施例８＞
偏光性薄膜の保護層として、ポリアミド樹脂（トロガミドＣＸ７３２３、ダイセルエボニック社製）を用いベント式単軸押出機により押出成形を行い０．３５ｍｍのポリアミド樹脂シートを得た。実施例６と同様に得られた偏光性薄膜の片面に前記ポリアミド樹脂を、もう一方の面に、厚み８０μｍのトリアセチルセルロースフィルム（フジタックＴ８０ＳＮ、富士フィルム社製）をウレタン系接着剤を用いて厚み０．４８ｍｍの偏光板を得た。この偏光板を用い、成形型の表面温度１３５℃、雰囲気温度１４３℃でトリアセチルセルロース樹脂層が凸面となるように２回の曲げ加工を行ったこと以外は実施例２と同様に偏光板成形体を得た。ここで用いた保護フィルム（Ｋ８０２０）の前記引張試験の最大引張強度は、１２０℃では０．７８Ｎ、１３０℃では０．４７Ｎであった。
＜実施例９＞
実施例１に記載の打ち抜きを行った保護フィルム付き偏光板を、表面温度１４５℃、中心線表面粗さ（Ｒａ）が１μｍ、曲率半径８８ｍｍのアルミニウム製の球面状の雌型の上に置き、その上から表面温度１４５℃、中心線表面粗さ（Ｒａ）が１μｍ、曲率半径８７．５ｍｍのアルミニウム製の球面状の雄型を２０ｋｇの力で２分間かけて押し付けることにより１次成形体を得た。得られた１次成形体をさらに表面温度１４５℃、中心線表面粗さ（Ｒａ）が１μｍ、曲率半径６６ｍｍのアルミニウム製の球面状の雌型の上に置き、その上から表面温度１４５℃、中心線表面粗さ（Ｒａ）が１μｍ、曲率半径６５．５ｍｍのアルミニウム製の球面状の雄型を２０ｋｇの力で２分間かけて押し付けることにより成形体を得たこと以外は、実施例１と同様に偏光板成形体を得た。得られた偏光板成形体を、実施例１と同様の方法にて評価した。
<Example 8>
As a protective layer for the polarizing thin film, a polyamide resin (Trogamide CX7323, manufactured by Daicel Evonik) was used and extruded by a vent type single screw extruder to obtain a 0.35 mm polyamide resin sheet. Using the polyamide resin on one side of the polarizing thin film obtained in the same manner as in Example 6 and a triacetyl cellulose film (Fujitac T80SN, manufactured by Fuji Film Co., Ltd.) having a thickness of 80 μm on the other side, using a urethane-based adhesive. A polarizing plate having a thickness of 0.48 mm was obtained. Using this polarizing plate, a polarizing plate was formed in the same manner as in Example 2 except that the bending process was performed twice so that the surface temperature of the mold was 135 ° C. and the ambient temperature was 143 ° C., so that the triacetyl cellulose resin layer became a convex surface. Got the body. The maximum tensile strength of the protective film (K8020) used here in the tensile test was 0.78 N at 120 ° C. and 0.47 N at 130 ° C.
<Example 9>
The polarizing plate with a protective film subjected to punching described in Example 1 was placed on an aluminum spherical female mold having a surface temperature of 145 ° C., a center line surface roughness (Ra) of 1 μm, and a radius of curvature of 88 mm. The primary molded body was pressed by pressing a spherical male die made of aluminum having a surface temperature of 145 ° C., a center line surface roughness (Ra) of 1 μm, and a curvature radius of 87.5 mm over 2 minutes with a force of 20 kg. Obtained. The obtained primary molded body was further placed on an aluminum spherical female mold having a surface temperature of 145 ° C., a center line surface roughness (Ra) of 1 μm, and a curvature radius of 66 mm, and a surface temperature of 145 ° C. from above. Example 1 except that a molded body was obtained by pressing an aluminum spherical male mold having a center line surface roughness (Ra) of 1 μm and a curvature radius of 65.5 mm with a force of 20 kg over 2 minutes. Similarly, a polarizing plate molding was obtained. The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
＜実施例１０＞
偏光性薄膜の保護層として、ポリカーボネート樹脂（ユーピロンＥ−２０００ＦＮ、三菱エンジニアプラスチック社製）を６０重量部、ポリエステル樹脂（スカイグリーンＪ−２００３、ＳＫケミカル社製）を４０重量部とをミキサーで混合し、ベント式単軸押出機により押出成形を行い得られた０．５ｍｍ厚みのシートを１．９倍に一軸延伸して０．３３ｍｍの樹脂シートを得たこと以外は実施例７と同様に、偏光板を得た。さらに成形型の雰囲気温度１３３℃表面温度１２５℃で２回の曲げ加工を行ったこと以外は実施例１と同様に偏光板成形体を得た。ここで用いた保護フィルム（ＵＣＦ−ＭＰＧＬ）（厚み６０μｍ）の前記引張試験の最大引張強度は、１０５℃では０．８５Ｎであった。得られた偏光板成形体を、実施例１と同様の方法にて評価した。
<Example 10>
