TWI552862B - A method of manufacturing a polarizer - Google Patents
A method of manufacturing a polarizer Download PDFInfo
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- TWI552862B TWI552862B TW101111581A TW101111581A TWI552862B TW I552862 B TWI552862 B TW I552862B TW 101111581 A TW101111581 A TW 101111581A TW 101111581 A TW101111581 A TW 101111581A TW I552862 B TWI552862 B TW I552862B
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
- G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
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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
- B29D11/00634—Production of filters
- B29D11/00644—Production of filters polarizing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J129/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Adhesives based on hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Adhesives based on derivatives of such polymers
- C09J129/02—Homopolymers or copolymers of unsaturated alcohols
- C09J129/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
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- Physics & Mathematics (AREA)
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Ophthalmology & Optometry (AREA)
- Mechanical Engineering (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Polarising Elements (AREA)
Description
本發明涉及作為液晶顯示構件所使用之偏光板之製造方法。 The present invention relates to a method of producing a polarizing plate used as a liquid crystal display member.
構成液晶顯示裝置之核心之液晶面板係於液晶胞之兩表面配置偏光板而構成。一般來說,偏光板為於聚乙烯醇系樹脂製之偏光膜之一側之面,經由接著劑而貼合有透明樹脂製之保護膜之構造。大多於偏光膜之另一側之面亦經由接著劑貼合有透明樹脂膜,該側之透明樹脂膜除與相反側之保護膜相同地為僅具有對偏光膜之保護功能者以外,亦有時為所謂之相位差膜,其除了保護功能以外,還以液晶胞之光學補償與視場角補償之目的而被賦予有面內及/或厚度方向之相位差。於本說明書中,將此種於偏光膜上經由接著劑所貼合之保護膜與相位差膜等稱為「光學膜」。用於向偏光膜貼合光學膜之接著劑一般為液狀,藉由該液狀接著劑之固化反應而於偏光膜與光學膜之間顯現接著力。 The liquid crystal panel constituting the core of the liquid crystal display device is configured by disposing a polarizing plate on both surfaces of the liquid crystal cell. In general, the polarizing plate has a structure in which a protective film made of a transparent resin is bonded to the surface of one side of the polarizing film made of a polyvinyl alcohol-based resin via an adhesive. The surface of the other side of the polarizing film is also bonded to the other side of the polarizing film via a bonding agent. The transparent resin film on the side is the same as the protective film on the opposite side, and has a function of protecting only the polarizing film. In the case of a so-called retardation film, in addition to the protective function, a phase difference in the in-plane and/or thickness direction is imparted for the purpose of optical compensation of the liquid crystal cell and compensation of the viewing angle. In the present specification, the protective film and the retardation film which are bonded to each other via the adhesive on the polarizing film are referred to as "optical films". The adhesive for bonding the optical film to the polarizing film is generally liquid, and an adhesive force is expressed between the polarizing film and the optical film by the curing reaction of the liquid adhesive.
近年來,以電視為代表之液晶顯示裝置之價格急劇降低,對構成其之構件低價格化之要求日趨強烈,另一方面,對品質之要求亦進一步增強。於該趨勢下,偏光板之製造所使用之接著劑,亦正自可適用之光學膜之種類限於纖維素系樹脂等特定樹脂之水系接著劑,向可適用之光學膜之種類豐富之活性能量線固化型接著劑變更。例如於特 開2004-245925號公報中提出有使用活性能量線固化型接著劑之偏光膜與光學膜之貼合。 In recent years, the price of a liquid crystal display device represented by a television has been drastically lowered, and the demand for a component that constitutes a component thereof has become increasingly strong. On the other hand, the demand for quality has been further enhanced. In this trend, the type of the optical film used for the production of the polarizing plate is limited to the water-based adhesive of a specific resin such as a cellulose resin, and the active energy rich in the applicable optical film. The line curing type adhesive is changed. For example In JP-A-2004-245925, a polarizing film using an active energy ray-curable adhesive is bonded to an optical film.
活性能量線固化型接著劑係以液狀準備,且使用於被塗佈物上直接塗佈該液狀接著劑之模塗佈機、或於形成於表面之凹槽中擔載液狀接著劑並將其轉印於被塗佈物表面之凹版輥,而預先塗佈於光學膜之向偏光膜之貼合面上。然後,於該接著劑塗佈面上重疊偏光膜並照射紫外線與電子束等活性能量線而使接著劑固化,從而顯現接著力。使用此種活性能量線固化型接著劑之方式可適用之光學膜多而為非常有效之方法。 The active energy ray-curable adhesive is prepared in a liquid form, and is applied to a coating machine directly coated with the liquid adhesive on the coated object, or in a groove formed on the surface to carry a liquid adhesive. This is transferred to a gravure roll on the surface of the object to be coated, and is applied in advance to the bonding surface of the optical film to the polarizing film. Then, a polarizing film is superposed on the adhesive-coated surface, and an active energy ray such as an ultraviolet ray or an electron beam is irradiated to cure the adhesive, thereby exhibiting an adhesive force. A method in which such an active energy ray-curable adhesive is used is a very effective method for many optical films.
作為使用該活性能量線固化型接著劑之偏光板之製造方法,例如於日本專利特開2009-134190號公報中公開有一種方法:於偏光膜之兩表面分別經由接著劑重合保護膜而獲得積層體,一面使該積層體密接於沿著該積層體之搬送方向呈圓弧狀形成之凸曲面之外表面,一面照射活性能量線。根據該方法,可抑制於所獲得之偏光板上容易產生之反向捲曲及波浪捲曲,從而可製造具有良好性能之偏光板。 As a method of producing a polarizing plate using the active energy ray-curable adhesive, a method of forming a laminate by superposing a protective film on both surfaces of a polarizing film via an adhesive is disclosed, for example, in Japanese Laid-Open Patent Publication No. 2009-134190 The body is irradiated with an active energy ray while adhering to the outer surface of the convex curved surface formed in an arc shape along the conveying direction of the laminated body. According to this method, the reverse curl and the wave curl which are easily generated on the obtained polarizing plate can be suppressed, so that a polarizing plate having good performance can be manufactured.
於照射紫外線使紫外線固化型接著劑固化而製造偏光板之方法中,紫外線照射裝置之燈經長期使用而劣化,即便負載相同之電力,紫外線之輻射照度亦會慢慢降低,該情況下,紫外線固化型接著劑之固化不充分,作為偏光板之 性能有可能不足。又,若仍然長期使用,則由於紫外線照射裝置之設置環境或該裝置之構造上之問題,燈或附屬於紫外線照射裝置之濾光片或反射板、配置於前表面之玻璃等會受到污染,該情況下,所照射之紫外線中例如波長400 nm以下之光之透過率減少,從而引起輻射照度降低,這樣亦會認為紫外線固化型接著劑之固化不充分。若紫外線固化型接著劑之固化變得不充分,則產生接著強度不足等問題,於耐久性試驗中,偏光膜引起脫色等,對於作為偏光板之性能亦會帶來不良影響,因此,要求一種紫外線固化型接著劑受到之紫外線之輻射照度得以恰當管理之偏光板之製造方法。 In the method of producing a polarizing plate by irradiating ultraviolet rays to cure the ultraviolet curable adhesive, the lamp of the ultraviolet irradiation device is deteriorated by long-term use, and even if the same electric power is applied, the ultraviolet illuminance of the ultraviolet ray is gradually lowered. In this case, the ultraviolet ray is gradually lowered. The curing of the curing type adhesive is insufficient, as a polarizing plate Performance may be insufficient. Further, if it is still used for a long period of time, the lamp or the filter or the reflection plate attached to the ultraviolet irradiation device, the glass disposed on the front surface, etc. may be contaminated due to the installation environment of the ultraviolet irradiation device or the structural problem of the device. In this case, in the ultraviolet light to be irradiated, for example, the transmittance of light having a wavelength of 400 nm or less is reduced, and the illuminance is lowered, so that the curing of the ultraviolet curable adhesive is also considered to be insufficient. When the curing of the ultraviolet curable adhesive is insufficient, there is a problem that the adhesive strength is insufficient, and the polarizing film causes discoloration or the like in the durability test, which adversely affects the performance as a polarizing plate. A method of manufacturing a polarizing plate in which an ultraviolet curable adhesive is appropriately managed by ultraviolet illuminance.
所照射之紫外線之輻射照度,一般使用被稱為功率監視器之GaN或AlGaN等之紫外線傳感器裝置進行測量。但功率監視器因如下原因而具有輻射照度之測量精度比較低之問題,即:1)紫外線傳感器裝置之檢測波長限定於特定之波長區域,此外測量感度(每個波長之光吸收之感度)因每個波長而不同;2)由於耐熱性之問題,無法直接計測所照射之紫外光之輻射照度,不得不測量照射之紫外光之反射光而間接地計測輻射照度。由於該問題,將功率監視器應用於使用有紫外線固化型接著劑之偏光板之製造,難以準確地檢測對紫外線固化型接著劑之固化度產生重大影響之、包含於紫外線固化型接著劑中之聚合起始劑之活化所需要之波長區域之輻射照度之降低。因此,期望開發出一種可準確地檢測該特定之波長區域內之輻射照度降低,且 可在維持需要之分光輻射照度之同時製造偏光板。 The illuminance of the ultraviolet ray to be irradiated is generally measured using an ultraviolet sensor device such as GaN or AlGaN called a power monitor. However, the power monitor has a problem that the measurement accuracy of the illuminance is relatively low for the following reasons, that is, 1) the detection wavelength of the ultraviolet sensor device is limited to a specific wavelength region, and the measurement sensitivity (sensitivity of light absorption per wavelength) is Each wavelength is different; 2) Due to the problem of heat resistance, the illuminance of the irradiated ultraviolet light cannot be directly measured, and the illuminance of the illuminating light is indirectly measured by measuring the reflected light of the irradiated ultraviolet light. Due to this problem, the power monitor is applied to the production of a polarizing plate using an ultraviolet curing type adhesive, and it is difficult to accurately detect the ultraviolet curing type adhesive which has a significant influence on the curing degree of the ultraviolet curing type adhesive. A decrease in the irradiance of the wavelength region required for activation of the polymerization initiator. Therefore, it is desirable to develop a radiation illuminance reduction that can accurately detect the specific wavelength region, and The polarizing plate can be manufactured while maintaining the required spectral illuminance.
因此,本發明之課題在於提供一種方法,該方法係於偏光膜上經由紫外線固化型接著劑貼合光學膜、且藉由紫外線照射使該紫外線固化型接著劑固化而製造偏光板之方法,可準確地檢測紫外線之輻射照度、特別係聚合起始劑之活化所需要之波長區域之輻射照度,藉由對其加以恰當地控制而可製造即便於高溫多濕之嚴酷條件下偏光膜之脫色亦難以產生之、耐久性高之偏光板。 Therefore, an object of the present invention is to provide a method for producing a polarizing plate by bonding an optical film to a polarizing film via an ultraviolet curable adhesive and curing the ultraviolet curable adhesive by ultraviolet irradiation. Accurately detecting the irradiance of ultraviolet ray illuminance, especially the wavelength region required for the activation of the polymerization initiator, by properly controlling it, it is possible to produce a discoloration of the polarizing film even under severe conditions of high temperature and humidity. A polarizing plate that is difficult to produce and has high durability.
本發明提供一種偏光板之製造方法,其係於聚乙烯醇系樹脂製之偏光膜上經由包含聚合起始劑之紫外線固化型接著劑貼合熱塑性樹脂製之光學膜而製造偏光板之方法,且具有以下(A)、(B)、(C)、(D)及(E)之各步驟。 The present invention provides a method for producing a polarizing plate, which is a method of producing a polarizing plate by bonding an optical film made of a thermoplastic resin to a polarizing film made of a polyvinyl alcohol-based resin via an ultraviolet-curable adhesive containing a polymerization initiator. It has the following steps (A), (B), (C), (D) and (E).
