TW201325871A - 偏光板之製造方法 - Google Patents

偏光板之製造方法 Download PDF

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Publication number
TW201325871A
TW201325871A TW101136477A TW101136477A TW201325871A TW 201325871 A TW201325871 A TW 201325871A TW 101136477 A TW101136477 A TW 101136477A TW 101136477 A TW101136477 A TW 101136477A TW 201325871 A TW201325871 A TW 201325871A
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Taiwan
Prior art keywords
film
roller
bonding
adhesive
active energy
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TW101136477A
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English (en)
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TWI576228B (zh
Inventor
Jun Furukawa
Azusa Hiroiwa
Hidemitsu Shimizu
Yuji Serikawa
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Sumitomo Chemical Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0073—Optical laminates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1435—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. transmission welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1429—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface
    • B29C65/1464—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1477—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier
    • B29C65/1483—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of an absorber or impact modifier coated on the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4845—Radiation curing adhesives, e.g. UV light curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/524—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by applying the adhesive from an outlet device in contact with, or almost in contact with, the surface of the part to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/526—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive by printing or by transfer from the surfaces of elements carrying the adhesive, e.g. using brushes, pads, rollers, stencils or silk screens
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/006—Preventing damaging, e.g. of the parts to be joined
    • B29C66/0062—Preventing damaging, e.g. of the parts to be joined of the joining tool, e.g. avoiding wear of the joining tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
    • B29C66/73365—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7336—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light
    • B29C66/73365—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light
    • B29C66/73366—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being opaque, transparent or translucent to visible light at least one of the parts to be joined being transparent or translucent to visible light both parts to be joined being transparent or translucent to visible light
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/733—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence
    • B29C66/7338—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the optical properties of the material of the parts to be joined, e.g. fluorescence, phosphorescence at least one of the parts to be joined being polarising
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • G—PHYSICS
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Abstract