As a protective layer for the polarizing thin film, 60 parts by weight of polycarbonate resin (Iupilon E-2000FN, manufactured by Mitsubishi Engineer Plastics) and 40 parts by weight of polyester resin (Sky Green J-2003, manufactured by SK Chemical) were mixed with a mixer. In the same manner as in Example 7, except that a 0.5 mm thick sheet obtained by extrusion molding with a vent type single screw extruder was uniaxially stretched 1.9 times to obtain a 0.33 mm resin sheet. A polarizing plate was obtained. Further, a polarizing plate molded body was obtained in the same manner as in Example 1 except that the bending process was performed twice at an atmosphere temperature of 133 ° C. and a surface temperature of 125 ° C. The maximum tensile strength of the tensile test of the protective film (UCF-MPGL) (thickness 60 μm) used here was 0.85 N at 105 ° C. The obtained polarizing plate molded body was evaluated in the same manner as in Example 1.
＜比較例１＞
成形機ＣＰＬ３２（レマ社製）を用いて成形型の表面温度１４５℃、雰囲気温度１５３℃、中央１カ所に真空孔を有する曲率半径６６ｍｍのアルミニウム製の球面状の雌型に真空度０．０９ＭＰａにて５分間真空吸引させることにより、１次の曲げ加工のみで偏光板成形体を得たこと以外は実施例１と同様に偏光板成形体を得た。得られた偏光板成形体を、実施例１と同様の方法にて評価したが、成形体に大きなシワが入り外観良好な偏光板成形体を得ることができなかった。
＜比較例２＞
実施例１に記載の打ち抜きを行った保護フィルム付き偏光板を、１５ｃｍ角の正方形の形状に裁断した後、中央１箇所に真空孔を有し、中心線表面粗さ（Ｒａ）が１０μｍであり、曲率半径が８８ｍｍ、断面の直径１２ｃｍのアルミニウム製の球面状の雌型におき、その上から中央部に直径１１ｃｍの円形の穴を設けた２．０ｍｍ厚みのアルミ板をおいて、その周囲を万力で保持した。これを成形機ＣＰＬ３２（レマ社製）を用い、成形型の表面温度１４５℃、雰囲気温度１５３℃、真空度０．０９ＭＰａにて５分間真空吸引させることにより、１次の曲げ加工のみ偏光板成形体を得たこと以外は実施例１と同様に偏光板成形体を得た。得られた偏光板成形体を、実施例１と同様の方法にて評価したが、干渉縞の評価において目立つ干渉縞が生じ良好な偏光板成形体を得ることができなかった。
<Comparative Example 1>
Using a molding machine CPL32 (manufactured by Rema), the mold surface temperature is 145 ° C., the ambient temperature is 153 ° C., and the vacuum degree is 0.09 MPa on an aluminum spherical female die having a radius of curvature of 66 mm having a vacuum hole in one central location. Was subjected to vacuum suction for 5 minutes to obtain a polarizing plate molding in the same manner as in Example 1 except that a polarizing plate molding was obtained only by the first bending. The obtained polarizing plate molded body was evaluated by the same method as in Example 1. However, a large wrinkle entered the molded body, and a polarizing plate molded body having a good appearance could not be obtained.
<Comparative example 2>
After the punched polarizing plate with a protective film described in Example 1 is cut into a 15 cm square shape, it has a vacuum hole at one central position, and the center line surface roughness (Ra) is 10 μm. Put a 2.0 mm thick aluminum plate with a circular hole with a diameter of 11 cm in the center from above on a spherical female die made of aluminum with a radius of curvature of 88 mm and a cross section diameter of 12 cm. Was held in a vise. By using a molding machine CPL32 (manufactured by Rema Co., Ltd.) and vacuum suction for 5 minutes at a molding die surface temperature of 145 ° C., an ambient temperature of 153 ° C., and a vacuum degree of 0.09 MPa, only the first bending process is performed. A polarizing plate molded body was obtained in the same manner as in Example 1 except that the body was obtained. The obtained polarizing plate molded body was evaluated by the same method as in Example 1. However, a conspicuous interference fringe was produced in the evaluation of interference fringes, and a favorable polarizing plate molded body could not be obtained.