(A)塗佈步驟,於光學膜之向偏光膜之貼合面上塗佈上述之紫外線固化型接著劑;(B)貼合步驟,於以塗佈步驟塗佈之紫外線固化型接著劑面上重疊偏光膜並加壓;(C)固化步驟,對經由紫外線固化型接著劑而於偏光膜上貼合有光學膜之積層體,自紫外線照射裝置照射紫外線,藉此使紫外線固化型接著劑固化;(D)計測步驟,使用分光儀測量於上述固化步驟中所照射之紫外線之分光輻射照度,並根據此而計測包含聚合起始劑之吸收峰值波長之特定之吸收波長區域、例如該吸收峰值波長之-40 nm~+40 nm之波長區域內之紫外線之分光 輻射照度之積分值;及(E)控制步驟,根據所設定之分光輻射照度之積分值Y與求得之分光輻射照度之積分值X而控制紫外線照射裝置。 (A) a coating step of applying the ultraviolet curable adhesive described above to the bonding surface of the optical film to the polarizing film; and (B) a bonding step for applying the ultraviolet curable adhesive to the coating step (C) a curing step in which a layered body in which an optical film is bonded to a polarizing film via an ultraviolet curing type adhesive is irradiated with ultraviolet rays from an ultraviolet irradiation device to thereby form an ultraviolet curing type adhesive (D) a measuring step of measuring a spectroscopic illuminance of the ultraviolet ray irradiated in the curing step using a spectrometer, and measuring a specific absorption wavelength region including an absorption peak wavelength of the polymerization initiator, for example, the absorption Ultraviolet light splitting in the wavelength range from -40 nm to +40 nm at the peak wavelength The integral value of the irradiance illuminance; and (E) the control step, the ultraviolet ray irradiation device is controlled according to the integral value Y of the set illuminating illuminance and the integral value X of the obtained illuminating illuminance.
本發明之偏光板之製造方法較佳為包括下述(E)步驟。 The method for producing a polarizing plate of the present invention preferably comprises the following step (E).
(E)控制步驟,於上述計測步驟中獲得之分光輻射照度之積分值X與所設定之分光輻射照度之積分值Y之差之絕對值相對於上述Y之比例為特定值以上時,例如為5%以上時,控制上述紫外線照射裝置之輸出。 (E) a control step, when the ratio of the absolute value of the difference between the integral value X of the spectral illuminance obtained by the measurement step and the integrated value Y of the set spectral illuminance is greater than or equal to a specific value, for example, When it is 5% or more, the output of the above ultraviolet irradiation device is controlled.
又,本發明之其他側面之方法係提供具有以下(A)、(B)、(C)、(D)及(E)之各步驟之偏光板之製造方法。 Further, the method of the other aspect of the present invention provides a method of producing a polarizing plate having the following steps (A), (B), (C), (D), and (E).
(A)步驟,於熱塑性樹脂製之光學膜上塗佈包含聚合起始劑之紫外線固化型接著劑;(B)步驟,於光學膜之紫外線固化型接著劑塗佈面重疊聚乙烯醇系樹脂製之偏光膜,並將光學膜相對於偏光膜加壓而獲得偏光膜與光學膜經由紫外線固化型接著劑貼合之積層體;(C)步驟,藉由自紫外線照射裝置對積層體照射紫外線而使紫外線固化型接著劑固化;(D)步驟,使用分光儀計測所照射之紫外線之分光輻射照度,求得包含聚合起始劑之吸收峰值波長之特定之吸收波長區域內、例如自較該吸收峰值波長小40 nm之波長至較該吸收峰值波長大40 nm之波長為止之波長區域內之分光輻射照度之積分值;及(E)步驟,根據所設定之分光輻射照度之積分值Y與求得 之分光輻射照度之積分值X而控制紫外線照射裝置。 (A) step of applying an ultraviolet curable adhesive containing a polymerization initiator to an optical film made of a thermoplastic resin; and (B), superposing a polyvinyl alcohol resin on the surface of the ultraviolet curable adhesive coated on the optical film The polarizing film is prepared, and the optical film is pressed against the polarizing film to obtain a laminate in which the polarizing film and the optical film are bonded via the ultraviolet curing type adhesive; and (C), the laminated body is irradiated with ultraviolet rays by the ultraviolet irradiation device. And curing the ultraviolet curable adhesive; (D), measuring the spectral irradiance of the irradiated ultraviolet light using a spectrometer, and determining a specific absorption wavelength region including the absorption peak wavelength of the polymerization initiator, for example, from An integral value of the illuminating illuminance in a wavelength region where the wavelength of the peak wavelength is 40 nm to a wavelength larger than the wavelength of the absorption peak by 40 nm; and (E), according to the integral value Y of the illuminance of the split radiant Obtain The integral value X of the split radiance illuminance controls the ultraviolet ray irradiation device.
本發明之其他側面之製造方法較佳為包括下述(E)步驟。 The manufacturing method of the other aspect of the invention preferably comprises the following step (E).
(E)步驟,於所求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y之差之絕對值相對於所設定之分光輻射照度之積分值Y之比例為特定值以上時,例如為5%以上時,控制紫外線照射裝置。 In the step (E), the ratio of the absolute value of the difference between the integral value X of the spectral illuminance obtained and the integrated value Y of the set spectroscopy illuminance is greater than a specific value of the integrated value Y of the set illuminating illuminance In the case of, for example, 5% or more, the ultraviolet irradiation device is controlled.
根據本發明,於經由紫外線固化型接著劑而於偏光膜上貼合光學膜,並藉由紫外線照射使該紫外線固化型接著劑固化而製造偏光板時,使用分光儀準確地計測包含紫外線固化型接著劑中所含之聚合起始劑之吸收峰值波長之特定之吸收波長區域內之分光輻射照度之積分值,根據其結果而控制紫外線照射裝置之輸出以免紫外線固化型接著劑之固化不充分,因此可提供具有良好之接著強度、且即便於高溫多濕之嚴酷條件下亦難以產生偏光膜之脫色之耐久性高之偏光板。 According to the present invention, when an optical film is bonded to a polarizing film via an ultraviolet curable adhesive, and the ultraviolet curable adhesive is cured by ultraviolet irradiation to produce a polarizing plate, the ultraviolet curable type is accurately measured using a spectrometer. The integrated value of the spectral illuminance in the specific absorption wavelength region of the absorption peak wavelength of the polymerization initiator contained in the subsequent agent, and the output of the ultraviolet irradiation device is controlled according to the result to prevent the curing of the ultraviolet curing adhesive from being insufficient. Therefore, it is possible to provide a polarizing plate having excellent adhesion strength and having high durability against discoloration of the polarizing film even under severe conditions of high temperature and high humidity.
於本實施形態中,於聚乙烯醇系樹脂製之偏光膜上經由紫外線固化型接著劑(以下僅稱為接著劑)貼合熱塑性樹脂製之光學膜而製造偏光板。光學膜可僅貼合於偏光膜之單面,亦可貼合於偏光膜之兩表面。於偏光膜之兩表面貼合光學膜時,可於一方之光學膜之貼合中應用本發明之方法,亦可於兩方之光學膜之貼合中應用本實施形態之方 法。 In the present embodiment, a polarizing plate is produced by laminating an optical film made of a thermoplastic resin to a polarizing film made of a polyvinyl alcohol-based resin via an ultraviolet curable adhesive (hereinafter simply referred to as an adhesive). The optical film may be attached only to one side of the polarizing film or may be attached to both surfaces of the polarizing film. When the optical film is bonded to both surfaces of the polarizing film, the method of the present invention can be applied to the bonding of one of the optical films, and the method of the present embodiment can be applied to the bonding of the two optical films. law.
偏光膜為聚乙烯醇系樹脂製,且係具有使入射至該膜之光中之具有某一方向之振動面之光透過並將具有與其正交之振動面之光吸收之性質之膜,典型的是,於聚乙烯醇系樹脂上吸附配向有二色性色素。構成偏光膜之聚乙烯醇系樹脂藉由使聚醋酸乙烯酯系樹脂皂化而獲得。作為聚乙烯醇系樹脂之原料之聚醋酸乙烯酯系樹脂,除了作為醋酸乙烯酯之均聚物之聚醋酸乙烯酯以外,亦可為醋酸乙烯酯及可與之共聚之其他單體之共聚物。藉由對該聚乙烯醇系樹脂製之膜實施單軸拉伸、利用二色性色素進行之染色及染色後之硼酸交聯處理而可製造偏光膜。作為二色性色素,使用碘或二色性之有機染料。單軸拉伸可於利用二色性色素進行染色之前進行,亦可與利用二色性色素進行染色同時進行,亦可於利用二色性色素進行染色之後,例如於硼酸交聯處理中進行。如此製造並吸附、配向有二色性色素之聚乙烯醇系樹脂製之偏光膜成為偏光板之原料之一。 The polarizing film is made of a polyvinyl alcohol-based resin, and is a film which transmits light having a vibration surface of a certain direction among light incident on the film and absorbs light having a vibration surface orthogonal thereto, typically The dichroic dye is adsorbed and aligned on the polyvinyl alcohol-based resin. The polyvinyl alcohol-based resin constituting the polarizing film is obtained by saponifying a polyvinyl acetate-based resin. The polyvinyl acetate-based resin which is a raw material of the polyvinyl alcohol-based resin may be a copolymer of vinyl acetate and other monomers copolymerizable therewith, in addition to polyvinyl acetate which is a homopolymer of vinyl acetate. . The polarizing film can be produced by subjecting the film made of the polyvinyl alcohol-based resin to uniaxial stretching, dyeing with a dichroic dye, and boric acid crosslinking treatment after dyeing. As the dichroic dye, an organic dye of iodine or dichroic is used. The uniaxial stretching may be carried out before the dyeing with the dichroic dye, or simultaneously with the dyeing with the dichroic dye, or after the dyeing with the dichroic dye, for example, in the boric acid crosslinking treatment. The polarizing film made of a polyvinyl alcohol-based resin which is produced and adsorbed and aligned with a dichroic dye is one of the raw materials of the polarizing plate.
於該偏光膜上貼合熱塑性樹脂製之光學膜而製造偏光板。光學膜較佳為,於溫度20℃藉由D射線所測量之折射率處於1.4~1.7之範圍。光學膜之折射率係依據JIS K 0062:1992「化學製品之折射率測量方法」進行測量。若光學膜具有該範圍之折射率,則將所製造之偏光板組裝於液晶面板時之顯示特性優異。基於相同之理由,光學膜較 佳之折射率為1.45~1.67之範圍。該光學膜之霧度值處於0.001~3%左右之範圍,這會使所獲得之偏光板之對比度提高,特別係組裝於液晶面板而進行黑顯示時,產生亮度降低等問題之可能性降低,因此較佳。霧度值係以(擴散透過率/總光線透過率)×100(%)定義之值,依據JIS K 7136:2000「塑膠-透明材料之霧度之求法」進行測量。 A polarizing plate was produced by laminating an optical film made of a thermoplastic resin on the polarizing film. Preferably, the optical film has a refractive index measured by D rays at a temperature of 20 ° C in the range of 1.4 to 1.7. The refractive index of the optical film is measured in accordance with JIS K 0062: 1992 "Measurement Method of Refractive Index of Chemicals". When the optical film has a refractive index in this range, the display characteristics of the produced polarizing plate when it is assembled to a liquid crystal panel are excellent. For the same reason, optical film comparison Good refractive index is in the range of 1.45~1.67. The haze value of the optical film is in the range of about 0.001 to 3%, which improves the contrast of the obtained polarizing plate, and in particular, when the liquid crystal panel is assembled and black-displayed, there is a possibility that the brightness is lowered, and the like. Preferably. The haze value is measured by (diffusion transmittance / total light transmittance) × 100 (%), and is measured in accordance with JIS K 7136: 2000 "Method for determining the haze of plastic-transparent material".
作為構成該光學膜之熱塑性樹脂,例如可列舉如下材料,於此,將於溫度20℃藉由D射線所測量之折射率設為nD(20℃)而一併示出。 Examples of the thermoplastic resin constituting the optical film include the following materials, and the refractive index measured by D rays at a temperature of 20 ° C is shown as n D (20 ° C).