本發明提供一種偏光板之製造方法，係使透明薄膜(2,3)貼合於偏光薄膜(1)的單面或兩面所構成的偏光板之製造方法，其特徵為具備：接著劑塗佈步驟；前述透明薄膜(2,3)隔著前述接著劑積層於前述偏光薄膜(1)的單面或兩面所構成的積層體(4)，在被夾持於朝傳送方向旋轉的一對貼合滾輪(51,52)間的狀態，藉由與前述貼合滾輪接觸而設置之至少一個按壓滾輪(61,62)，將至少一側的貼合滾輪(51,52)朝另一側的貼合滾輪的方向按壓，使前述透明薄膜(2,3)與前述偏光薄膜(1)貼合之貼合步驟；以及對前述積層體(4)照射活性能量線，使前述接著劑硬化之活性能量線照射步驟；其中，前述按壓滾輪(61,62)的中央部的直徑，大於接觸該按壓滾輪之前述貼合滾輪(51,52)的中央部的直徑。

Description

偏光板之製造方法
本發明係關於一種作為構成液晶顯示裝置等的光學零件之一有用的偏光板之製造方法。
偏光薄膜，被廣泛地使用作為以二色性色素吸附配向於聚乙烯醇系樹脂薄膜者，已知有以碘作為二色性色素之碘系偏光薄膜、以二色性直接染料作為二色性色素之染料系偏光薄膜等。該等偏光薄膜，通常於其單面或兩面，隔著接著劑，貼合三乙醯纖維素薄膜等的透明薄膜，成為偏光板。
作為透明薄膜積層於偏光薄膜的單面或兩面之方法，係有：預先將透明薄膜的表面，塗佈活性能量線硬化型樹脂後，將偏光薄膜與透明薄膜藉由一對夾持滾輪(貼合滾輪)夾壓而貼合，然後，照射活性能量線而硬化接著的方法(專利文獻1：日本特開2004-245925號公報、專利文獻2：日本特開2009-134190號公報、專利文獻3：日本特開2011-95560號公報)。
但是，如第5圖(a)及(b)所示，藉由貼合滾輪51、52所進行之積層體(偏光薄膜與透明薄膜)的夾壓，通常係以 油壓、空壓、螺絲等按壓一側貼合滾輪51的兩端之軸承等而進行(第5圖(b)的箭號)，貼合滾輪51的中央附近彎曲，積層體(偏光薄膜與透明薄膜)有被不均勻加壓的情況。於不均勻加壓的情況，於所得之偏光板，出現各薄膜間產生氣泡，各薄膜間的密合性變差等的問題。而且，亦有傳送的流程變差，容易產生製造步驟時的障礙之問題。再者，如此的現象為須對積層體施加高壓時所產生的現象。活性能量線硬化型樹脂作為接著劑使用時，與其它聚乙烯醇系樹脂等作為接著劑使用時相比較，因黏度高，而必須對積層體施加高壓。
因此，為了使按壓時不易產生貼合滾輪的彎曲，以往貼合滾輪一般係使用具有大於300mm左右的直徑之滾輪。但是，由於貼合滾輪的直徑越大，貼合滾輪與積層體的接觸面積變大，故施加於貼合滾輪之外力為一定時，施加於積層體之單位面積的壓力將變小。所以，在積層體必須施加高壓時，期望盡可能地使貼合滾輪的直徑變小。
[先前技術文獻] [專利文獻]
[專利文獻1]日本特開2004-245925號公報
[專利文獻2]日本特開2009-134190號公報
[專利文獻3]日本特開2011-95560號公報
本發明之目的係提供：即使使用較小直徑之貼合滾 輪，亦可對構成偏光板的積層體(偏光薄膜與透明薄膜)均勻加壓的偏光板之製造方法及偏光板之製造裝置。
本發明係透明薄膜貼合於偏光薄膜的單面或兩面所構成的偏光板之製造方法，其特徵為具備：於前述透明薄膜的單面或者前述偏光薄膜的單面或兩面，塗佈活性能量線硬化型接著劑之接著劑塗佈步驟；前述透明薄膜隔著前述接著劑積層於前述偏光薄膜的單面或兩面所構成的積層體，在被夾持於朝傳送方向旋轉的一對貼合滾輪間的狀態，藉由與前述貼合滾輪接觸而設置之至少一個按壓滾輪，將至少一側的滾輪朝另一側的貼合滾輪的方向按壓，使前述透明薄膜與前述偏光薄膜貼合之貼合步驟；以及對前述積層體照射活性能量線，使前述接著劑硬化之活性能量線照射步驟；其中，前述按壓滾輪的中央部的直徑，大於接觸該按壓滾輪之前述貼合滾輪之中央部的直徑。
前述一對貼合滾輪，以分別獨立地被驅動較理想。而且，前述一對貼合滾輪以及前述按壓滾輪，以直徑實質上均一之滑面滾輪較理想。
而且，本發明亦關於一種偏光板之製造裝置，係透明薄膜貼合於偏光薄膜的單面或兩面所構成的偏光板之製造裝置，其特徵為具備：於前述透明薄膜的單面或者前述偏光薄膜的單面或兩 面，塗佈活性能量線硬化型接著劑用之接著劑塗佈裝置；將前述透明薄膜隔著前述接著劑積層於前述偏光薄膜的單面或兩面所構成的積層體予以一邊傳送一邊夾壓，使前述透明薄膜與前述偏光薄膜貼合用之一對貼合滾輪；為了使前述一對貼合滾輪中至少一側之貼合滾輪朝另一側之貼合滾輪的方向按壓，與前述貼合滾輪接觸而設置之至少一個按壓滾輪；以及對前述積層體照射活性能量線，使前述接著劑硬化用之活性能量線照射裝置；其中，前述按壓滾輪的中央部的直徑，大於接觸該按壓滾輪之前述貼合滾輪的中央部的直徑。
根據本發明，可提供：即使使用較小直徑之貼合滾輪，對構成偏光板的積層體(偏光薄膜與透明薄膜)可均勻加壓的偏光板之製造方法及偏光板之製造裝置。
而且，根據本發明，可得到抑制各薄膜間產生氣泡、各薄膜間的密合性變差之偏光板。而且，亦可抑制起因於傳送的流程變差等之製造步驟的障礙之發生。
1‧‧‧偏光薄膜
2、3‧‧‧透明薄膜
4‧‧‧積層體(偏光板)
11、12‧‧‧接著劑塗佈裝置
13‧‧‧滾輪(冷卻滾輪)
14、15、16、17、18‧‧‧活性能量線照射裝置
19‧‧‧傳送用夾持滾輪
20‧‧‧捲取滾輪
51、52‧‧‧貼合滾輪
61、62‧‧‧按壓滾輪
61a‧‧‧軸承構件
第1圖為表示本發明的偏光板之製造裝置的一實施態樣的概略側面圖。
第2圖為表示本發明所使用的貼合滾輪及按壓滾輪的一實施態樣的概略側面圖。
第3圖為對於第2圖所示之貼合滾輪及按壓滾輪的一 實施態樣之概略正面圖。
第4圖為表示本發明的偏光板之製造裝置的其它實施態樣的概略側面圖。
第5圖(a)及(b)為說明傳統的偏光板之製造方法用的概略圖。
(偏光薄膜)
本發明的偏光板所使用的偏光薄膜，具體上為使二色性色素吸附配向於經一軸延伸的聚乙烯醇系樹脂薄膜者。聚乙烯醇系樹脂可藉由聚乙酸乙烯酯系樹脂經皂化而得。作為聚乙酸乙烯酯系樹脂，除了乙酸乙烯酯的單獨聚合物之聚乙酸乙烯酯之外，可列舉如：乙酸乙烯酯與可與其共聚之其它單體的共聚物(例如乙烯-乙酸乙烯酯共聚物)等。作為可與乙酸乙烯酯共聚之其它單體，其它可列舉如：不飽和羧酸類、烯烴類、乙烯醚類、不飽和磺酸類、具有銨基之丙烯醯胺類等。聚乙烯醇系樹脂的皂化度為85莫耳%以上，較理想為90莫耳%以上，更理想為98至100莫耳%。聚乙烯醇系樹脂的平均聚合度，通常為1000至10000，較理想為1500至5000。該等聚乙烯醇系樹脂，可為改性者，例如可使用醛類改性之聚乙烯甲醛、聚乙烯乙醛、聚乙烯丁醛等。
如此的聚乙烯醇系樹脂製成膜者，被使用作為偏光薄膜的胚膜。聚乙烯醇系樹脂製膜的方法，並無特別限制，可使用傳統習知之適當的方法製膜。由聚乙烯醇系樹脂所 構成的胚膜的膜厚，並無特別限制，例如為10至150μm左右。通常以捲狀供給，厚度為20至100μm的範圍內，較理想為30至80μm的範圍內，而且，工業上實用的寬度為1500至6000mm的範圍內。
有市售的聚乙烯醇系薄膜(Vinylon VF-PS#7500、可樂麗製(Kuraray)/OPL film M-7500、日本合成製)的原料厚度為75μm、(Vinylon VF-PS#6000、可樂麗製、Vinylon VF-PE#6000、可樂麗製)的原料厚度為60μm等。
偏光薄膜，通常經由將聚乙烯醇系樹脂薄膜以二色性色素染色而使二色性色素吸附之步驟(染色處理步驟)、吸附有二色性色素的聚乙烯醇系樹脂薄膜以硼酸水溶液處理之步驟(硼酸處理步驟)以及藉由該硼酸水溶液處理後之水洗的步驟(水洗處理步驟)而製造。