＜比較例３＞
保護フィルムとして、厚み５０μｍのＥＣ−７５３（スミロン社製）を用いたこと以外は実施例１と同様に偏光板成形体を作製した。なお、この保護フィルムの前記引張試験の最大引張強度は、１３０℃では０．８３Ｎ、１４０℃では０．９９Ｎであった。
得られた偏光板成形体を、実施例１と同様の方法にて評価したところ、成形体表面にゆず肌状の凹凸がみられ、外観良好な成形体を得ることができなかった。
<比較例４＞
実施例１に記載の打ち抜きを行った保護フィルム付き偏光板を、表面温度１４５℃、中心線表面粗さ（Ｒａ）が１μｍ、曲率半径６６ｍｍのアルミニウム製の球面状の雌型の上に置き、表面温度１４５℃、中心線表面粗さ（Ｒａ）が１μｍ、曲率半径６５．５ｍｍのアルミニウム製の球面状の雄型を２０ｋｇの力で２分間かけて押し付けることにより、１次の曲げ加工のみで成形体を得たこと以外は、実施例１と同様に偏光板成形体を得た。得られた偏光板成形体を、実施例１と同様の方法にて評価したが成形体にシワが入り外観良好な成形体を得ることができなかった。
<Comparative Example 3>
A polarizing plate molded body was prepared in the same manner as in Example 1 except that EC-753 (manufactured by Sumilon Co., Ltd.) having a thickness of 50 μm was used as the protective film. The maximum tensile strength of the protective film in the tensile test was 0.83 N at 130 ° C. and 0.99 N at 140 ° C.
When the obtained polarizing plate molded body was evaluated in the same manner as in Example 1, the surface of the molded body was found to have uneven skin-like irregularities, and a molded body having a good appearance could not be obtained.
<Comparative Example 4>
The polarizing plate with a protective film subjected to punching described in Example 1 is placed on a spherical female die made of aluminum having a surface temperature of 145 ° C., a center line surface roughness (Ra) of 1 μm, and a radius of curvature of 66 mm. By pressing a spherical male die made of aluminum having a surface temperature of 145 ° C., a center line surface roughness (Ra) of 1 μm, and a radius of curvature of 65.5 mm with a force of 20 kg over 2 minutes, only the first bending process is required. A polarizing plate molded body was obtained in the same manner as in Example 1 except that the molded body was obtained. Although the obtained polarizing plate molded body was evaluated by the same method as in Example 1, the molded body was wrinkled and a molded body having a good appearance could not be obtained.
Claims (7)
裁断または打ち抜きにより形状加工する工程、
加熱しながら前記保護フィルムを貼り合わせた偏光板を金属製の成形型に密着させ、賦形させることにより曲率半径が８５ｍｍ以下となるように曲げ加工する工程、を含む偏光板成形体の製造方法であって、
前記曲げ加工工程が、周囲を保持せずに目的の偏光板成形体形状よりも曲率半径の大きな成形型で１次の曲げ加工を行い、１次の曲げ加工を行った成形体をさらに曲率半径の小さな異なる成形型で２次の曲げ加工を行うことで偏光板成形体の曲げ加工を行う方法であり、
前記保護フィルムの１３０℃の最大引張強度が０．９５Ｎ以下の保護フィルムを用いる、
偏光板成形体の製造方法。 A step of bonding a protective film to at least one side of a polarizing plate having a thickness of 1 mm or less in which a thermoplastic resin sheet is bonded to both surfaces of a polarizing thin film;
A process of shape processing by cutting or punching,
A method for producing a polarizing plate molded body, comprising: a step of closely bonding a polarizing plate having the protective film bonded thereto while heating to a metal mold and bending the polarizing plate so that the radius of curvature is 85 mm or less. Because
In the bending process, a primary bending process is performed with a mold having a larger radius of curvature than the shape of the objective polarizing plate without holding the periphery, and the molded body subjected to the primary bending process is further subjected to a radius of curvature. Is a method of bending a polarizing plate molded body by performing secondary bending with a small different mold,
A protective film having a maximum tensile strength at 130 ° C. of 0.95 N or less is used.
Manufacturing method of polarizing plate molding.
An antiglare product or a protective product produced using the polarizing plate molding according to claim 6.
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| JP2013210476A (en) * | 2012-03-30 | 2013-10-10 | Sumitomo Bakelite Co Ltd | Method of manufacturing polarizing plate formed body, polarizing plate formed body, anti-glare product, and protection product |
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