環烯系樹脂[nD(20℃)=1.51~1.54左右]、結晶性聚烯烴系樹脂[nD(20℃)=1.46~1.50左右]、聚酯系樹脂[nD(20℃)=1.57~1.66左右]、聚碳酸酯系樹脂[nD(20℃)=1.57~1.59左右]、丙烯酸系樹脂[nD(20℃)=1.49~1.51左右]、三乙醯纖維素系樹脂[nD(20℃)=1.48前後]等。 Cycloolefin resin [n D (20 ° C) = 1.51 to 1.54], crystalline polyolefin resin [n D (20 ° C) = 1.46 to 1.50], polyester resin [n D (20 ° C) = 1.57~1.66], polycarbonate resin [n D (20 ° C) = 1.57~1.59], acrylic resin [n D (20 ° C) = 1.49~1.51], triacetyl cellulose resin [ n D (20 ° C) = 1.48 before and after] and so on.
環烯系樹脂係以諸如降冰片烯般之環烯系單體為主要之構成單位之聚合物,其中包括:向環烯系單體之開環聚合物加氫而獲得之樹脂;及環烯系單體與諸如乙烯與丙烯般之碳數2~10之鏈狀烯烴系單體及/或諸如苯乙烯般之乙烯基芳香族單體之加成聚合物等。 The cycloolefin-based resin is a polymer mainly composed of a norbornene-like cycloolefin-based monomer, and includes a resin obtained by hydrogenating a ring-opening polymer of a cycloolefin-based monomer; and a cyclic olefin It is a monomer and a chain olefin monomer having a carbon number of 2 to 10 such as ethylene and propylene, and/or an addition polymer of a vinyl aromatic monomer such as styrene.
結晶性聚烯烴系樹脂係以碳數2~10之鏈狀烯烴系單體為主要之構成單位之聚合物,其中包括:鏈狀烯烴系單體之均聚物;及使用有兩種以上之鏈狀烯烴系單體之二元或三元以上之共聚物。具體來說,包括聚乙烯系樹脂、聚丙烯 系樹脂、乙烯-丙烯共聚物、4-甲基-1-戊烯之均聚物、或4-甲基-1-戊烯與乙烯或丙烯之共聚物等。 The crystalline polyolefin resin is a polymer having a chain olefin monomer having 2 to 10 carbon atoms as a main constituent unit, and includes a homopolymer of a chain olefin monomer; and two or more kinds thereof are used. A binary or ternary copolymer of a chain olefin monomer. Specifically, it includes polyethylene resin and polypropylene. A resin, an ethylene-propylene copolymer, a homopolymer of 4-methyl-1-pentene, or a copolymer of 4-methyl-1-pentene and ethylene or propylene.
聚酯系樹脂除了諸如聚對苯二甲酸乙二醇酯或諸如聚萘二甲酸乙二酯般之芳香族聚酯系樹脂以外,亦包括脂肪族聚酯系樹脂。聚碳酸酯系樹脂典型的是藉由雙酚A與光氣反應而獲得,且於主鏈具有碳酸酯鍵合-O-CO-O-之聚合物。丙烯酸系樹脂典型的是以甲基丙烯酸甲酯為主要構成單位之聚合物,除甲基丙烯酸甲酯之均聚物以外,還包括甲基丙烯酸甲酯與其他甲基丙烯酸酯及/或丙烯酸酯之共聚物等。三乙醯纖維素系樹脂係纖維素之醋酸酯。 The polyester-based resin includes an aliphatic polyester-based resin in addition to an aromatic polyester-based resin such as polyethylene terephthalate or polyethylene naphthalate. The polycarbonate resin is typically obtained by reacting bisphenol A with phosgene and having a carbonate-bonded-O-CO-O- polymer in the main chain. The acrylic resin is typically a polymer mainly composed of methyl methacrylate, and includes methyl methacrylate and other methacrylates and/or acrylates in addition to the homopolymer of methyl methacrylate. Copolymer and the like. The triacetate cellulose resin is an acetate of cellulose.
利用該些熱塑性樹脂,藉由溶劑澆鑄法或熔融擠出法等製成膜,可作為用於本實施形態之光學膜。又,亦可將製膜後進一步進行單軸或雙軸拉伸而得者作為用於本實施形態之光學膜。於光學膜向偏光膜貼合之前,亦可先對其貼合面實施諸如皂化處理、電暈處理、電漿處理、底塗處理或錨塗(anchor coating)處理般之易接著處理。又,亦可於光學膜之向偏光膜之貼合面之相反側之面設置諸如硬敷層、防反射層或防眩層般之各種處理層。 The film is formed by a solvent casting method or a melt extrusion method using the thermoplastic resins, and can be used as the optical film of the present embodiment. Further, it is also possible to use uniaxial or biaxial stretching after film formation as the optical film used in the present embodiment. Before the optical film is attached to the polarizing film, the bonding surface may be subjected to an easy subsequent treatment such as saponification treatment, corona treatment, plasma treatment, primer treatment or anchor coating treatment. Further, various treatment layers such as a hard coat layer, an antireflection layer or an antiglare layer may be provided on the surface of the optical film opposite to the bonding surface of the polarizing film.
光學膜較佳為通常具有5~200 μm左右之厚度。若光學膜過薄,則欠缺處理性,於偏光板製造線中產生斷裂或誘發褶皺之產生之可能性變高。另一方面,若過厚,則獲得之偏光板變厚,重量亦變大,因此損害商品性。自該些理由出發,更佳之厚度為10~120 μm,進而佳為10~85 μm。 The optical film preferably has a thickness of usually about 5 to 200 μm. If the optical film is too thin, handling property is insufficient, and there is a high possibility that cracks or wrinkles are generated in the polarizing plate manufacturing line. On the other hand, if it is too thick, the obtained polarizing plate becomes thick and the weight also becomes large, and the commercial property is impaired. For these reasons, a preferred thickness is 10 to 120 μm, and preferably 10 to 85 μm.
於以上之偏光膜貼合光學膜時,首先於光學膜之向偏光膜之貼合面上塗佈紫外線固化型接著劑。接著劑之厚度通常為0.5~5 μm之範圍。若其厚度低於0.5 μm,則接著強度產生不均勻。另一方面,若其厚度超過5 μm,則不僅製造成本增大,有時亦會因接著劑之種類而影響到偏光板之色調。若於該範圍內比較厚,例如為3.5 μm以上,特別係4 μm以上,則其厚度即便有一些變動,亦難以出現由此引起之氣泡等缺陷,但另一方面,如此加厚會帶來成本之增加,因此較佳為於可能之範圍變薄。出於該些理由,紫外線固化型接著劑之較佳厚度為1~4 μm,更佳為1.5~3.5 μm之範圍。 When the optical film is bonded to the above polarizing film, first, an ultraviolet curable adhesive is applied to the bonding surface of the optical film to the polarizing film. The thickness of the subsequent agent is usually in the range of 0.5 to 5 μm. If the thickness is less than 0.5 μm, the subsequent strength is uneven. On the other hand, when the thickness exceeds 5 μm, not only the manufacturing cost increases, but also the color tone of the polarizing plate may be affected by the type of the adhesive. If it is thicker in this range, for example, 3.5 μm or more, especially 4 μm or more, even if there is some variation in the thickness, defects such as bubbles are hard to occur, but on the other hand, such thickening brings about The increase in cost is therefore preferred to be thinner in the range possible. For these reasons, the UV curable adhesive preferably has a thickness of from 1 to 4 μm, more preferably from 1.5 to 3.5 μm.
紫外線固化型接著劑,只要係以液狀之可塗佈之狀態供給,則可使用自先前以來用於偏光板之製造中之各種接著劑,但自耐候性與聚合性等之觀點出發,較佳為陽離子聚合性之化合物,例如環氧化合物,更具體地說,如日本專利特開2004-245925號公報所述般之包含分子內不具有芳香環之環氧化合物作為紫外線固化性成分之一之紫外線固化型接著劑。該環氧化合物例如可為如下等:將以雙酚A之二縮水甘油醚為代表例之作為芳香族環氧化合物之原料之芳香族多羥基化合物核氫化,並使其縮水甘油醚化而獲得之氫化環氧化合物;於分子內至少具有1個與脂肪族環鍵合之環氧基之脂環式環氧化合物;及以脂肪族多羥基化合物之縮水甘油醚為代表例之脂肪族環氧化合物等。 The ultraviolet curable adhesive can be used in the form of a liquid coating, and various adhesives used in the production of a polarizing plate from the prior art can be used, but from the viewpoints of weather resistance and polymerizability, etc. A compound which is preferably a cationically polymerizable compound, for example, an epoxy compound, and more specifically, an epoxy compound having no aromatic ring in the molecule as one of ultraviolet curable components, as described in Japanese Laid-Open Patent Publication No. 2004-245925 UV curable adhesive. The epoxy compound can be obtained by, for example, hydrogenating an aromatic polyhydroxy compound which is a raw material of an aromatic epoxy compound, which is a representative example of bisphenol A diglycidyl ether, and etherification of glycidol. a hydrogenated epoxy compound; an alicyclic epoxy compound having at least one epoxy group bonded to an aliphatic ring in the molecule; and an aliphatic epoxy represented by a glycidyl ether of an aliphatic polyhydroxy compound Compounds, etc.
於紫外線固化型接著劑中,除了以環氧化合物為代表例 之陽離子聚合性化合物以外,還調配有聚合起始劑,特別係調配有藉由紫外線之照射產生陽離子活性種或路易斯酸而用以使陽離子聚合性化合物開始聚合之光陽離子聚合起始劑。此外,亦可調配有藉由加熱而引發開始聚合之熱陽離子聚合起始劑,又亦可調配有光敏劑等各種添加劑。 In the ultraviolet curing type of adhesive, in addition to the epoxy compound as a representative example In addition to the cationically polymerizable compound, a polymerization initiator is prepared, and in particular, a photocationic polymerization initiator for causing a cationically polymerizable compound to start polymerization by a cationic active species or a Lewis acid by irradiation with ultraviolet rays is prepared. Further, a thermal cationic polymerization initiator which initiates polymerization by heating may be formulated, or various additives such as a photosensitizer may be formulated.
於偏光膜之兩表面貼合光學膜時,適用於各個光學膜之紫外線固化型接著劑可相同,亦可不同,但自生產率之觀點出發,於可獲得適度之接著力之前提下,較佳為兩表面均設為相同之接著劑。 When the optical film is bonded to both surfaces of the polarizing film, the ultraviolet curable adhesives suitable for the respective optical films may be the same or different, but from the viewpoint of productivity, it is preferable to obtain a suitable adhesive force, preferably. Both surfaces are set to the same adhesive.
於本實施形態中,於以上說明之聚乙烯醇系樹脂製之偏光膜上經由紫外線固化型接著劑貼合熱塑性樹脂製之光學膜而製造偏光板。 In the present embodiment, a polarizing plate is produced by laminating an optical film made of a thermoplastic resin to a polarizing film made of a polyvinyl alcohol-based resin described above via an ultraviolet curable adhesive.
此時,經過以下(A)、(B)、(C)、(D)及(E)之各步驟。 At this time, each of the following steps (A), (B), (C), (D), and (E) is performed.
(A)塗佈步驟,於光學膜之向偏光膜之貼合面上塗佈上述之紫外線固化型接著劑;(B)貼合步驟,於以塗佈步驟塗佈之紫外線固化型接著劑面上重疊偏光膜並加壓;(C)固化步驟,對於偏光膜上經由紫外線固化型接著劑而貼合有光學膜之積層體,自紫外線照射裝置照射紫外線,藉此使紫外線固化型接著劑固化;(D)計測步驟,使用分光儀測量於上述固化步驟照射之紫外線之分光輻射照度,並基於此計測包含聚合起始劑之吸收峰值波長之特定之吸收波長區域內之紫外線之分光輻 射照度之積分值;及(E)控制步驟,於上述計測步驟中求得之分光輻射照度之積分值X與所設定之分光輻射照度之積分值Y之差之絕對值相對於上述Y之比例為特定值以上時,例如為5%以上時,控制上述紫外線照射裝置之輸出。 (A) a coating step of applying the ultraviolet curable adhesive described above to the bonding surface of the optical film to the polarizing film; and (B) a bonding step for applying the ultraviolet curable adhesive to the coating step (C) a curing step in which a layered body in which an optical film is bonded via an ultraviolet curing type adhesive on a polarizing film is irradiated with ultraviolet rays from an ultraviolet irradiation device, thereby curing the ultraviolet curing type adhesive (D) a measuring step of measuring a spectroscopic illuminance of the ultraviolet ray irradiated by the curing step using a spectrometer, and based on the measuring, the radiance of the ultraviolet ray in a specific absorption wavelength region including the absorption peak wavelength of the polymerization initiator The integral value of the illuminance; and (E) the control step, the ratio of the absolute value of the difference between the integral value X of the spectroscopic illuminance and the integral value Y of the set spectroscopic illuminance obtained in the above measuring step with respect to the above Y When it is more than a specific value, for example, when it is 5% or more, the output of the said ultraviolet-ray irradiation apparatus is control.