而且，製造偏光薄膜時，通常係將聚乙烯醇系樹脂薄膜進行一軸延伸，該一軸延伸可在染色處理步驟之前進行，亦可在染色處理步驟中進行，或可在染色處理步驟之後進行。一軸延伸在染色處理步驟之後進行時，該一軸延伸可在硼酸處理步驟之前進行，亦可在硼酸處理步驟中進行。當然，亦可在該等複數階段進行一軸延伸。
一軸延伸，可在轉速相異的滾輪間進行一軸延伸，可使用熱滾輪進行一軸延伸。而且，可為在大氣中進行延伸的乾式延伸，亦可為以溶劑膨潤的狀態下進行延伸之濕式延伸。延伸倍率，通常為3至8倍左右。
染色處理步驟之聚乙烯醇系樹脂薄膜藉由二色性色素 之染色，例如藉由將聚乙烯醇系樹脂薄膜浸漬於含有二色性色素的水溶液而進行。作為二色性色素，例如使用碘、二色性染料等。於二色性染料，包含例如C.I.直接紅39等之雙偶氮化合物所構成的二色性直接染料、三偶氮、四偶氮等之化合物所構成的二色性直接染料。再者，聚乙烯醇系樹脂薄膜，係以於染色處理前，預先實施水的浸漬處理較理想。
使用碘作為二色性色素時，通常採用於含有碘及碘化鉀的水溶液中浸漬聚乙烯醇系樹脂薄膜而染色之方法。該水溶液中之碘的含量，通常對水每100重量份為0.01至1重量份，碘化鉀的含量通常對水每100重量份為0.5至20重量份。使用碘作為二色性色素時，染色所使用的水溶液的溫度，通常為20至40℃，對該水溶液的浸漬時間(染色時間)，通常為20至1800秒。
另一方面，使用二色性染料作為二色性色素時，通常採用於包含水溶液二色性染料的水溶液中浸漬聚乙烯醇系樹脂薄膜而染色之方法。該水溶液中之二色性染料的含量，通常對水每100重量份為1×10-4至10重量份，較理想為1×10-3至1重量份，特別理想為1×10-3至1×10-2重量份。該水溶液可含有硫酸鈉等無機鹽作為染色助劑。於使用二色性染料作為二色性色素時，染色所使用的水溶液的溫度，通常為20至80℃，而且，對該水溶液的浸漬時間(染色時間)，通常為10至1800秒。
硼酸處理步驟，係將經二色性色素染色之聚乙烯醇系 樹脂薄膜，藉由浸漬於含有硼酸之水溶液中而進行。含有硼酸之水溶液的硼酸量，對水每100重量份，通常為2至15重量份，較理想為5至12重量份。在使用碘作為上述染色處理步驟中之二色性色素時，該硼酸處理步驟中使用之含有硼酸的水溶液，以含有碘化鉀較理想。於該情況，含有硼酸的水溶液中之碘化鉀的量，對水每100重量份，通常為0.1至15重量份，較理想為5至12重量份。對含有硼酸的水溶液之浸漬時間，通常為60至1200秒，較理想為150至600秒，更理想為200至400秒。含有硼酸的水溶液之溫度，通常為40℃以上，較理想為50至85℃，更理想為55至80℃。
接著於水洗處理步驟中，將上述經硼酸處理後的聚乙烯醇系樹脂薄膜，例如藉由浸漬於水而進行水洗處理。水洗處理中之水的溫度，通常為4至40℃，浸漬時間通常為1至120秒。水洗處理後，通常實施乾燥處理，得到偏光薄膜。乾燥處理，例如適合使用熱風乾燥機、遠紅外線加熱器等進行。乾燥處理的溫度，通常為30至100℃，較理想為50至80℃。乾燥處理的時間，通常為60至600秒，較理想為120至600秒。
如此對聚乙烯醇系樹脂薄膜，實施一軸延伸、藉由二色性色素之染色、硼酸處理以及水洗處理而得到偏光薄膜。該偏光薄膜的厚度，通常為5至50μm的範圍內。
(透明薄膜)
本發明中，係於上述偏光薄膜的單面或兩面貼合透明 薄膜。透明薄膜貼合於偏光薄膜的兩面時，各個透明薄膜可為相同，亦可為不同種類的薄膜。
作為構成透明薄膜的材料，可列舉例如：環烯烴系樹脂、乙酸纖維素系樹脂、如聚對苯二甲酸乙二酯、聚萘二甲酸乙二酯、聚對苯二甲酸丁二酯之聚酯系樹脂、聚碳酸酯系樹脂、如聚甲基丙烯酸甲酯(PMMA)等之丙烯酸系樹脂、如聚丙烯等的烯烴系樹脂等，可使用本技術領域中傳統廣為使用之薄膜材料。
所謂環烯烴系樹脂，係指具有例如降莰烯、多環降莰烯系單體之環狀烯烴(環烯烴)所構成的單體單元之熱塑性樹脂(亦稱為熱塑性環烯烴系樹脂)。環烯烴系樹脂，可為上述環烯烴的開環聚合物或使用2種以上的環烯烴之開環共聚物之氫化物，亦可為環烯烴與鏈狀烯烴、具有乙烯基之芳香族化合物等的加成聚合物。而且，導入極性基者也有效。
於使用環烯烴與鏈狀烯烴或/及具有乙烯基之芳香族化合物的共聚物時，作為鏈狀烯烴，例如乙烯、丙烯等，而且作為具有乙烯基之芳香族化合物，例如苯乙烯、α-甲基苯乙烯、核烷基取代苯乙烯等。於如此的共聚物中，環烯烴所構成的單體單元可為50莫耳%以下(較理想為15至50莫耳%)。特別是在使用環烯烴、鏈狀烯烴及具有乙烯基之芳香族化合物的三元共聚物時，環烯烴所構成的單體單元可作成如上述之較少的量。於如此的三元共聚物中，鏈狀烯烴所構成的單體單元，通常為5至80莫耳%， 具有乙烯基之芳香族化合物所構成的單體單元，通常為5至80莫耳%。
環烯烴系樹脂，可使用適合的市售品，例如Topas(Ticona公司製)、Arton(JSR公司製)、ZEONOR(日本ZEON(股)製)、ZEONEX(日本ZEON(股)製)、APEL(三井化學(股)製)、OXIS(大倉工業公司製)等。如此的環烯烴系樹脂製膜成為薄膜時，適合使用溶劑鑄膜法、熔融擠出法等習知的方法。而且，例如可使用Escena(積水化學工業(股)製)、SCA40(積水化學工業(股)製)、ZEONOR薄膜((股)Optes製)等預先製膜之環烯烴系樹脂製的薄膜之市售品。
環烯烴系樹脂薄膜，可為一軸延伸或二軸延伸者。藉由延伸，可賦予環烯烴系樹脂薄膜任意的相位差值。延伸，通常一邊捲出薄膜捲狀物，一邊連續地進行，於加熱爐中，朝捲狀物的行進方向(薄膜的長度方向)、與其行進方向垂直的方向(薄膜的寬度方向)或其兩者延伸。加熱爐的溫度，通常採用從環烯烴系樹脂的玻璃轉化溫度附近至玻璃轉化溫度+100℃的範圍。延伸倍率，通常為1.1至6倍，較理想為1.1至3.5倍。
環烯烴系樹脂薄膜，在捲繞狀態時，因薄膜彼此接著而有容易產生結塊的傾向，因此，一般係在貼合保護膜後而捲繞。而且，環烯烴系樹脂薄膜，因一般表面活性差，故於與偏光薄膜接著的表面，進行電漿處理、電暈處理、紫外線照射處理、火焰處理、皂化處理等表面處理者較理想。其中，較容易實施之電漿處理，特別是大氣壓電漿處 理、電暈處理為適合。
所謂乙酸纖維素系樹脂，係指纖維素的部分或完全酯化物，例如纖維素的乙酸酯、丙酸酯、丁酸酯、該等的混合酯等所構成的薄膜。更具體而言，可列舉例如：三乙醯纖維素薄膜、二乙醯纖維素薄膜、纖維素乙酸酯丙酸酯薄膜、纖維素乙酸酯丁酸酯薄膜等。作為如此的纖維素酯系樹脂薄膜，可適合使用適宜的市售品，例如Fujitac TD80(富士薄膜(股)製)、Fujitac TD80UF(富士薄膜(股)製)、Fujitac TD80UZ(富士薄膜(股)製)、KC8UX2M(Konica Minolta Opto(股)製)、KC8UY(Konica Minolta Opto(股)製)、Fujitac TD60UL(富士薄膜(股)製)、KC4UYW(Konica Minolta Opto(股)製)、KC6UAW(Konica Minolta Opto(股)製)等。
而且，作為透明薄膜，賦予相位差特性之乙酸纖維素系樹脂薄膜也適合使用。如此的賦予相位差特性之乙酸纖維素系樹脂薄膜之市售品，可列舉例如：WV BZ 438(富士薄膜(股)製)、KC4FR-1(Konica Minolta Opto(股)製)、KC4CR-1(Konica Minolta Opto(股)製)、KC4AR-1(Konica Minolta Opto(股)製)等。乙酸纖維素，亦稱為乙醯纖維素、纖維素乙酸酯。
該等乙酸纖維素系樹脂薄膜，因容易吸水，而有偏光板的水分率會影響偏光板的端部鬆弛的情況。製造偏光板時的水分率，宜接近偏光板的保存環境，例如潔淨室的製造產線、捲狀物的保存倉庫中之平衡水分率，雖也與積層薄膜的構成有關，例如為2.0至3.5%左右，更理想為2.5 %至3.0%。該偏光板的水分率的數值，係以乾燥重量法所測定者，係105℃/120分鐘後的重量變化。