圖1係概略地表示較佳地適用於本發明之製造裝置之配置例之側視圖,圖2係表示本發明之各步驟間之關係之一例之方塊圖。以下,一面參照該些附圖,一面對於偏光板之製造方法詳細地進行說明。 Fig. 1 is a side view schematically showing an arrangement example of a manufacturing apparatus which is preferably applied to the present invention, and Fig. 2 is a block diagram showing an example of the relationship between the steps of the present invention. Hereinafter, a method of manufacturing a polarizing plate will be described in detail with reference to the drawings.
圖1所示之製造裝置構成為,一面連續地搬送偏光膜1,一面於其一側之面貼合第一光學膜2、且於另一側之面貼合第二光學膜3而製造偏光板4,並捲取於捲取輥30上。如該圖所示,典型的是於偏光膜1之兩表面分別貼合光學膜,但僅於偏光膜1之一側之面貼合光學膜之形態當然亦包含於本實施形態中。該情況之形態自以下之說明中除去關於另一光學膜之說明,藉此本領域技術人員可容易地理解至能實施之程度。 The manufacturing apparatus shown in FIG. 1 is configured such that the polarizing film 1 is continuously conveyed, and the first optical film 2 is bonded to one surface thereof, and the second optical film 3 is bonded to the other surface to produce polarized light. The plate 4 is taken up on the take-up roll 30. As shown in the figure, the optical film is typically bonded to both surfaces of the polarizing film 1, but the form in which the optical film is bonded only to the surface on one side of the polarizing film 1 is of course included in the present embodiment. The form of this case is removed from the description below with respect to another optical film, so that those skilled in the art can easily understand the extent to which it can be carried out.
於第一光學膜2之向偏光膜1貼合之面,由第一塗佈機10塗佈紫外線固化型接著劑,另一方面,於第二光學膜3之向偏光膜1貼合之面,由第二塗佈機12亦塗佈接著劑。塗佈紫外線固化型接著劑之後之第一光學膜2及第二光學膜3各自之接著劑塗佈面重合於偏光膜1之兩表面,以貼合用夾輥20、21夾持而於厚度方向加壓,其次接受來自紫外線照射裝置16之紫外線之照射而使接著劑固化,其後經過捲 取前夾輥22、23而使所獲得之偏光板4捲取於捲取輥30上。於此,圖1所示之製造裝置於紫外線照射裝置16與被搬送之薄膜之間設置有由分光儀構成之分光輻射照度計17,其可於在線上即於偏光板之製造線上為使紫外線固化型接著劑固化而自紫外線照射裝置照射紫外線之期間,測量對經由紫外線固化型接著劑而於偏光膜上貼合有光學膜之積層體照射之紫外線之分光輻射照度。然後,根據來自分光輻射照度計17之分光輻射照度之測量,計測包含紫外線固化型接著劑中所含之聚合起始劑之吸收峰值波長之特定之吸收波長區域內之分光輻射照度積分值。 On the surface of the first optical film 2 to which the polarizing film 1 is bonded, the first coater 10 is coated with the ultraviolet curable adhesive, and on the other hand, the second optical film 3 is bonded to the polarizing film 1. The adhesive is also applied by the second coater 12. The adhesive coating surface of each of the first optical film 2 and the second optical film 3 after the application of the ultraviolet curing type adhesive is superposed on both surfaces of the polarizing film 1, and is sandwiched by the nip rollers 20 and 21 to be thick. The direction is pressurized, and then the ultraviolet light from the ultraviolet irradiation device 16 is irradiated to cure the adhesive, and then the roll is passed. The obtained nip rollers 22, 23 are taken up and the obtained polarizing plate 4 is taken up on the take-up roll 30. Here, the manufacturing apparatus shown in FIG. 1 is provided with a spectroscopic illuminometer 17 composed of a spectrometer between the ultraviolet irradiation device 16 and the film to be conveyed, which can be used to make ultraviolet rays on the line on the manufacturing line of the polarizing plate. While the curable adhesive is cured and the ultraviolet ray is irradiated from the ultraviolet ray irradiation device, the illuminating illuminance of the ultraviolet ray irradiated to the laminated body in which the optical film is bonded to the polarizing film via the ultraviolet curable adhesive is measured. Then, based on the measurement of the spectroscopy illuminance from the spectroscopic illuminometer 17, the integrated illuminating illuminance value of the spectroscopy in the specific absorption wavelength region including the absorption peak wavelength of the polymerization initiator contained in the ultraviolet curable adhesive is measured.
再者,如圖1所示,亦較佳為於線上即於偏光板之製造線上之接著劑塗佈之後且偏光膜與光學膜貼合之前,使用第一膜厚計14及第二膜厚計15計測塗佈於光學膜上之紫外線固化型接著劑之厚度,並根據其計測結果,以可維持均勻之預期之接著劑厚度之方式控制塗佈機之塗佈厚度控制機構。 Furthermore, as shown in FIG. 1, it is also preferable to use the first film thickness gauge 14 and the second film thickness on the line after the application of the adhesive on the manufacturing line of the polarizing plate and before the polarizing film is bonded to the optical film. The thickness of the ultraviolet curable adhesive applied to the optical film was measured, and based on the measurement result, the coating thickness control mechanism of the coater was controlled in such a manner as to maintain a uniform desired thickness of the adhesive.
於第一塗佈機10及第二塗佈機12中,由設置於各自上之凹版輥11、13對第一光學膜2及第二光學膜3塗佈紫外線固化型接著劑。於偏光膜1之一側之面,或第一光學膜2及第二光學膜3各自之塗佈有接著劑之面之相反側之面,適當設置搬送用之導輥24。如上所述,於僅於偏光膜1之一側之面貼合光學膜時,只要應用圖1所示之第一光學膜2與第二光學膜3中之一者(例如僅為第一光學膜2)即可。圖中之直線箭頭表示膜之流動方向,曲線箭頭表示輥之旋轉方 向。 In the first coater 10 and the second coater 12, the first optical film 2 and the second optical film 3 are coated with an ultraviolet curable adhesive by the gravure rolls 11 and 13 provided thereon. The guide roller 24 for conveyance is appropriately provided on the surface on one side of the polarizing film 1 or on the surface on the opposite side to the surface on which the adhesive film is applied to each of the first optical film 2 and the second optical film 3. As described above, when the optical film is bonded only to the side of one side of the polarizing film 1, only one of the first optical film 2 and the second optical film 3 shown in FIG. 1 is applied (for example, only the first optical The film 2) is sufficient. The straight arrow in the figure indicates the flow direction of the film, and the curved arrow indicates the rotation of the roller. to.
偏光膜1大多係於未圖示之偏光膜製造步驟中對聚乙烯醇系樹脂膜經過單軸拉伸、利用二色性色素進行之染色與染色後之硼酸交聯處理而製造之後,直接即以不捲取於輥上之狀態供給,當然,於偏光膜製造步驟中製造之膜一旦捲取於輥上,則之後再由抽出機抽出即可。另一方面,第一光學膜2及第二光學膜3自各個未圖示之輥藉由抽出機抽出。各個膜分別以相同之線速度,例如10~50 m/分鐘左右之線速度,以流動方向相同之方式搬送。第一光學膜2與第二光學膜3於流動方向上,一面賦予有例如50~1000 N/m左右之張力一面被抽出。 The polarizing film 1 is usually produced by uniaxially stretching a polyvinyl alcohol-based resin film, dyeing with a dichroic dye, and boric acid cross-linking treatment after being subjected to a polarizing film production step (not shown). It is supplied without being wound up on the roll. Of course, once the film produced in the polarizing film production step is taken up on the roll, it may be taken out by the extractor. On the other hand, the first optical film 2 and the second optical film 3 are taken out from the rolls (not shown) by an extractor. Each film is transported at the same linear velocity, for example, a linear velocity of about 10 to 50 m/min, in the same flow direction. The first optical film 2 and the second optical film 3 are extracted while being subjected to a tension of, for example, about 50 to 1000 N/m in the flow direction.
然後,藉由第一塗佈機10與第二塗佈機12進行上述之塗佈步驟(A),藉由貼合用夾輥20、21進行上述之貼合步驟(B),藉由紫外線照射裝置16進行上述之固化步驟(C),藉由分光輻射照度計17進行上述之計測步驟(D),藉由將分光輻射照度計17之計測結果反饋至紫外線照射裝置16而進行上述之控制步驟(E)。 Then, the coating step (A) described above is performed by the first coater 10 and the second coater 12, and the bonding step (B) is performed by the bonding nip rollers 20, 21 by ultraviolet rays. The irradiation device 16 performs the above-described curing step (C), and the above-described measurement step (D) is performed by the spectroscopic illuminometer 17, and the above control is performed by feeding back the measurement result of the spectroscopic illuminometer 17 to the ultraviolet irradiation device 16. Step (E).
根據圖2之方塊圖,說明該些各步驟之關係之一例。首先,於進行塗佈步驟(A)與貼合步驟(B)之後,於設定(0)設定作為分光輻射照度之積分對象之波長區域、且設定紫外線之分光輻射照度之積分值之設定值(所設定之分光輻射照度之積分值)Y。該設定(0)當然亦可於貼合步驟(B)之前或塗佈步驟(A)之前實施。作為分光輻射照度之積分對象之波長區域係包含聚合起始劑之吸收峰值波長之吸收波長 區域,根據所使用之聚合起始劑決定。所設定之分光輻射照度之積分值Y,自預先驗證可使接著劑良好地固化、即便於高溫多濕之嚴酷條件下亦可獲得偏光膜難以產生脫色之耐久性高之偏光板之範圍內選擇。 An example of the relationship between the various steps will be described based on the block diagram of FIG. First, after the coating step (A) and the bonding step (B), setting (0) sets the wavelength region of the integration target of the spectroscopic illuminance and sets the integral value of the illuminating illuminance of the ultraviolet spectroscopy ( The integral value of the set spectroscopic illuminance) Y. This setting (0) can of course also be carried out before the bonding step (B) or before the coating step (A). The wavelength region of the integral object of the astigmatism irradiance includes the absorption wavelength of the absorption peak wavelength of the polymerization initiator The area is determined by the polymerization initiator used. The integrated value Y of the astigmatism of the astigmatism radiant is selected from the range of the polarizing plate which is excellent in the durability of the polarizing film and which is difficult to produce discoloration even under the severe conditions of high temperature and high humidity. .
繼而,自紫外線照射裝置16照射紫外線而實施固化步驟(C),並且使用由分光儀構成之分光輻射照度計,計測所照射之紫外線之於設定(0)設定之波長區域內之分光輻射照度之積分值(所求得之分光輻射照度之積分值)X,並將其輸出(計測步驟(D))。另一方面,於控制步驟(E)中,將求得之分光輻射照度之積分值X與所設定之分光輻射照度之積分值Y進行對比。然後,例如於所求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y之差之絕對值相對於所設定之分光輻射照度之積分值Y而為特定閾值以上,例如5%以上時,以使兩者之差之絕對值變小,較佳為使所求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y之差之絕對值,相對於所設定之分光輻射照度之積分值Y而未達特定閾值,例如未達5%之方式,調整向紫外線照射裝置16輸入之電力而控制輸出。如上所述,存在因紫外線照射裝置所具有之燈之長期使用所致之劣化、或附設於紫外線照射裝置之構件之長期使用所致之污染而導致特定波長區域之輻射照度降低之情況,但亦包含該情況,通常因紫外線照射裝置之長期使用而導致所求得之分光輻射照度之積分值X慢慢低於所設定之分光輻射照度之積分值Y。 Then, the ultraviolet ray irradiation device 16 irradiates the ultraviolet ray to perform the curing step (C), and the spectroscopic illuminance meter composed of the spectrometer is used to measure the illuminating illuminance of the irradiated ultraviolet ray in the wavelength region set by the setting (0). The integral value (the integral value of the obtained spectral illuminance) X is obtained and output (measurement step (D)). On the other hand, in the control step (E), the integral value X of the obtained astigmatism illuminance is compared with the integrated value Y of the set illuminating illuminance. Then, for example, the absolute value of the difference between the integral value X of the obtained spectral radiance and the integrated value Y of the set spectroscopy illuminance is equal to or greater than a specific threshold value with respect to the integrated value Y of the set illuminating illuminance, for example, 5 In the case of % or more, in order to make the absolute value of the difference between the two smaller, it is preferable to make the absolute value of the difference between the integral value X of the obtained spectral radiance and the integral value Y of the set spectral illuminance, with respect to The integrated value Y of the astigmatism illuminance is set to a specific threshold value, for example, less than 5%, and the electric power input to the ultraviolet ray irradiation device 16 is adjusted to control the output. As described above, there is a case where the illuminance of a specific wavelength region is lowered due to deterioration due to long-term use of the lamp of the ultraviolet ray irradiation device or contamination due to long-term use of a member attached to the ultraviolet ray irradiation device, but also In this case, the integral value X of the obtained astigmatism illuminance is usually lower than the integral value Y of the set spectroscopy illuminance due to the long-term use of the ultraviolet ray irradiation device.
於此,所求得之分光輻射照度之積分值X與所設定之分光輻射照度之積分值Y之差之絕對值相對於所設定之分光輻射照度之積分值Y為5%以上之情況意味著滿足下式(I),於圖2中示出根據是否滿足該式而決定是否進行紫外線照射裝置之輸出條件之變更。再者,於本實施形態中求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y之對比方法,並不限定於圖2之說明中所述之方法。即,所求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y之對比,亦可不為基於求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y之差者,亦可不為基於絕對值者。例如,亦可根據求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y之差相對於所設定之分光輻射照度之積分值Y之比例為特定閾值以下或特定閾值以上,例如為-5%以下或+5%以上而進行對比,亦可根據求得之分光輻射照度之積分值X相對於設定之分光輻射照度之積分值Y之比例於特定閾值以下或特定閾值以上,例如於95%以下或105%以上而進行對比。上述閾值並不限定於5%(或-5%、95%等),亦可為更低之值,例如1%或3%,亦可為更高之值,例如7%或10%。又,上側之閾值與下側之閾值亦可採用不同之值(例如-3%以下或7%以上)。 In this case, the absolute value of the difference between the integral value X of the spectral illuminance and the integrated value Y of the set spectroscopy illuminance is 5% or more with respect to the integrated value Y of the set spectroscopy illuminance. The following formula (I) is satisfied, and FIG. 2 shows whether or not the change of the output condition of the ultraviolet irradiation device is determined depending on whether or not the formula is satisfied. Further, the method of comparing the integral value X of the spectral irradiance illuminance obtained in the present embodiment with the integral value Y of the set spectroscopy illuminance is not limited to the method described in the description of FIG. That is, the comparison between the integral value X of the obtained astigmatism illuminance and the integral value Y of the set spectroscopy illuminance may not be the integral value of the illuminance based on the obtained astigmatism illuminance and the integral value of the set illuminating illuminance Y The difference may not be based on absolute value. For example, the ratio of the difference between the integral value X of the obtained astigmatism illuminance and the integrated value Y of the set spectroscopy illuminance to the integrated value Y of the set spectroscopy illuminance may be below a certain threshold or above a certain threshold. For example, a comparison of -5% or less or +5% or more may be performed according to the ratio of the integral value X of the obtained spectral radiance to the integrated value Y of the set spectral illuminance, below a certain threshold or above a certain threshold. For example, comparison is made below 95% or above 105%. The above threshold is not limited to 5% (or -5%, 95%, etc.), and may be a lower value, such as 1% or 3%, or a higher value, such as 7% or 10%. Further, the upper threshold and the lower threshold may be different values (for example, -3% or less or 7% or more).
以下,對構成本實施形態之方法之塗佈步驟(A)、貼合步驟(B)、固化步驟(C)、計測步驟(D)及控制步驟(E)進行詳細說明。 Hereinafter, the coating step (A), the bonding step (B), the curing step (C), the measuring step (D), and the controlling step (E) constituting the method of the present embodiment will be described in detail.
於塗佈步驟(A)中,於光學膜2、3之向偏光膜1之貼合面塗佈紫外線固化型接著劑。作為此處所使用之塗佈機,可列舉使用參照圖1進行說明之凹版輥11、13之方式。於使用凹版輥之塗佈機中,例如有直接凹版塗佈機、封閉式刮刀塗佈機、間接凹版塗佈機、使用有凹版輥之吻合式塗佈機、由多個輥構成之逆轉輥式塗佈機等。此外還可利用如下等各種塗佈機:具有圓筒狀之刮板,一面向塗佈部供給接著劑並由刮板刮落,一面進行塗佈之逗號刮刀式塗佈機;應用狹縫模具等直接供給接著劑之模塗佈機;製作貯液器,一面以刀片刮落多餘之液體一面進行塗佈之刮刀塗佈機等。該些中,若考慮薄膜塗佈或軌跡線之自由度等,於使用凹版輥之塗佈機中,較佳為直接凹版塗佈機、封閉式刮刀塗佈機、間接凹版塗佈機等,又除凹版輥以外,亦較佳為使用有狹縫模具之模塗佈機。自易於應對偏光板之寬幅化或使以液體供給之接著劑之異味難以釋放出之角度出發,更佳為封閉式刮刀塗佈機。 In the coating step (A), an ultraviolet curable adhesive is applied to the bonding surface of the optical films 2 and 3 to the polarizing film 1. Examples of the coater used herein include the use of the gravure rolls 11 and 13 described with reference to Fig. 1 . In the coater using the gravure roll, there are, for example, a direct gravure coater, a closed blade coater, an indirect gravure coater, an anastomotic coater using a gravure roll, and a reverse roll composed of a plurality of rolls. Coating machine, etc. Further, various coaters such as a squeegee blade having a cylindrical squeegee and a coating agent for supplying the adhesive to the coating portion and scraping off by the squeegee may be applied; A die coater that directly supplies an adhesive; a doctor blade that produces a liquid reservoir while applying a blade to scrape off excess liquid. Among these, in consideration of the degree of freedom of film coating or track line, etc., in the coater using the gravure roll, a direct gravure coater, a closed blade coater, an indirect gravure coater, etc. are preferable. Further, in addition to the gravure roll, a die coater using a slit die is also preferred. It is more preferably a closed blade coater since it is easy to cope with the widening of the polarizing plate or the point that the odor of the adhesive supplied by the liquid is hard to be released.
於此,所謂封閉式刮刀塗佈機係使凹版輥抵接於吸收有液狀塗料(接著劑)之封閉式刮刀,將封閉式刮刀中之塗料(接著劑)轉移至凹版輥之凹槽中,再將之轉印於作為被塗佈物之光學膜2、3上之方式之塗佈機。設計為小型者亦稱 為微型封閉式刮刀塗佈機。 Here, the closed blade coater is such that the gravure roll abuts against the closed blade that absorbs the liquid paint (adhesive), and the paint (adhesive) in the closed blade is transferred into the groove of the gravure roll. Then, the coating machine is transferred to the optical film 2, 3 as a coated object. Designed for small people, also known as It is a miniature closed knife coater.
使用凹版輥塗佈接著劑時,接著劑層之厚度可根據凹版輥相對於線速度之速度比進行調整。使光學膜2、3之線速度為10~50 m/分鐘,使凹版輥相對於光學膜2、3之搬送方向而逆向旋轉,使凹版輥之旋轉周速度為10~500 m/分鐘,藉此可將接著劑之塗佈厚度調整為0.5~5 μm。此時之塗佈厚度因亦會受凹版輥表面之空隙率之影響,故較佳為事前選擇具有合適之表面空隙率之凹版輥。再者,使凹版輥相對於光學膜2、3之搬送方向而逆向旋轉之方式,亦被稱為反向凹版印刷。 When the adhesive is applied using a gravure roll, the thickness of the adhesive layer can be adjusted according to the speed ratio of the gravure roll to the linear velocity. The linear speeds of the optical films 2 and 3 are set to 10 to 50 m/min, and the gravure roll is reversely rotated with respect to the conveying direction of the optical films 2 and 3, so that the circumferential speed of the gravure roll is 10 to 500 m/min. This can adjust the coating thickness of the adhesive to 0.5 to 5 μm. Since the coating thickness at this time is also affected by the void ratio of the surface of the gravure roll, it is preferred to select a gravure roll having a suitable surface void ratio in advance. Further, the manner in which the gravure roll is reversely rotated with respect to the conveyance direction of the optical films 2 and 3 is also referred to as reverse gravure printing.
如上所述,亦較佳為於與偏光膜貼合之前使用第一膜厚計14及第二膜厚計15於線上計測塗佈於光學膜上之紫外線固化型接著劑之厚度,並根據此計測結果,以可維持均勻之預期之接著劑厚度之方式控制塗佈機之塗佈厚度控制機構。作為膜厚計,例如可使用如下類型之各種分光干涉式膜厚計:其對塗佈之接著劑面照射光,將作為干涉光而獲得之反射光於特定之波長區域進行分光,根據所獲得之光譜波形圖求得膜厚。於分光干涉式膜厚計中,有可直接計測所塗佈之接著劑之厚度(0.5~5 μm左右)者(圖1之第一膜厚計14及第二膜厚計15係其例)與不能直接計測者。於後者之情況下,於塗佈機之上游側與下游側設置膜厚計,以上游側之膜厚計計測光學膜自身之厚度,以下游側之膜厚計計測光學膜與接著劑之合計厚度,根據其計測值之差求得接著劑之厚度亦可。 As described above, it is also preferred to measure the thickness of the ultraviolet curable adhesive applied to the optical film on the line using the first film thickness gauge 14 and the second film thickness gauge 15 before bonding to the polarizing film, and As a result of the measurement, the coating thickness control mechanism of the coater is controlled in such a manner as to maintain a uniform desired thickness of the adhesive. As the film thickness meter, for example, various types of spectral interference type film thickness meters can be used which irradiate light to the applied adhesive agent surface, and split the reflected light obtained as the interference light in a specific wavelength region, according to the obtained The spectral waveform is obtained to determine the film thickness. In the spectral interference type film thickness meter, the thickness of the applied adhesive (about 0.5 to 5 μm) can be directly measured (the first film thickness meter 14 and the second film thickness meter 15 of Fig. 1 are examples). And those who cannot measure directly. In the latter case, a film thickness meter is provided on the upstream side and the downstream side of the coater, the thickness of the optical film itself is measured by the film thickness of the upstream side, and the total thickness of the optical film and the adhesive is measured by the film thickness of the downstream side. The thickness may be determined by the difference between the measured values.
經過塗佈步驟(A)之後,進行貼合步驟(B),即於光學膜2、3各自之接著劑塗佈面重疊偏光膜1並加壓。於該步驟之加壓中,可使用公知之方法,但自可一面連續搬送一面進行加壓之觀點出發,如圖1所示,較佳為藉由一對夾輥20、21夾持之方式。該情況下,較為理想的是使光學膜2、3重合於偏光膜1之時機、與藉由一對夾輥20、21相對於偏光膜1而加壓光學膜2、3之時機相同,即便不同,兩者之時機之差異亦越短越好。一對夾輥20、21之組合為金屬輥/金屬輥、金屬輥/橡膠輥、橡膠輥/橡膠輥等之任意一種均可。加壓時之壓力,以藉由一對夾輥20、21夾持時之線壓計較佳為150~500 N/cm左右。 After the coating step (A), the bonding step (B) is carried out, that is, the polarizing film 1 is superposed on the respective adhesive application surfaces of the optical films 2 and 3 and pressurized. In the pressurization of this step, a known method can be used, but from the viewpoint of being continuously pressurized while being continuously transferred, as shown in Fig. 1, it is preferably sandwiched by a pair of nip rolls 20, 21. . In this case, it is preferable that the timing at which the optical films 2 and 3 are superposed on the polarizing film 1 is the same as the timing at which the optical films 2 and 3 are pressed against the polarizing film 1 by the pair of nip rolls 20 and 21, even if The difference between the timings of the two is as short as possible. The combination of the pair of nip rolls 20, 21 may be any of a metal roll/metal roll, a metal roll/rubber roll, a rubber roll/rubber roll, or the like. The pressure at the time of pressurization is preferably about 150 to 500 N/cm when sandwiched by a pair of nip rolls 20, 21.