本發明之偏光板所使用的透明薄膜之厚度，以薄者較理想，惟太薄時，因強度降低而使加工性變差。另一方面，太厚時，因透明性降低、而有積層後所需的養生時間會變長等的問題。因此，透明薄膜的適當厚度，例如為5至200μm，較理想為10至150μm，更理想為10至100μm。
為了提高接著劑與偏光薄膜及/或透明薄膜的接著性，於偏光薄膜及/或透明薄膜，可實施電暈處理、火焰處理、電漿處理、紫外線處理、底塗處理、皂化處理等的表面改質處理。
而且，於透明薄膜中，抗眩光處理、抗反射處理、硬塗處理、抗靜電處理、抗污處理等表面處理，可分別單獨或組合2種以上而實施。而且，透明薄膜及/或透明薄膜表面保護層，亦可含有二苯基酮系化合物、苯并***系化合物等紫外線吸收劑、苯基磷酸酯系化合物、鄰苯二甲酸酯系化合物等塑化劑。
再者，亦可使透明薄膜中具有作為相位差薄膜的功能、作為提升亮度之薄膜的功能、作為反射薄膜的功能、作為半透過反射薄膜的功能、作為擴散薄膜的功能、作為光學補償薄膜的功能等之光學功能。於該情況，例如藉由於透明薄膜的表面，積層相位差薄膜、提升亮度之薄膜、反射薄膜、半透過反射薄膜、擴散膜、光學補償薄膜等光學功能性薄膜，可具有如此的功能之外，亦可在透明薄膜 本身賦予如此的功能。而且，透明薄膜可具有如具有提升亮度之薄膜的功能的擴散薄膜等之複數功能。
例如，於上述透明薄膜中，實施日本專利第2841377號公報、日本專利第3094113號公報等記載之延伸處理，藉由實施日本專利第3168850號公報記載之處理，可賦予作為相位差薄膜的功能。相位差薄膜中之相位差特性，例如可適當選擇正面相位差值為5至100nm，厚度方向相位差值為40至300nm的範圍等。而且，於上述透明薄膜中，以如日本特開2002-169025號公報、特開2003-29030號公報記載之方法，藉由形成細微孔，或藉由重疊選擇反射之中心波長相異的2層以上的膽固醇液晶層，即可賦予作為提升亮度之薄膜的功能。
如於上述透明薄膜中以蒸鍍、濺鍍等形成金屬薄膜，即可賦予作為反射薄膜或半透過反射薄膜的功能。於上述透明薄膜，藉由塗佈包含微粒子之樹脂溶液，即可賦予作為擴散薄膜之功能。而且，於上述透明薄膜中，藉由塗佈盤形(discotic)液晶性化合物等的液晶性化合物，使其配向，即可賦予作為光學補償薄膜的功能。而且，亦可於透明薄膜中含有顯現相位差的化合物。再者，亦可使用適當的接著劑，使各種光學功能性薄膜直接貼合於偏光薄膜。作為光學功能性薄膜的市售品，可列舉例如：DBEF(3M公司製、可從住友3M(股)取得)等提升亮度之薄膜、WV film(富士薄膜(股)製)等視角改良薄膜、Arton film(JSR(股)製)、ZEONOR薄膜((股)Optes製)、Escena(積水化學工業(股) 製)、VA-TAC(Konica Minolta Opto(股)製)、SUMIKALITE(住友化學(股)製)等的相位差薄膜等。
(活性能量線硬化型接著劑)
偏光薄膜與透明薄膜，係隔著活性能量線硬化型接著劑而貼合。作為活性能量線硬化型接著劑，從耐候性、折射率、陽離子聚合性等的觀點，例如含有藉由活性能量線的照射而硬化之環氧樹脂的環氧系樹脂組成物所構成的接著劑。但是，並不限於該等，可採用傳統偏光板之製造所使用的各種活性能量線硬化型接著劑(有機溶劑系接著劑、熱融系接著劑、無溶劑型接著劑等)。作為活性能量線硬化型接著劑，可列舉例如：丙烯醯胺、丙烯酸酯、胺甲酸乙酯丙烯酸酯、丙烯酸環氧酯等丙烯酸系樹脂組成物所構成的接著劑。
所謂環氧樹脂，係指分子內具有2個以上的環氧基之化合物。從耐候性、折射率、陽離子聚合性等的觀點，作為接著劑之硬化性環氧樹脂組成物中所含有的環氧樹脂，係以分子內不包含芳香環的環氧樹脂(例如參考專利文獻1)較理想。作為如此的環氧樹脂，例如氫化環氧樹脂、脂環式環氧樹脂、脂肪族環氧樹脂等。
氫化環氧樹脂，可藉由作為芳香族環氧樹脂的原料之聚羥基化合物在觸媒的存在下、加壓下選擇性地進行核氫化反應所得之核氫化聚羥基化合物，經環氧丙基醚化之方法而得。作為芳香族環氧樹脂，可列舉例如：雙酚A的二環氧丙基醚、雙酚F的二環氧丙基醚以及雙酚S的二環氧 丙基醚等的雙酚型環氧樹脂；酚酚醛(phenolic novolak)環氧樹脂、甲酚酚醛環氧樹脂以及羥基苯甲醛酚酚醛環氧樹脂等酚醛型環氧樹脂；四羥基苯基甲烷的環氧丙基醚、四羥基二苯基酮的環氧丙基醚以及環氧化聚乙烯基酚等多官能型環氧樹脂等。氫化環氧樹脂中，較理想為氫化雙酚A的環氧丙基醚。
所謂脂環式環氧樹脂，係指分子內具有1個以上鍵結於脂環式環之環氧基的環氧樹脂。所謂「鍵結於脂環式環之環氧基」，係指下式所示的構造中之橋接(bridged)的氧原子-O-。下式中，m為2至5的整數。
除去上述式之(CH2)m中之1個或複數個氫原子的形態之基鍵結於其它化學構造之化合物，可成為脂環式環氧樹脂。(CH2)m中之1個或複數個氫原子，可適當地被甲基、乙基等直鏈狀烷基取代。脂環式環氧樹脂中，由於顯示良好的接著性，故使用具有氧雜二環己烷環(上述式中之m=3者)之環氧樹脂、具有氧雜二環庚烷環(上述式中之m=4者)之環氧樹脂較理想。以下，具體地例示較理想使用的脂環式環氧樹脂，但不限於該等化合物。
(a)下式(I)所示的環氧基環己烷羧酸環氧基環己基甲酯類： (式中，R1及R2互相獨立地表示氫原子或碳數1至5之直鏈狀烷基)。
(b)下式(II)所示的烷二醇的環氧基環己烷羧酸酯類： (式中，R3及R4互相獨立地表示氫原子或碳數1至5之直鏈狀烷基，n表示2至20的整數)。
(c)下式(III)所示的二羧酸的環氧基環己基甲酯類： (式中，R5及R6互相獨立地表示氫原子或碳數1至5之直鏈狀烷基，p表示2至20的整數)。
(d)下式(IV)所示的聚乙二醇的環氧基環己基甲醚類： (式中，R7及R8互相獨立地表示氫原子或碳數1至5之直鏈狀烷基，q表示2至10的整數)。
(e)下式(V)所示的烷二醇的環氧基環己基甲醚類： (式中，R9及R10互相獨立地表示氫原子或碳數1至5之直鏈狀烷基，r表示2至20的整數)。
(f)下式(VI)所示的二環氧基三螺化合物類： (式中，R11及R12互相獨立地表示氫原子或碳數1至5之直鏈狀烷基)。
(g)下式(VII)所示的二環氧基單螺化合物類： (式中，R13及R14互相獨立地表示氫原子或碳數1至5之直鏈狀烷基)。
(h)下式(VIII)所示的乙烯基環己烯二環氧化物類： (式中，R15表示氫原子或碳數1至5之直鏈狀烷基)。
(i)下式(IX)所示的環氧基戊基醚類： (式中，R16及R17互相獨立地表示氫原子或碳數1至5之直鏈狀烷基)。
(j)下式(X)所示的二環氧基三環癸烷類： (式中，R18表示氫原子或碳數1至5之直鏈狀烷基)。
上述例示的脂環式環氧樹脂中，以下的脂環式環氧樹脂，有市售品或其類似物，因取得較容易等的理由，使用該等較理想。
(A)7-氧雜二環[4.1.0]庚烷-3-羧酸與(7-氧雜-二環[4.1.0]庚-3-基)甲醇的酯化物〔於式(I)中，R1=R2=H的化合物〕；(B)4-甲基-7-氧雜二環[4.1.0]庚烷-3-羧酸與(4-甲基-7-氧雜-二環[4.1.0]庚-3-基)甲醇的酯化物〔於式(I)中，R1=4-CH3、R2=4-CH3的化合物〕；(C)7-氧雜二環[4.1.0]庚烷-3-羧酸與1,2-乙二醇的酯化物〔於式(II)中，R3=R4=H、n=2的化合物〕；(D)(7-氧雜二環[4.1.0]庚-3-基)甲醇與己二酸的酯化物〔於式(III)中，R5=R6=H、p=4的化合物〕；(E)(4-甲基-7-氧雜二環[4.1.0]庚-3-基)甲醇與己二酸 的酯化物〔於式(III)中，R5=4-CH3、R6=4-CH3、p=4的化合物〕；(F)(7-氧雜二環[4.1.0]庚-3-基)甲醇與1,2-乙二醇的醚化物〔於式(V)中，R9=R10=H、r=2的化合物〕。