於偏光膜1上貼合光學膜2、3之後,相對於經由紫外線固化型接著劑而於偏光膜1上貼合有光學膜之積層體,自紫外線照射裝置16照射紫外線,使紫外線固化型接著劑固化而製造偏光板4。紫外線照射至積層體時,透過光學膜2照射至紫外線固化型接著劑。 After the optical films 2 and 3 are bonded to the polarizing film 1, the laminated body in which the optical film is bonded to the polarizing film 1 via the ultraviolet curing type adhesive is irradiated with ultraviolet rays from the ultraviolet irradiation device 16 to form an ultraviolet curing type. The polarizing plate 4 was produced by curing the agent. When the ultraviolet rays are irradiated onto the laminate, the ultraviolet curable adhesive is applied through the optical film 2.
於圖1所示之例子中,向上述積層體照射紫外線係於在位於紫外線照射裝置16之前後之貼合用夾輥20、21與捲取前夾輥22、23之間對積層體賦予有張力之狀態下進行。但並不限於此,例如上述之日本專利特開2009-134190號公報所公開般以由沿著搬送方向形成為圓弧狀之凸曲面、典型的是輥之外周面支撐之狀態下照射紫外線亦較佳。特別 係由於紫外線之照射產生熱而有可能對製品造成不良影響時,較佳為如後者般以積層體由輥之外周面支撐之狀態對其照射紫外線,此時,支撐積層體之輥,較佳為可於10~60℃左右之範圍進行溫度調節。又,紫外線照射裝置可於照射部位僅設置有1個,但沿著積層體之流動方向設置有2個以上而形成來自多個光源之照射之情況於有效地提高累積光量之方面較為有效。 In the example shown in FIG. 1, the laminated body is irradiated with ultraviolet rays, and the laminated nip rollers 20 and 21 and the pre-winding nip rollers 22 and 23 before and after the ultraviolet irradiation device 16 are provided with a laminated body. Performed under tension. However, it is not limited to this, and it is also disclosed by the above-mentioned Japanese Patent Laid-Open Publication No. 2009-134190, which is irradiated with ultraviolet rays by a convex curved surface which is formed in an arc shape along the conveying direction, and is typically supported by the outer peripheral surface of the roller. Preferably. particular When heat is generated by irradiation of ultraviolet rays and there is a possibility of adversely affecting the product, it is preferred that the laminate is irradiated with ultraviolet rays in a state where the laminate is supported by the outer peripheral surface of the roller as in the latter case, and in this case, it is preferable to support the roller of the laminate. Temperature adjustment is possible in the range of about 10 to 60 °C. Further, the ultraviolet irradiation device may be provided in only one irradiation site, but it is effective to provide two or more irradiation directions along the flow direction of the laminate to form an irradiation from a plurality of light sources to effectively increase the amount of accumulated light.
使用之紫外線光源並無特別限定,可使用於波長400 nm以下具有發光分佈之例如低壓水銀燈、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、金屬鹵化物燈等。於使用以環氧化合物為紫外線固化性成分之接著劑時,若考慮一般性之聚合起始劑顯示之吸收波長,則作為紫外線光源,較佳為使用大量具有400 nm以下之光之高壓水銀燈或金屬鹵化物燈。 The ultraviolet light source to be used is not particularly limited, and can be used for, for example, a low-pressure mercury lamp, a medium-pressure mercury lamp, a high-pressure mercury lamp, an ultra-high pressure mercury lamp, a chemical lamp, a black lamp, a microwave-excited mercury lamp, a metal halide lamp, etc. having a light-emitting distribution at a wavelength of 400 nm or less. . When an epoxy compound is used as an ultraviolet curable component, it is preferable to use a large number of high pressure mercury lamps having a light of 400 nm or less as an ultraviolet light source in consideration of an absorption wavelength exhibited by a general polymerization initiator. Metal halide lamp.
於對以環氧化合物為固化性成分之接著劑照射紫外線而使之固化時,積層體之線速度並無特別限定,但一般來說,大體上原樣維持塗佈步驟(A)或貼合步驟(B)中之線速度。又,較佳為一面於積層體之長度方向(搬送方向)賦予100~1000 N/m之張力,一面使對聚合起始劑之活化有效之波長區域之照射量以累計光量(照射至積層體之總能量)計,為100~1500 mJ/cm2。若對接著劑之累計光量過少,則紫外線固化型接著劑之固化反應不足,充分之接著強度難以體現,另一方面,若該累計光量過大,則自光源所輻射之熱與接著劑聚合時產生之熱,有可能引起紫外線固化 型接著劑之黃變與偏光膜之劣化。 When the ultraviolet ray is cured by irradiating ultraviolet rays with an epoxy resin as a curable component, the linear velocity of the laminate is not particularly limited, but generally, the coating step (A) or the bonding step is maintained as it is. (B) The speed of the line. In addition, it is preferable to apply a light amount of 100 to 1000 N/m in the longitudinal direction (transport direction) of the laminate, and to integrate the amount of irradiation in the wavelength region effective for activation of the polymerization initiator (irradiation to the laminate) The total energy) is 100 to 1500 mJ/cm 2 . When the total amount of light to the adhesive is too small, the curing reaction of the ultraviolet curable adhesive is insufficient, and the sufficient bonding strength is hard to be expressed. On the other hand, if the integrated light amount is too large, the heat radiated from the light source and the polymerization of the adhesive are generated. The heat may cause yellowing of the ultraviolet curable adhesive and deterioration of the polarizing film.
又,若以1次紫外線照射達成需要之累積光量,則亦有時會因發熱致使膜成為超過150℃之高溫,該情況下,有可能引起偏光膜之劣化等。於避免該事態上,如上所述,有效的是沿著膜之搬送方向設置多個紫外線照射裝置,分數次進行照射。 In addition, when the required amount of accumulated light is achieved by one-time ultraviolet irradiation, the film may be heated to a temperature higher than 150 ° C due to heat generation. In this case, deterioration of the polarizing film may occur. In order to avoid this, as described above, it is effective to provide a plurality of ultraviolet irradiation devices along the transport direction of the film, and to irradiate them in fractions.
作為目標,有如下較佳之情況:來自1處之紫外線照射裝置之照射量以累積光量計為600 mJ/cm2以下,最終可獲得上述之100~1500 mJ/cm2之累積光量。 As a target, there is a case where the irradiation amount of the ultraviolet irradiation device from one place is 600 mJ/cm 2 or less in terms of the cumulative light amount, and finally the cumulative light amount of 100 to 1500 mJ/cm 2 described above can be obtained.
於計測步驟中,使用分光輻射照度計17,計測於固化步驟(C)中照射之紫外線之分光輻射照度,基於此,求得包含聚合起始劑之吸收峰值波長之特定之吸收波長區域內之紫外線之分光輻射照度之積分值X。分光輻射照度計17係可藉由分光儀於220~800 nm之波長區域內對於紫外線按波長進行分光,且計測每個波長之分光輻射照度之分光輻射照度計。分光可藉由繞射光柵或稜鏡等進行。使用由分光儀構成之分光輻射照度計之分光輻射照度之測量,於如下方面有利:1)可跨越寬闊之波長區域測量分光輻射照度,又,因為每個波長之測量感度相同,故即便於用於紫外線固化型接著劑之聚合起始劑之種類產生變更之情況下,分光輻射照度計亦不用隨之變更;2)可直接計測所照射之紫外光之分光輻射照度,又因為每個波長之測量感度相同,故可準確地計測特定之吸收波長區域內之紫外線之分光輻 射照度之積分值。 In the measuring step, the spectroscopic illuminometer 17 is used to measure the illuminating illuminance of the ultraviolet ray irradiated in the curing step (C), and based on this, the specific absorption wavelength region including the absorption peak wavelength of the polymerization initiator is determined. The integral value X of the illuminance of the ultraviolet ray. The spectroradiometer 17 is a spectroradiometer that can split the wavelength of ultraviolet light by a spectrometer in a wavelength range of 220 to 800 nm, and measure the illuminance of the split spectroscopy of each wavelength. The splitting can be performed by a diffraction grating, a chirp, or the like. The measurement of the spectroscopic illuminance using a spectroradiometer composed of a spectrometer is advantageous in that: 1) the spectroscopic illuminance can be measured across a wide wavelength region, and since the measurement sensitivity of each wavelength is the same, even if it is used In the case where the type of the polymerization initiator of the ultraviolet curing type adhesive is changed, the spectroradiometer does not need to be changed; 2) the spectroscopic illuminance of the irradiated ultraviolet light can be directly measured, and because each wavelength is The measurement sensitivity is the same, so it is possible to accurately measure the ultraviolet radiation of the specific absorption wavelength region. The integral value of the illuminance.
作為分光輻射照度之積分對象之波長區域,只要為包含聚合起始劑之吸收峰值波長之吸收波長區域,則任何之波長區域均可,但吸光度低之波長區域之光,由於對固化反應之貢獻小,故較佳為於聚合起始劑之吸收峰值波長之-40 nm~+40 nm之波長區域內進行分光輻射照度之積分,更佳為於聚合起始劑之吸收峰值波長之-30 nm~+30 nm之波長區域內進行分光輻射照度之積分。再者,於上述說明中,聚合起始劑之吸收峰值波長之-40 nm~+40 nm之波長區域(作為波長區域A),亦可係自較聚合起始劑之吸收峰值波長小40 nm之波長至較上述吸收峰值波長大40 nm之波長之波長區域。又,作為分光輻射照度之積分之對象之波長區域,例如,於處於上述波長區域A內時,作為分光輻射照度之積分對象之波長區域不限定於波長區域A,包含處於上述波長區域A內且包含上述吸收峰值波長之任意之波長區域。 The wavelength region to be integrated with the illuminating illuminance of the spectroscopic radiance may be any wavelength region as long as it is an absorption wavelength region including the absorption peak wavelength of the polymerization initiator, but the light in the wavelength region having a low absorbance contributes to the curing reaction. Small, it is preferred to integrate the spectroscopic illuminance in the wavelength range of -40 nm to +40 nm of the absorption peak wavelength of the polymerization initiator, more preferably -30 nm at the absorption peak wavelength of the polymerization initiator. The integration of the spectroscopic illuminance is performed in the wavelength region of ~+30 nm. Furthermore, in the above description, the wavelength range of -40 nm to +40 nm (as the wavelength region A) of the absorption peak wavelength of the polymerization initiator may be 40 nm smaller than the absorption peak wavelength of the polymerization initiator. The wavelength is in a wavelength region of a wavelength 40 nm larger than the above absorption peak wavelength. Further, when the wavelength region to which the illuminating illuminance is integrated is, for example, in the wavelength region A, the wavelength region to be integrated as the astigmatism illuminance is not limited to the wavelength region A, and is included in the wavelength region A. Any wavelength region including the above absorption peak wavelength.
再者,就求得之分光輻射照度之積分值X而言,亦可使計測次數為1次,根據該1次之分光輻射照度之計測求得,但例如於若計測次數為1次則預計偏差較大時,亦可使分光輻射照度之計測次數為多次,使用該些計測值實施傅裏葉變換等降低偏差處理而獲得所求出之分光輻射照度之積分值X。 Furthermore, in the case of the integral value X of the astigmatism illuminance obtained, the number of times of measurement may be one, and it may be obtained from the measurement of the illuminance of the astigmatism of the first time, but for example, if the number of measurements is one, it is expected When the deviation is large, the number of measurement of the spectral illuminance can be made a plurality of times, and the integrated value X of the obtained spectral illuminance can be obtained by performing a Fourier transform or the like to reduce the deviation processing using the measured values.