而且，作為脂肪族環氧樹脂，可列舉例如：脂肪族多元醇或其環氧烷(alkylene oxide)加成物的聚環氧丙基醚。更具體而言，例如1,4-丁二醇的二環氧丙基醚；1,6-己二醇的二環氧丙基醚；丙三醇的三環氧丙基醚；三羥基丙烷的三環氧丙基醚；聚乙二醇的二環氧丙基醚；丙二醇的二環氧丙基醚；藉由於乙二醇、丙二醇及丙三醇等脂肪族多元醇中加成1種或2種以上的環氧烷(環氧乙烷、環氧丙烷)所得之聚醚多元醇的聚環氧丙基醚等。
構成環氧系樹脂組成物所成的接著劑之環氧樹脂，可只單獨使用1種，亦可併用2種以上。該組成物所使用的環氧樹脂的環氧當量，通常為30至3,000 g/當量，較理想為50至1,500 g/當量的範圍內。環氧當量低於30 g/當量時，會有硬化後的複合偏光板的可撓性低，接著強度降低之情形。另一方面，超過3,000 g/當量時，會有與含於接著劑之其它成分的相溶性低之情形。
於該接著劑中，從反應性的觀點，作為環氧樹脂的硬化反應，以使用陽離子聚合較理想。因此，在作為活性能量線硬化型接著劑之硬化性環氧樹脂中，以調配陽離子聚合引發劑較理想。陽離子聚合引發劑，藉由可見光線、紫外線、X射線、電子束等的活性能量線之照射，產生陽離 子物種或路易斯酸，引發環氧基的聚合反應。以下，藉由活性能量線之照射而產生陽離子物種或路易斯酸，引發環氧基的聚合反應之陽離子聚合引發劑，稱為「光陽離子聚合引發劑」。
使用光陽離子聚合引發劑，藉由活性能量線之照射，進行接著劑的硬化之方法，可在常溫下硬化，減少需考慮偏光薄膜的耐熱性或因膨脹之彎曲，使薄膜間可良好地接著之點上為有利。而且，光陽離子聚合引發劑係因光而進行觸媒作用，即使混合於環氧樹脂，保存安定性、操作性亦佳。
作為光陽離子聚合引發劑，可列舉例如：芳香族重氮鹽；芳香族錪鹽、芳香族鋶鹽等的鎓鹽；鐵-芳烴錯合物等。
作為芳香族重氮鹽，例如六氟銻酸苯重氮鹽、六氟磷酸苯重氮鹽、六氟硼酸苯重氮鹽等。而且，作為芳香族錪鹽，可列舉例如：四(五氟苯基)硼酸二苯基錪鹽、六氟磷酸二苯基錪鹽、六氟銻酸二苯基錪鹽、六氟磷酸二(4-壬基苯基)錪鹽等。
作為芳香族鋶鹽，可列舉例如：六氟磷酸三苯基鋶鹽、六氟銻酸三苯基鋶鹽、四(五氟苯基)硼酸三苯基鋶鹽、雙(六氟磷酸)4,4’-雙(二苯基鋶基)二苯硫醚、雙(六氟銻酸)4,4’-雙[二(β-羥基乙氧基)苯基鋶基]二苯硫醚、雙(六氟磷酸)4,4’-雙[二(β-羥基乙氧基)苯基鋶基]二苯硫醚、六氟銻酸7-[二(對-甲苯甲醯基)鋶基]-2-異丙基硫雜蒽酮(thioxanthone)、四(五氟苯基)硼酸7-[二(對-甲苯甲醯基)鋶 基]-2-異丙基硫雜蒽酮、六氟磷酸4-苯基羰基-4’-二苯基鋶基-二苯硫醚、六氟銻酸4-(對-第三丁基苯基羰基)-4’-二苯基鋶基-二苯硫醚、四(五氟苯基)硼酸4-(對-第三丁基苯基羰基)-4’-二(對-甲苯甲醯基)鋶基-二苯硫醚等。
而且，作為鐵-芳烴錯合物，可列舉例如：六氟銻酸二甲苯-環戊二烯鐵(II)、六氟磷酸異丙苯-環戊二烯鐵(II)、二甲苯-環戊二烯鐵(II)-三(三氟甲基磺醯基)甲烷化物(methanide)等。
該等光陽離子聚合引發劑的市售品，可容易取得，以分別的商品名，可列舉例如：「KAYARAD PCI-220」以及「KAYARAD PCI-620」(以上日本化藥(股)製)、「UVI-6990」(美國聯合碳化物(Union Carbide)公司製)、「ADEKA OPTOMER SP-150」以及「ADEKA OPTOMER SP-170」(以上ADEKA公司製)、「CI-5102」、「CIT-1370」、「CIT-1682」、「CIP-1866S」、「CIP-2048S」以及「CIP-2064S」(以上日本曹達(股)製)、「DPI-101」、「DPI-102」、「DPI-103」、「DPI-105」、「MPI-103」、「MPI-105」、「BBI-101」、「BBI-102」、「BBI-103」、「BBI-105」、「TPS-101」、「TPS-102」、「TPS-103」、「TPS-105」、「MDS-103」、「MDS-105」、「DTS-102」以及「DTS-103」(以上綠化學(股)製)、「PI-2074」(Rhodia公司製)等。
光陽離子聚合引發劑，可單獨只使用1種，亦可混合2種以上使用。其中，芳香族鋶鹽，即使在300nm以上的波長區域中亦具有紫外線吸收特性，因此，硬化性佳，可 賦予具有良好的機械強度、接著強度之硬化物，故適合使用。
光陽離子聚合引發劑的調配量，對環氧樹脂100重量份而言，通常為0.5至20重量份，較理想為1重量份以上，而且較理想為15重量份以下。光陽離子聚合引發劑的調配量，對環氧樹脂100重量份而言，低於0.5重量份時，硬化變得不充分，會有機械強度、接著強度降低之傾向。而且，光陽離子聚合引發劑的調配量，對環氧樹脂100重量份而言，超過20重量份時，因硬化物中的離子性物質增加，使硬化物的吸濕性變高，會有耐久性能降低的情形。
在使用光陽離子聚合引發劑時，硬化性環氧樹脂組成物，依據需要，可更含有光增感劑。藉由使用光增感劑，提高陽離子聚合的反應性，可提高硬化物的機械強度、接著強度。作為光增感劑，例如羰基化合物、有機硫化合物、過硫化物、氧化還原系化合物、偶氮及重氮化合物、鹵化合物、光還原性色素等。
光增感劑的更具體例，例如安息香甲醚、安息香異丙醚及α,α’-二甲氧基-α-苯基苯乙酮等安息香衍生物；二苯基酮、2,4-二氯二苯基酮、o-安息香安息香酸甲酯、4,4’-雙(二甲基胺基)二苯基酮及4,4’-雙(二乙基胺基)二苯基酮等二苯基酮衍生物；2-氯硫雜蒽酮及2-異丙基硫雜蒽酮等硫雜蒽酮衍生物；2-氯蒽醌及2-甲基蒽醌等蒽醌衍生物；N-甲基吖啶酮及N-丁基吖啶酮等吖啶酮衍生物；其它亦有α,α-二乙氧基苯乙酮、二苯乙二酮、茀酮(Fluorenone)、 氧雜蒽酮(Xanthone)、鈾醯化合物、鹵化合物等。光增感劑，可單獨只使用1種，亦可併用2種以上。光增感劑，於硬化性環氧樹脂組成物100重量份中，以含有0.1至20重量份的範圍內較理想。
含於接著劑之環氧樹脂，係因光陽離子聚合而硬化，亦可藉由光陽離子聚合以及熱陽離子聚合而硬化。於後者的情況，以併用光陽離子聚合引發劑及熱陽離子聚合引發劑較理想。
作為熱陽離子聚合引發劑，可列舉例如：苯甲基鋶鹽、噻吩鎓鹽(thiophenium)、四氫噻吩鎓鹽(thiolanium)、苯甲基銨、吡啶鎓鹽、聯胺鎓鹽(hydrazinium)、羧酸酯、磺酸酯、胺醯亞胺等。該等熱陽離子聚合引發劑，作為市售品可容易取得，以分別的商品名，例如「Adeka opton CP77」及「Adeka opton CP66」(以上Adeka公司製)、「CI-2639」及「CI-2624」(以上曹達公司製)、「Sunaid SI-60L」、「Sunaid SI-80L」及「Sunaid SI-100L」(以上三新化學工業公司製)等。
活性能量線硬化型接著劑，可更含有氧雜環丁烷類、多元醇類等促進陽離子聚合之化合物。
氧雜環丁烷類為分子內具有4員環醚的化合物，可列舉例如：3-乙基-3-羥基甲基氧雜環丁烷、1,4-雙[(3-乙基-3-氧雜環丁基)甲氧基甲基]苯、3-乙基-3-(苯氧基甲基)氧雜環丁烷、二[(3-乙基-3-氧雜環丁基)甲基]醚、3-乙基-3-(2-乙基己氧基甲基)氧雜環丁烷、酚酚醛氧雜環丁烷等。該等氧 雜環丁烷類，作為市售品可容易取得，以分別的商品名，可列舉例如：「Aron oxetane OXT-101」、「Aron oxetane OXT-121」、「Aron oxetane OXT-211」、「Aron oxetane OXT-221」及「Aron oxetane OXT-212」(以上東亞合成(股)製)等。該等氧雜環丁烷類，在硬化性環氧樹脂組成物中，通常含有5至95重量%，較理想為30至70重量%的比例。
作為多元醇類，以不存在酚性羥基以外的酸性基者較理想，例如不具有羥基以外的官能基之多元醇化合物、聚酯多元醇化合物、聚己內酯多元醇化合物、具有酚性羥基之多元醇化合物、聚碳酸酯多元醇等。該等多元醇類的分子量，通常為48以上，較理想為62以上，更理想為100以上，而且較理想為1000以下。該等多元醇類，在硬化性環氧樹脂組成物中，通常含有50重量%以下，較理想為30重量%以下的比例。
於活性能量線硬化型接著劑中，可再調配離子捕捉劑、抗氧化劑、鏈轉移劑、黏著賦予劑、熱塑性樹脂、填充劑、流動調整劑、調平劑、塑化劑、消泡劑等添加劑。作為離子捕捉劑，可列舉例如：粉末狀的鉍系、銻系、鎂系、鋁系、鈣系、鈦系及該等混合系等的無機化合物，作為抗氧化劑，可列舉例如：受阻酚系抗氧化劑等。
活性能量線硬化型接著劑，可使用作為實質上不含有溶劑成分之無溶劑型接著劑，為了於各種塗佈方式為分別適合的黏度範圍，可含有用以調整黏度之溶劑。作為溶劑，以使用不降低偏光薄膜的光學特性、可良好地溶解環氧樹 脂組成物等者較理想，例如以甲苯為代表之烴類、以乙酸乙酯為代表之酯類等有機溶劑。本發明所使用的活性能量線硬化型接著劑的黏度，例如為5至1000 mPa‧s左右的範圍，較理想為10至200 mPa‧s的範圍，更理想為20至100 mPa‧s的範圍。
〈偏光板的製造方法〉
然後，一邊參考圖式，一邊說明本發明的偏光板之製造裝置及製造方法。第1圖為表示本發明的偏光板之製造裝置的一實施態樣的概略圖。
第1圖所示之偏光板之製造裝置30中，沿著傳送方向依序設置：塗佈接著劑於透明薄膜2、3的單面用之接著劑塗佈裝置11、12；將透明薄膜2、3與偏光薄膜1貼合而得到積層體4用之貼合滾輪(夾持滾輪)51、52；於積層體4，使透明薄膜2、3與偏光薄膜1密合用之滾輪13；在該滾輪13的外周面的對向位置設置之第1活性能量線照射裝置14、15。朝傳送方向更下游側設置之第2以後的活性能量線照射裝置16至18；以及傳送用夾持滾輪19。
再者，如第1圖、第2圖及第3圖所示，設置有分別接觸貼合滾輪51、52之按壓滾輪61、62。此處，按壓滾輪61、62的中央部之直徑，大於與其所接觸之貼合滾輪51、52的中央部之直徑。
首先，從捲繞成捲狀物的狀態連續送出的透明薄膜2、3的單面，藉由接著劑塗佈裝置11、12塗佈活性能量線硬化型接著劑(接著劑塗佈步驟)。
然後，從捲繞成捲狀物的狀態連續送出的偏光薄膜1的兩面，塗佈有接著劑之透明薄膜2、3，隔著接著劑積層所構成之積層體，在夾於傳送方向旋轉的一對貼合滾輪51、52間的狀態，藉由按壓滾輪61、62，將至少一側的貼合滾輪朝另一側的貼合滾輪的方向按壓，使偏光薄膜1與透明薄膜2、3貼合，形成積層體4(貼合步驟)。
然後，在該積層體4一邊密接於滾輪13的外周面一邊傳送的過程，從第1活性能量線照射裝置14、15朝滾輪13的外周面照射活性能量線，使接著劑聚合硬化(活性能量線照射步驟)。
再者，配置於傳送方向下游側之第2以後的活性能量線照射裝置16至18，係使接著劑完全聚合硬化用之裝置，可依所需而追加/省略。最後，積層體4通過傳送用夾持滾輪19，而作為偏光板被捲取於捲取滾輪20。以下，詳細說明各步驟。
(接著劑塗佈步驟)
透明薄膜2、3塗佈接著劑之方法，並無特別限制，例如可利用刮刀(doctor blade)、線棒、狹縫塗佈法、缺角輪塗佈法、凹版塗佈法等各種塗佈方式。其中，考慮薄膜塗佈、路徑線的自由度、寬度的對應等，接著劑塗佈裝置11、12係以凹版滾輪較理想。
於使用凹版滾輪作為接著劑塗佈裝置11、12進行接著劑的塗佈時，塗佈的接著劑之厚度(塗佈厚度)，較理想為約0.1至10μm，更理想為0.2μm至4μm。接著劑的塗佈 厚度，係根據對透明薄膜的線速度之凹版滾輪的速度比之牽引拉伸比(draw ratio)而調整。一般而言，拉伸比(凹版滾輪的速度/線速度)調整為0.5至10，可使接著劑的塗佈厚度調整為約0.1至10μm。更具體地，將透明薄膜2、3的線速度設為10至100m/分鐘，使凹版滾輪朝與透明薄膜2、3的傳送方向之反方向旋轉，凹版滾輪的速度設為5至1000 m/分鐘，可使接著劑的塗佈厚度調整為約0.1至10μm。
接著劑在調製後，通常在調整為15至40℃的範圍內之既定溫度±5℃(例如既定溫度為30℃時，係30℃±5℃)，較理想為±3℃，更理想為±1℃的環境下塗佈。
(貼合步驟)
於本步驟中，首先，於從捲繞成捲狀物的狀態連續送出的偏光薄膜1的兩面，由上述步驟之塗佈有接著劑之透明薄膜2、3，隔著接著劑積層。
該積層體，在夾於傳送方向旋轉的一對貼合滾輪51、52間的狀態，如第3圖所示，將按壓滾輪61的軸承構件61a朝箭頭方向(貼合滾輪52的方向)按壓，以按壓滾輪的全體，將貼合滾輪51全體朝箭頭方向按壓，使偏光薄膜1與透明薄膜2、3貼合，形成積層體4。此時，使偏光薄膜的傳送方向，對貼合滾輪的按壓方向垂直的面較理想為±3°的範圍內，更理想為±1°的範圍內的角度，將偏光薄膜於貼合滾輪間傳送。特別理想為使偏光薄膜的傳送方向與貼合滾輪的按壓方向垂直的面重疊之方式，將偏光薄膜於貼合滾輪間傳送。藉此，偏光薄膜與透明薄膜，在貼合滾 輪前接觸，不會產生氣泡。此處，由於按壓滾輪61的中央部之直徑大於與其連接之貼合滾輪51的中央部之直徑，因此，即使於按壓軸承構件61a時，按壓滾輪61亦不易產生彎曲，可以均勻的壓力按壓貼合滾輪51的全體。藉此，對構成偏光板的積層體(偏光薄膜1及透明薄膜2、3)可均勻地加壓。
通常，施加按壓滾輪自體旋轉的驅動力，亦會使貼合滾輪旋轉，但於本實施態樣中，分別獨立地驅動一對貼合滾輪，可藉此調整彎曲。
再者，於第1圖中，雖然顯示於透明薄膜2、3的單面均勻塗佈接著劑，使塗佈有透明薄膜2、3的接著劑的面與偏光薄膜1重疊，並藉由貼合滾輪51、52而貼合之方法，然亦可於偏光薄膜1的兩面均勻塗佈接著劑，使塗佈有偏光薄膜1的接著劑的面與透明薄膜2、3重疊，並藉由貼合滾輪51、52而貼合。
而且，如第4圖所示，可只在一對貼合滾輪51、52中之一，設置按壓滾輪61。
接觸按壓滾輪之貼合滾輪的中央部之直徑，較理想者係均為30mm以上且未達300mm，更理想為50至270mm。藉由使用如此較小直徑之貼合滾輪，使偏光薄膜與透明薄膜之間不易咬入空氣，為了不咬入氣泡之接著劑的厚度之調整範圍變寬，故可容易地製造不易在偏光薄膜與透明薄膜之間產生氣泡之偏光板。特別是貼合滾輪的直徑為300mm以上時，偏光薄膜與透明薄膜之間變得容易咬入空 氣。而且，於貼合滾輪的直徑未達50mm時，會有強度降低之不良情形。再者，貼合滾輪雖由至少一對滾輪構成，構成該對的滾輪之直徑，可為相同，亦可為相異。貼合滾輪的寬度，較理想為300至3000mm。
而且，前述按壓滾輪的中央部之直徑，較理想為200至500mm。未達200mm時，於按壓滾輪的軸承構件施加外力而按壓貼合滾輪時，按壓滾輪容易產生彎曲，會有無法以均勻壓力按壓貼合滾輪的情形。而且，在大於500mm時，在設備變大的點上會有不方便的情形。
一對的貼合滾輪51、52及按壓滾輪61、62，皆以直徑實質上均勻的滑面滾輪較理想。但是，一對貼合滾輪51、52中之一者、按壓滾輪61、62中之一者，可為具有直徑從中央部朝端部變小之錐形的外周形狀的滾輪(凸面滾輪(crowned roll))等。