於本實施形態中,根據以上說明之計測步驟(D)之結 果,設置固化步驟(C)中之控制紫外線照射裝置16之輸出之控制步驟(E)。即,於上述計測步驟(D)求得之分光輻射照度之積分值,由於紫外線照射裝置所具有之燈因長期使用導致之劣化、或附設於紫外線照射裝置之構件因長期使用而受到污染而處於慢慢降低之傾向。又,來自燈之紫外線之輻射照度,一般來說自紫外線照射開始於數十分鐘內大致處於穩定狀態,但亦有由於燈之發熱等因燈之點燈造成之燈環境之變化而慢慢降低之情況。該輻射照度之降低導致自預期之分光輻射照度之積分值(設定之分光輻射照度之積分值Y)產生偏移。又,特別係於紫外線照射初期,紫外線照射裝置之電壓不穩定,求得之分光輻射照度之積分值X較期望之分光輻射照度之積分值(設定之分光輻射照度之積分值Y)高或低。為了修正該偏移,於計測步驟(D)中,以求得之分光輻射照度之積分值X為基礎,控制紫外線照射裝置16之輸出。 In the present embodiment, according to the above-described measurement step (D) The control step (E) of controlling the output of the ultraviolet irradiation device 16 in the curing step (C) is set. In other words, the integral value of the astigmatism illuminance obtained in the above-described measurement step (D) is deteriorated due to long-term use of the lamp of the ultraviolet ray irradiation device, or the member attached to the ultraviolet ray irradiation device is contaminated by long-term use. Slowly lower the tendency. Moreover, the illuminance of the ultraviolet ray from the lamp is generally stable in a few tens of minutes since the ultraviolet ray is irradiated, but it is also slowly lowered due to the change of the lamp environment due to the heating of the lamp or the like. The situation. This decrease in irradiance results in an offset from the integral value of the expected spectroscopic illuminance (the integral value Y of the set spectroscopic illuminance). Further, in particular, in the initial stage of ultraviolet irradiation, the voltage of the ultraviolet irradiation device is unstable, and the integral value X of the spectral irradiance obtained is higher or lower than the integral value of the desired spectral illuminance (the integral value Y of the set spectroscopy illuminance). . In order to correct the offset, in the measuring step (D), the output of the ultraviolet irradiation device 16 is controlled based on the integral value X of the obtained spectral illuminance.
例如,於設定之分光輻射照度之積分值Y與求得之分光輻射照度之積分值X之差之絕對值相對於設定之分光輻射照度之積分值Y為5%以上時,使兩者之差作為絕對值變小,較佳為使設定之分光輻射照度之積分值Y與求得之分光輻射照度之積分值X之差之絕對值,相對於設定之分光輻射照度之積分值Y低於5%,如此來調整向紫外線照射裝置16輸入之電力,從而使其輸出增大或降低。更具體地說,求得之分光輻射照度之積分值X較設定之分光輻射照度之積分值Y大時,以減小求得之分光輻射照度之積分值 之方式控制紫外線照射裝置16;求得之分光輻射照度之積分值X較設定之分光輻射照度之積分值Y小時,以增大求得之分光輻射照度之積分值之方式控制紫外線照射裝置16。該控制可使用計算機進行,亦可手動進行。 For example, when the absolute value of the difference between the integral value Y of the set spectral irradiance and the integral value X of the obtained spectroscopy illuminance is 5% or more with respect to the integrated illuminance of the set spectroscopy illuminance, the difference between the two is made As the absolute value becomes smaller, it is preferable to make the absolute value of the difference between the integrated value Y of the set spectral irradiance and the integral value X of the obtained spectral illuminance, and the integral value Y of the illuminating illuminance with respect to the set is lower than 5 %, the electric power input to the ultraviolet irradiation device 16 is adjusted in such a manner that its output is increased or decreased. More specifically, when the integral value X of the astigmatism illuminance obtained is larger than the integral value Y of the set spectroscopy illuminance, the integral value of the obtained astigmatism illuminance is reduced. The ultraviolet irradiation device 16 is controlled in such a manner that the integral value X of the astigmatism illuminance is smaller than the integral value Y of the set spectroscopy illuminance, and the ultraviolet ray irradiation device 16 is controlled in such a manner as to increase the integral value of the astigmatic illuminance. This control can be done using a computer or manually.
設定之分光輻射照度之積分值Y如上所述,自預先驗證可使接著劑良好地固化且即便於高溫多濕之嚴酷之條件下亦可獲得偏光膜難以產生脫色之耐久性高之偏光板之範圍內選擇,通常於50~6000 mW/cm2之範圍內。於該範圍內,分光輻射照度之積分值越高,即便線速度為高速,亦會越容易地製造出具有良好之性能之偏光板。於設定之分光輻射照度之積分值Y低於50 mW/cm2時,為了滿足上述之累計光量而產生增大紫外線照射裝置(使線延長等)或增加紫外線照射裝置之數量之需要。即,上述之紫外線之累計光量,因為由生產率速度之管理與紫外線之輻射照度決定,故使設定之分光輻射照度之積分值Y處於上述範圍內於達成上述較佳之累計光量之方面亦較為重要。 The integral value Y of the set spectroscopic illuminance is as described above, and it is preliminarily verified that the adhesive can be cured well, and a polarizing plate having high durability in which the polarizing film is hard to be decolored can be obtained even under severe conditions of high temperature and high humidity. The range is selected, usually in the range of 50~6000 mW/cm 2 . Within this range, the higher the integrated value of the spectral illuminance, the easier it is to produce a polarizing plate having good performance even if the linear velocity is high. When the integrated value Y of the set spectroscopic illuminance is less than 50 mW/cm 2 , in order to satisfy the above-described integrated light amount, there is a need to increase the amount of the ultraviolet irradiation device (to extend the line, etc.) or to increase the number of the ultraviolet irradiation devices. That is, since the cumulative amount of ultraviolet light is determined by the management of the productivity speed and the illuminance of the ultraviolet ray, it is also important to achieve the above-described preferred integrated light amount by setting the integral value Y of the set spectroscopy illuminance within the above range.
以如上方式製造之偏光板,紫外線固化型接著劑之固化反應充分進行,其反應量亦穩定,因此具有良好之接著強度,並且於高溫多濕之嚴酷條件下偏光膜亦難以產生脫色,作為製品之品質穩定性亦優異。 In the polarizing plate manufactured as described above, the curing reaction of the ultraviolet curable adhesive is sufficiently performed, the reaction amount thereof is also stable, and therefore, the bonding strength is good, and the polarizing film is hard to be decolored under the severe conditions of high temperature and high humidity, and is used as a product. The quality stability is also excellent.
以下顯示實施例與比較例而更具體地說明本發明,但本發明不受該些示例限定。 The present invention will be more specifically illustrated by the following examples and comparative examples, but the invention is not limited by the examples.
圖3係概略地表示於以下之實施例及比較例中使用之裝 置之配置之側視圖。圖3所示之配置與先前說明之圖1相比僅以下1點不同,對差異點以外之部位附加與圖1相同之符號,因此該些部位之詳細說明需參照圖1之說明。 Figure 3 is a schematic view showing the use of the following examples and comparative examples. Side view of the configuration. The arrangement shown in FIG. 3 differs from the first embodiment described above in only one point, and the same reference numerals as in FIG. 1 are attached to portions other than the difference points. Therefore, a detailed description of the parts will be described with reference to FIG.
圖3相對於圖1之差異點:(1)對於於偏光膜1之兩表面分別貼合有第一光學膜2與第二光學膜3之後之積層體照射紫外線時,一面使該積層體之第二光學膜3側與照射用捲繞輥26之外周面密接,一面夾持該積層體,自配置於捲繞輥26之相反側之紫外線照射裝置16,向積層體之第一光學膜2側照射紫外線。 3 is a difference from FIG. 1 : (1) When the laminated body after the first optical film 2 and the second optical film 3 are bonded to both surfaces of the polarizing film 1 is irradiated with ultraviolet rays, the laminated body is made The second optical film 3 side is in close contact with the outer peripheral surface of the irradiation winding roller 26, and the laminated body is sandwiched by the ultraviolet irradiation device 16 disposed on the opposite side of the winding roller 26, and the first optical film 2 is laminated to the laminated body. The side is exposed to ultraviolet light.
又,作為分光輻射照度計17,使用大塚電子(股份)製造之UV固化型燈監控系統。該分光輻射照度計使用先前說明之分光儀進行分光,計測各波長下之分光輻射照度。然後,每隔預先設定之計測間隔,以相同之預先設定之計測時間計測自紫外線照射裝置16照射之紫外線之分光輻射照度,對於預先設定之波長區域之各波長之分光輻射照度進行積分,並作為求得之分光輻射照度之積分值X輸出。 Further, as the spectroscopic illuminometer 17, a UV-curable lamp monitoring system manufactured by Otsuka Electronics Co., Ltd. was used. The spectroradiometer is split using the spectrometer previously described, and the spectroscopic illuminance at each wavelength is measured. Then, the spectroscopic illuminance of the ultraviolet ray irradiated from the ultraviolet ray irradiation device 16 is measured at the predetermined measurement interval in advance, and the illuminance of the spectroscopy radiance of each wavelength in the predetermined wavelength region is integrated and used as The integral value X of the astigmatism illuminance obtained is obtained.
於該例中,作為第一光學膜2,使用厚度60 μm、寬度1490 mm且自輥供給之環烯系樹脂製之雙軸配向性相位差膜「ZEONOR」[自日本ZEON(股份)獲取]。作為第二光學膜3,使用厚度75 μm、寬度1490 mm且自輥供給之丙烯系樹脂膜。上述丙烯系樹脂膜藉由如下方式獲得:藉由單軸擠出機對丙烯系樹脂(熔點=164℃)以達到275℃之擠出溫 度之方式進行熔融混煉並自T模呈膜狀擠出,使之與設定為20℃之冷卻輥密接而冷卻固化後,以切刀刃除去兩端部而獲得。用於偏光膜1與第一光學膜2之接著之接著劑,以及用於偏光膜1與第二光學膜3之接著之接著劑,均係包含環氧化合物與光聚合起始劑(吸收峰值波長=290 nm)、且實質上不含溶劑之環氧系紫外線固化型接著劑。 In this example, as the first optical film 2, a biaxial alignment retardation film "ZEONOR" made of a cycloolefin resin having a thickness of 60 μm and a width of 1490 mm is obtained from [Japan ZEON (share)] . As the second optical film 3, a propylene-based resin film having a thickness of 75 μm and a width of 1490 mm and supplied from a roll was used. The above propylene resin film is obtained by a uniaxial extruder for a propylene resin (melting point = 164 ° C) to achieve an extrusion temperature of 275 ° C. The mixture was melt-kneaded in the form of a film, extruded from a T-die, and cooled and solidified by a cooling roll set at 20 ° C, and then both ends were removed by a cutting blade. The adhesive for the polarizing film 1 and the first optical film 2, and the adhesive for the polarizing film 1 and the second optical film 3, both containing an epoxy compound and a photopolymerization initiator (absorption peak) An epoxy-based ultraviolet curable adhesive having a wavelength of 290 nm and substantially no solvent.
將於聚乙烯醇吸附配向有碘之厚度25 μm之偏光膜1、作為第一光學膜2之上述環烯系樹脂膜、及作為第二光學膜3之上述丙烯系樹脂膜,分別以15 m/分鐘之線速度,以流動方向相同之方式進行供給。於上述環烯系樹脂膜2之向偏光膜1貼合之面,使用具有凹版輥11之第一塗佈機10[富士機械(股份)製造之「微型封閉式刮刀」]塗佈上述之環氧系紫外線固化型接著劑。又,於上述丙烯系樹脂膜3之向偏光膜1貼合之面,亦使用具有凹版輥13之第二塗佈機12[同為富士機械(股份)製造之「微型封閉式刮刀」]塗佈上述之環氧系紫外線固化型接著劑。 The polarizing film 1 having a thickness of 25 μm with iodine adsorbed by polyvinyl alcohol, the above-mentioned cycloolefin-based resin film as the first optical film 2, and the above-mentioned propylene-based resin film as the second optical film 3 are respectively 15 m. The line speed of /min is supplied in the same way as the flow direction. The above-mentioned ring is applied to the surface of the cycloolefin-based resin film 2 to which the polarizing film 1 is bonded, using a first coater 10 having a gravure roll 11 ["Micro-closed blade" manufactured by Fuji Machinery Co., Ltd.] Oxygen-based UV-curable adhesive. In addition, the second coater 12 having the gravure roll 13 (the "micro-closed scraper" manufactured by Fuji Machinery Co., Ltd.) is also applied to the surface of the propylene resin film 3 to which the polarizing film 1 is bonded. The above epoxy-based ultraviolet curable adhesive is used.