一對貼合滾輪51、52中之一者或按壓滾輪61、62中之一者為凸面滾輪時，凸面滾輪的中央部的直徑與端部的直徑之差的比例，對前述凸面滾輪的長度(軸方向的長度)而言為0.0020%至0.0500%左右較理想。通常於該比例範圍中，凸面滾輪的形狀，可設計為貼合步驟在進行按壓的狀態下使凸面滾輪與滑面滾輪的間隔變成均勻。
藉由貼合滾輪51、52施加於積層體之壓力，並無特別限制，於使用金屬製滾輪與橡膠製滾輪時，富士薄膜製兩片式PRESCACE(商品名)(超低壓用)之瞬間壓力以0.5至3.0 MPa較理想，更理想為1.0至2.5 MPa。本發明中，對 該貼合滾輪之按壓的外力，通常係對按壓滾輪的兩端之軸承構件施加。
作為貼合滾輪及按壓滾輪的材質，例如為金屬、橡膠。以一對貼合滾輪之一者為金屬製滾輪，另一者為橡膠製滾輪者較理想。而且，貼合滾輪及按壓滾輪的配置，並無特別限制，可互相配置成為任意角度。亦即，按壓滾輪之設置不限於貼合滾輪的上下，亦可水平或其以外的角度配置。
傳統的貼合滾輪，通常係按壓的上側之貼合滾輪為橡膠製，下側之貼合滾輪為金屬製者。此係因下側之貼合滾輪附有驅動馬達以控制旋轉速度，下側之貼合滾輪為金屬製者，按壓時下側之貼合滾輪不會變形，貼合滾輪的周速容易維持一定。但是，於該情況，因容易調整後述的正向彎曲之彎曲，本發明中，以按壓(上側)之貼合滾輪為金屬製，另一(下側)貼合滾輪為橡膠製者較理想。
而且，與金屬製的貼合滾輪接觸而設置之按壓滾輪為橡膠製較理想。與橡膠製的貼合滾輪接觸而設置之按壓滾輪，可為金屬製、橡膠製的任一種。互相接觸之貼合滾輪及按壓滾輪均為金屬製時，因使用時滾輪間容易擦傷，故難以連續使用。另一方面，互相接觸之貼合滾輪及按壓滾輪均為橡膠製時，並無問題。
作為金屬製滾輪的基材，可使用各種習知的材質，較理想為不鏽鋼，更理想為SUS304(包含18%的鉻與8%的鎳之不鏽鋼)。於金屬製滾輪的表面，以實施鍍鉻處理較理想。
橡膠製滾輪的材質，並無特別限制，例如NBR(腈橡膠)、鈦、胺甲酸乙酯、矽、EPDM(乙烯-丙烯-二烯橡膠)等，較理想為NBR、鈦、胺甲酸乙酯。橡膠滾輪的硬度，並無特別限制，通常為60至100°，更理想為85至95°。再者，橡膠滾輪的硬度，可用根據JISK6253之硬度計測定。作為市售的硬度計，例如使用ASKA公司製之橡膠硬度計「A型」等。具體而言，表面用棒狀物按壓時，橡膠滾輪的表面阻力以硬度計測定。
一對貼合滾輪中，一貼合滾輪與另一貼合滾輪的周速可有差異。例如，設置於積層體4的貼合於液晶面板的面側之貼合滾輪(第1貼合滾輪)的周速，以比相反側的貼合滾輪(第2貼合滾輪)的周速快者較理想。藉此，於所得之偏光板，可賦予貼合於液晶面板的面變凸，其相反側的面變凹的彎曲(正向彎曲)。於所得之偏光板，賦予貼合於液晶面板的面變凹，其相反側的面變凸的彎曲(反向彎曲)時，偏光板貼合於液晶胞時，會產生中央部咬入氣泡等不良情形。而且，於該情況，以使用金屬製滾輪作為第1貼合滾輪，使用橡膠製滾輪作為第2貼合滾輪者較理想。再者，第2貼合滾輪的圓周速度為1時，第1貼合滾輪的圓周速度之比為1.0050至1.0200更理想。第1貼合滾輪的圓周速度大於該範圍時，正向彎曲的彎曲量變太大，偏光板貼合於液晶胞時，容易產生端部咬入氣泡等不良情形，再者，放置於嚴苛的環境下時，更加助長正向彎曲，惟恐偏光板的端部從液晶胞剝離。
滾輪13，其外周面構成為鏡面之凸曲面，其表面一邊與積層體4密接，一邊傳送，一邊在該過程，藉由活性能量線照射裝置14、15，使接著劑聚合硬化。接著劑聚合硬化，只要使積層體4充分密接，滾輪13的直徑，無特別限制。於接著劑未硬化狀態之積層體4，使通過滾輪13間的累積光量成為10 mJ/cm2以上之方式，照射活性能量線者較理想。滾輪13，可與積層體4的線動作從動，或使其旋轉驅動，或者使其固定而積層體4可滑過其表面。而且，滾輪13，藉由活性能量線的照射而聚合硬化時，亦可作用為將積層體4所產生的熱散熱之冷卻滾輪，於該情況，冷卻滾輪的表面溫度，以設定為4至30℃較理想。
(活性能量線照射步驟)
藉由活性能量線的照射進行接著劑的聚合硬化所使用的光源，並無特別限制，以具有波長400nm以下的發光分佈之光源較理想。作為如此的光源，例如低壓水銀燈、中壓水銀燈、高壓水銀燈、超高壓水銀燈、化學燈、黑光燈、微波激發水銀燈、金屬鹵素燈。
對活性能量線硬化型接著劑之光照射強度，係由每一接著劑的組成決定，而無特別限制，以10至5000 mW/cm2較理想。對樹脂組成物之光照射強度未達10 mW/cm2時，反應時間會過長，超過5000 mW/cm2時，經由燈的輻射之熱以及組成物在聚合時的發熱，會有產生接著劑的構成材料之環氧樹脂組成物等的黃變、偏光薄膜的劣化之情形。再者，照射強度較理想為光陽離子聚合引發劑的活性化有 效的波長區域之強度，更理想為波長400nm以下之波長區域之強度，更加理想為波長280至320nm之波長區域之強度。
對活性能量線硬化型接著劑之活性能量線的照射時間，係受限於各硬化組成物者，而無特別限制，表示照射強度與照射時間的乘積之累積光量，宜設定為10 mJ/cm2以上，較理想為10至5,000 mJ/cm2。對上述接著劑之累積光量未達10 mJ/cm2時，來自引發劑之活性物種的產生不充分，接著劑的硬化不足。另一方面，其累積光量超過5,000 mJ/cm2時，照射時間變的極長而不利於生產性的提高。此時，隨著使用的薄膜及接著劑種類的組合等，而決定何種波長區域(UVA(320至390nm))、UVB(280至320nm)等)的累積光量是否需要。
於本發明中，對積層體照射活性能量線使接著劑聚合硬化，惟亦可併用藉由加熱之聚合硬化。
當活性能量線為紫外線時，在對積層體4照射活性能量線之步驟中，對積層體4，一邊於長度方向(傳送方向)賦予100至800 N/m的張力，一邊以照射時間為0.1秒以上之線速度傳送積層體4者較理想。而且，紫外線的照射強度為10 mW/cm2以上者較理想。
而且，於藉由活性能量線照射裝置14、15之活性能量線的累積光量不足時，以再設置第2以後的活性能量線照射裝置16至18，並追加照射活性能量線以促進積層體4的接著劑之硬化者較理想。該等全部步驟之累積光量宜設 定為10 mJ/cm2以上，較理想為10至5,000 mJ/cm2。如此，於照射活性能量線的步驟中，活性能量線的照射，以分成複數次進行較理想。
為了偏光板(積層體)端部之接著劑的硬化確實進行，可列舉例如：無電極D閥門燈(valve lamp)之FUSION製「Light Hammer 10」，對薄膜的移動而言橫跨排列的方法等。
活性能量線硬化型樹脂的硬化比例，亦即反應率，較理想為90%以上，更理想為95%以上。
(偏光板捲取步驟)
捲繞積層體(偏光板)4之張力，並無特別限制，為30 N/cm2至150 N/cm2的範圍內。較理想為30 N/cm2至120 N/cm2的範圍內。未達30 N/cm2時，移動長條的捲狀物時，有引起捲取偏移之虞而不理想。大於150 N/cm2時，捲取過緊而有容易產生鬆弛的傾向。
再者，捲的長度變得越長，因在相同張力容易引起捲取過緊(捲出時難以回復平坦的現象)，故可將偏光板一邊捲至捲芯，一邊連續地或階段性地降低張力。如此賦予所謂錐形狀而降低張力之方法，此時的張力為150 N/cm2以下。
捲取於捲芯之偏光板的長度，並無特別限制，較理想為100 m以上4000 m以下。
圓筒狀的捲芯之直徑為6至12吋較理想。捲芯之直徑大者較理想，以11吋、12吋等更理想，而且，過大時， 會有移動、保管變困難的傾向。
圓筒狀捲芯之材質，因在無塵室使用，只要本身不易發塵，並可確保在適當的強度下捲取寬幅的偏光板，即無特別限制，可選擇FRP(玻璃纖維強化塑膠)等。
實施例
以下，舉出實施例以更詳細地說明本發明，但本發明不限於該等實施例。
〔實施例1〕 (偏光薄膜的製作)
作為聚乙烯醇的胚膜，係使用聚合度2400、皂化度99.9莫耳%、厚度75μm、寬度3000mm的長條聚乙烯醇薄膜「VINYLON VF-PS#7500(可樂麗製)」。延伸，係於處理槽前後的驅動夾持滾輪賦予圓周速度差進行。
首先，使胚膜不鬆弛之情形下，保持薄膜的緊張狀態，於裝有30℃的純水之膨潤槽中浸漬80秒，使薄膜充分膨潤，伴隨膨潤槽的膨潤，入口與出口的滾輪速度比為1.2。在夾持滾輪進行除水後，於裝有30℃的純水之水浸漬槽中浸漬160秒。該槽中，機械方向的延伸倍率為1.09倍。
然後，一邊浸漬於裝有碘/碘化鉀/水以重量比為0.02/2.0/100的水溶液之染色槽中，一邊以延伸倍率約1.5倍進行一軸延伸。然後，於裝有碘化鉀/硼酸/水以重量比為12/3.7/100的水溶液之硼酸槽中，一邊於55.5℃浸漬130秒，一邊從胚膜的累積延伸倍率成為5.7倍為止進行一軸延伸。然後，於裝有碘化鉀/硼酸/水以重量比為9/2.4/100 的水溶液之硼酸槽中，於40℃浸漬60秒。
再者，於水洗槽中，以8℃的純水、約16秒進行洗淨，然後，依序通過約60℃的乾燥爐、約85℃的乾燥爐，在該等乾燥爐的滯留時間合計為160秒，進行乾燥。如此，得到碘吸附配向之厚度28μm的偏光薄膜。
(偏光板的製作)
作為透明薄膜，係準備厚度50μm的環烯烴系樹脂薄膜「Zeonor」(日本Zeon(股)製)以及厚度80μm的三乙醯纖維素薄膜「KC8UX2MW」(柯尼卡美能達公司製)。
然後，於上述厚度50μm的環烯烴系樹脂薄膜「Zeonor」的單面，使用接著劑塗佈裝置(Micro Chamber Doctor：富士機械公司製)，塗佈紫外線硬化型接著劑之環氧樹脂組成物「KR系列」(ADEKA公司製；包含陽離子聚合引發劑)。而且，於上述厚度80μm的三乙醯纖維素薄膜「KC8UX2MW」的單面，使用相同的接著劑塗佈裝置，塗佈紫外線硬化型接著劑之環氧樹脂組成物「KR系列」(ADEKA公司製；包含陽離子聚合引發劑)。此時，接著劑塗佈裝置的偏光薄膜積層體的線速度為25 m/分鐘，使凹版滾輪以與積層材料的傳送方向相反方向旋轉，使厚度50μm的環烯烴系樹脂薄膜「Zeonor」上的接著劑層的厚度約成為3.5μm，厚度80μm的三乙醯纖維素薄膜「KC8UX2MW」上的接著劑層的厚度約成為3.5μm。
然後，於上述偏光薄膜的兩面，將上述厚度50μm的環烯烴系樹脂薄膜「Zeonor」以及厚度80μm的三乙醯纖 維素薄膜「KC8UX2MW」，隔著上述環氧樹脂組成物(紫外線硬化型接著劑)進行貼合。於貼合時，如第1圖所示，係使用直徑為250mm的一對貼合滾輪以及與各貼合滾輪接觸而設置之直徑為400mm的一對按壓滾輪，使貼合滾輪的平均夾持壓(藉由貼合滾輪施加於積層體的壓力)成為1.53 MPa之方式加以夾持。
貼合有上述2種透明薄膜之偏光薄膜，一邊與長度方向上賦予600 N/m的張力之冷卻滾輪密接，一邊以線速度25 m/分鐘移動，使其通過從薄膜的寬度方向上串聯連續設置之金屬鹵素燈2盞(GS-YUASA公司製、每1盞的電力為120 W/cm)照射之紫外線中，進行第1活性能量線照射步驟，然後，使其通過從薄膜的寬度方向上串聯連續配置之無電極D閥門燈6盞(Fusion公司製「Light Hammer 10」、每1盞的單位長度之電力為216 W/cm)照射之紫外線中，進行第2活性能量線照射步驟，製作偏光板。
通過金屬鹵素燈時，使貼合於上述偏光薄膜的厚度80μm之三乙醯纖維素薄膜「KC8UX2MW」接觸設定於23℃之冷卻滾輪的外周面，從厚度50μm之環烯烴系樹脂薄膜「Zeonor」側照射紫外線。藉此，抑制第1活性能量線照射步驟之熱的影響造成之接著劑、偏光薄膜的劣化。
(貼合滾輪的夾持壓分佈及偏光板的氣泡之評價)
將實施例1的一對貼合滾輪之夾持壓，使用富士薄膜製兩片式按壓箱(超低壓用)測定時，夾持壓分佈在寬度方向幾乎均勻。而且，評價製作的偏光板時，沒有觀察到氣 泡。結果表示於表1。
〔實施例2〕
於本實施例中，除了使貼合滾輪的平均夾持壓成為2.25 MPa之方式進行夾持外，與實施例1同樣地，製作偏光板。
(貼合滾輪的夾持壓分佈及偏光板的氣泡之評價)
實施例2的貼合滾輪的夾持壓，在使用富士薄膜製兩片式按壓箱(超低壓用)測定時，夾持壓分佈在寬度方向幾乎均勻。而且，評價製作的偏光板時，沒有觀察到氣泡。 結果表示於表1。
〔比較例1〕
除了只使用一對貼合滾輪，平均夾持壓成為1.13 MPa之方式進行夾持外，與實施例1同樣地，製作偏光板。
(貼合滾輪的夾持壓分佈及偏光板的氣泡之評價)
比較例1的貼合滾輪的夾持壓，在使用富士薄膜製兩片式按壓箱(超低壓用)測定時，夾持壓在寬度方向的分佈變大。而且，評價製作的偏光板時，觀察到氣泡。結果表示於表1。
[產業上之可利用性]
本發明的偏光板，可有效地應用於以液晶顯示裝置為代表之各種顯示裝置。
1‧‧‧偏光薄膜
2、3‧‧‧透明薄膜
4‧‧‧積層體(偏光板)
11、12‧‧‧接著劑塗佈裝置
13‧‧‧滾輪(冷卻滾輪)
14、15、16、17、18‧‧‧活性能量線照射裝置
19‧‧‧傳送用夾持滾輪
20‧‧‧捲取滾輪
51、52‧‧‧貼合滾輪
61、62‧‧‧按壓滾輪

Claims (4)

  1. 一種偏光板之製造方法，係使透明薄膜(2,3)貼合於偏光薄膜(1)的單面或兩面所構成的偏光板之製造方法，其特徵為具備：於前述透明薄膜的單面或者前述偏光薄膜(1)的單面或兩面，塗佈活性能量線硬化型接著劑之接著劑塗佈步驟；前述透明薄膜(2,3)隔著前述接著劑積層於前述偏光薄膜(1)的單面或兩面所構成的積層體(4)，在被夾持於朝傳送方向旋轉的一對貼合滾輪(51,52)間的狀態，藉由與前述貼合滾輪(51,52)接觸而設置之至少一個按壓滾輪(61,62)，將至少一側的貼合滾輪(51,52)朝另一側的貼合滾輪的方向按壓，藉此使前述透明薄膜(2,3)與前述偏光薄膜(1)貼合之貼合步驟；以及對前述積層體(4)照射活性能量線，使前述接著劑硬化之活性能量線照射步驟；其中，前述按壓滾輪(61,62)的中央部的直徑，大於接觸該按壓滾輪之前述貼合滾輪(51,52)的中央部的直徑。
  2. 如申請專利範圍第1項所述之偏光板之製造方法，其中，前述一對貼合滾輪(51,52)，分別獨立地被驅動。
  3. 如申請專利範圍第1項所述之偏光板之製造方法，其中，前述一對貼合滾輪(51,52)以及前述按壓滾輪(61,62)，為直徑實質上均一之滑面滾輪。
  4. 一種偏光板之製造裝置，其係透明薄膜(2,3)貼合於偏光薄膜(1)的單面或兩面所構成的偏光板之製造裝置，其特徵為具備：於前述透明薄膜(2,3)的單面或者前述偏光薄膜(1)的單面或兩面，塗佈活性能量線硬化型接著劑用之接著劑塗佈裝置(11,12)；將前述透明薄膜(2,3)隔著前述接著劑積層於前述偏光薄膜(1)的單面或兩面所構成的積層體(4)予以一邊傳送一邊夾壓，藉此使前述透明薄膜(2,3)與前述偏光薄膜(1)貼合用之一對貼合滾輪(51,52)；為了使前述一對貼合滾輪(51,52)的至少一側之貼合滾輪(51,52)朝另一側之貼合滾輪的方向按壓，與前述貼合滾輪(51,52)接觸而設置之至少一個按壓滾輪(61,62)；以及對前述積層體(4)照射活性能量線，使前述接著劑硬化用之活性能量線照射裝置(14,15,16,17,18)；其中，前述按壓滾輪(61,62)的中央部的直徑，大於接觸該按壓滾輪之前述貼合滾輪(51,52)的中央部的直徑。
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