使設於塗佈機10、12之凹版輥11、13相對於膜之搬送方向逆向旋轉。而且,於環烯系樹脂膜2側,使第一塗佈機10具有之凹版輥11之旋轉周速度為21 m/分鐘,於光學膜上以大約2.6 μm之厚度塗佈接著劑。丙烯系樹脂膜3側之第二塗佈機12設定為使其具有之凹版輥13之旋轉周速度為19.5 m/分鐘,且於膜上以大約3.0 μm之厚度塗佈接著劑。 The gravure rolls 11 and 13 provided in the coaters 10 and 12 are rotated in the reverse direction with respect to the conveyance direction of the film. Further, on the side of the cycloolefin-based resin film 2, the first coater 10 had a gravure roll 11 having a rotation peripheral speed of 21 m/min, and the adhesive was applied to the optical film at a thickness of about 2.6 μm. The second coater 12 on the side of the propylene resin film 3 was set so that the gravure roll 13 had a peripheral speed of 19.5 m/min, and the adhesive was applied to the film at a thickness of about 3.0 μm.
塗佈有接著劑之環烯系樹脂膜2與丙烯系樹脂膜3使各自之接著劑塗佈面重合於偏光膜1,且藉由貼合用夾輥20、21以240 N/cm之線壓力夾持。 The cycloolefin-based resin film 2 and the propylene-based resin film 3 coated with the adhesive agent have their respective adhesive-coated surfaces superposed on the polarizing film 1, and are bonded to the nip rolls 20 and 21 at a line of 240 N/cm. Pressure clamping.
對於通過夾輥20、21之後之環烯系樹脂膜2/偏光膜1/丙烯系樹脂膜3之積層體以使其丙烯系樹脂膜3側與設定為20℃之照射用捲繞輥26之外周面密接之方式,且一面於長度方向(搬送方向)賦予600 N/m之張力,一面以與貼合前相同之線速度15 m/分鐘進行搬送。對於捲繞於照射用捲繞輥26上之積層體,自環烯系樹脂膜2側使用紫外線照射裝置16照射紫外線(固化步驟(C))。此時,使用由分光儀構成之分光輻射照度計17,一面計測紫外線之分光輻射照度之積分值,一面照射紫外線(計測步驟(D)),該由分光儀構成之分光輻射照度計17設定為對跨越上述紫外線固化型接著劑包含之聚合起始劑之吸收峰值波長290 nm之-30 nm~+40 nm之波長區域之分光輻射照度進行積分。於上述固化步驟(C)中,作為紫外線照射裝置16使用(股份)GS湯淺(GS Yuasa)製造之裝置,自其配備之作為紫外線燈之2盞「EHAN1700NAL高壓水銀燈」,以使每1盞燈之上述波長區域內之分光輻射照度之積分值為55 mW/cm2(設定之分光輻射照度之積分值Y=55 mW/cm2)之方式照射紫外線。紫外線之累計光量2盞燈共計為77 mJ/cm2。如此使接著劑層固化,製作於偏光膜1之單面貼合有環烯系樹脂膜2、且於另一面貼合有丙烯系樹脂膜3之偏光板4,並捲取於捲取 輥30上。 The laminated body of the cycloolefin-based resin film 2 / the polarizing film 1 / the propylene-based resin film 3 after passing through the nip rolls 20 and 21 is made to have the propylene-based resin film 3 side and the irradiation winding roll 26 set to 20 ° C When the outer peripheral surface is in close contact with each other and a tension of 600 N/m is applied in the longitudinal direction (transport direction), the conveyance is performed at the same linear velocity of 15 m/min as before the bonding. The layered body wound around the irradiation winding roller 26 is irradiated with ultraviolet rays from the cycloolefin-based resin film 2 side by the ultraviolet irradiation device 16 (curing step (C)). At this time, the spectroscopic illuminometer 17 composed of the spectrometer is used to measure the integrated value of the illuminating illuminance of the ultraviolet ray, and the ultraviolet ray is irradiated (measurement step (D)), and the spectroscopic illuminometer 17 composed of the spectrometer is set to The spectral illuminance of the wavelength region of -30 nm to +40 nm across the absorption peak wavelength of 290 nm across the polymerization initiator contained in the above ultraviolet curable adhesive is integrated. In the above-mentioned curing step (C), the device manufactured by GS Yuasa is used as the ultraviolet irradiation device 16, and the "EHAN1700NAL high-pressure mercury lamp" which is equipped as an ultraviolet lamp is provided for each lamp. The ultraviolet ray is irradiated in such a manner that the integrated value of the astigmatism illuminance in the above-mentioned wavelength region is 55 mW/cm 2 (the integrated value of the set spectroscopy illuminance Y = 55 mW/cm 2 ). The cumulative amount of ultraviolet light 2 lamps is 77 mJ/cm 2 in total . In this way, the adhesive layer is cured, and the polarizing plate 4 in which the cycloolefin-based resin film 2 is bonded to the single surface of the polarizing film 1 and the propylene-based resin film 3 is bonded to the other surface is formed and wound up on the take-up roll 30. on.
於上述計測步驟(D)中,將分光輻射照度計17之分光輻射照度之計測條件預先設定為,1次計測之計測次數1次、計測間隔3秒、計測時間25毫秒,計測之上述波長區域之分光輻射照度之積分值之瞬間值大約每隔1分鐘輸出,將該瞬間值作為求得之分光輻射照度之積分值X。 In the above-described measurement step (D), the measurement condition of the spectroscopic illuminance of the spectroradiometer 17 is set in advance to the number of measurement times of one measurement, the measurement interval of 3 seconds, and the measurement time of 25 milliseconds, and the above-mentioned wavelength region is measured. The instantaneous value of the integrated value of the astigmatism illuminance is outputted approximately every one minute, and this instantaneous value is used as the integral value X of the obtained astigmatic illuminance.
然後於控制步驟(E)中,於上述求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y=55 mW/cm2相比降低5%以上時,即(Y-X)2.75 mW/cm2時,控制紫外線照射裝置16,進行輸出調整,使其輸出以每1盞燈5W為單位增加。將進行300分鐘作業時求得之分光輻射照度之積分值X之平均值自設定之分光輻射照度之積分值Y之偏移即(Y-X之平均值)/Y(%)稱為「分光輻射照度之積分值之偏移」而示出於表1中。 Then, in the control step (E), when the integral value X of the astigmatism illuminance obtained above is reduced by 5% or more compared with the integral value of the set spectroscopy illuminance Y=55 mW/cm 2 , that is, (YX) At 2.75 mW/cm 2 , the ultraviolet irradiation device 16 is controlled to perform output adjustment so that the output is increased by 5 W per lamp. The average value of the integral value X of the spectroscopic illuminance obtained when the operation is performed for 300 minutes is the offset of the integral value Y of the spectroscopic illuminance from the set (that is, the average value of YX) / Y (%) is called "spectral illuminance" The offset of the integral value is shown in Table 1.
於實施例1中,不設置控制步驟(E),即,即便於計測步驟(D)求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y相比降低5%以上,亦不控制紫外線照射裝置16之輸出而進行紫外線照射製作偏光板。將進行300分鐘作業時之「分光輻射照度之積分值之偏移」示出於表1中。 In the first embodiment, the control step (E) is not provided, that is, even if the integral value X of the spectroscopic illuminance obtained in the measuring step (D) is reduced by 5% or more compared with the integral value Y of the set spectroscopic illuminance, The polarizing plate is also produced by controlling the output of the ultraviolet irradiation device 16 without performing ultraviolet irradiation. The "offset of the integrated value of the spectral illuminance" at the time of the 300-minute operation is shown in Table 1.
將厚度38 μm、寬度1330 mm之雙軸拉伸聚對苯二甲酸乙二醇酯膜作為第一光學膜2使用,將厚度60 μm、寬度 1330 mm之環烯系樹脂製之雙軸配向性相位差膜「ZEONOR」作為第二光學膜3使用,作為紫外線固化型接著劑,使用包含環氧化合物與光聚合起始劑(吸收峰值波長=320 nm)之環氧系紫外線固化型接著劑。然後除以下之點以外,均與實施例1相同地實施(A)塗佈步驟、(B)貼合步驟、(C)固化步驟、(D)計測步驟與控制步驟(E),製作偏光板。 A biaxially stretched polyethylene terephthalate film having a thickness of 38 μm and a width of 1330 mm is used as the first optical film 2, and has a thickness of 60 μm and a width. A biaxially oriented retardation film "ZEONOR" made of a 1330 mm cycloolefin resin is used as the second optical film 3. As an ultraviolet curable adhesive, an epoxy compound and a photopolymerization initiator are used (absorption peak wavelength = 320 nm) epoxy-based UV-curable adhesive. Then, in the same manner as in Example 1, except for the following points, (A) coating step, (B) bonding step, (C) curing step, (D) measurement step and control step (E) were carried out to prepare a polarizing plate. .
(1)於固化步驟(C)中,使每1盞燈於下述(2)所示之波長區域內之分光輻射照度之積分值為200 mW/cm2(2盞燈總共之累計光量為280 mJ/cm2)而照射紫外線(即,設定之分光輻射照度之積分值Y=200 mW/cm2);(2)於計測步驟(D)中,對於跨越聚合起始劑之吸收峰值波長320 nm之-30 nm~+30 nm之波長區域之分光輻射照度進行積分,如此設定分光輻射照度計17;及(3)於控制步驟(E)中,於求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y相比降低5%以上時,即(Y-X)10 mW/cm2時,控制紫外線照射裝置16而進行使其輸出以每1盞燈5W為單位增加之輸出調整。 (1) In the curing step (C), the integral value of the illuminating illuminance of each of the lamps in the wavelength region shown in the following (2) is 200 mW/cm 2 (the total amount of light of the two lamps is 280 mJ/cm 2 ) and ultraviolet rays (ie, the integrated value of the set spectroscopic illuminance Y=200 mW/cm 2 ); (2) in the measuring step (D), the absorption peak wavelength across the polymerization initiator The spectral irradiance of the wavelength range of -30 nm to +30 nm at 320 nm is integrated, so that the spectroscopic illuminometer 17 is set; and (3) the integrated value of the astigmatism of the spectroscopic radiance obtained in the control step (E) When X is reduced by 5% or more compared with the integral value Y of the set split illuminance, that is, (YX) At 10 mW/cm 2 , the ultraviolet irradiation device 16 is controlled to perform an output adjustment in which the output is increased by 5 W per 1 lamp.
將進行300分鐘作業時之「分光輻射照度之積分值之偏移」示出於表1中。 The "offset of the integrated value of the spectral illuminance" at the time of the 300-minute operation is shown in Table 1.
於實施例2中,不設置控制步驟(E),即,即便於計測步驟(D)求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y相比降低5%以上,亦不控制紫外線照射裝置 16之輸出而進行紫外線照射製作偏光板。將進行300分鐘作業時之「分光輻射照度之積分值之偏移」示出於表1中。 In the second embodiment, the control step (E) is not provided, that is, even if the integral value X of the spectroscopic illuminance obtained in the measuring step (D) is reduced by 5% or more compared with the integrated value Y of the set spectroscopic illuminance, Also does not control the ultraviolet irradiation device The output of 16 was irradiated with ultraviolet rays to prepare a polarizing plate. The "offset of the integrated value of the spectral illuminance" at the time of the 300-minute operation is shown in Table 1.
於獲得之偏光板之任意位置均切割為80 mm(流動方向)×整個寬度之短條狀,再將該短條切斷成300~400 mm寬度,將如此獲得之多個小片群作為1個試樣,將該些小片群於調整為60℃×90%RH之恆溫/恆濕器中以互不接觸之狀態懸掛並保持500小時。一面於燈箱上使光透過,一面藉由目視與未放入恆溫/恆濕器中之偏光板進行比較,評價有無漏光。對於於偏光板之任意位置切割之4個試樣實施該脫色評價試驗,將4個試樣全部未產生漏光之情況設為「OK」,將於4個試樣中之1個以上之試樣產生漏光時設為「NG」,結果示出於表1之「脫色評價結果」一欄中。該欄之括弧內之數值表示4個試樣中之產生漏光之試樣數。 At any position of the obtained polarizing plate, it is cut into a strip shape of 80 mm (flow direction) × whole width, and the strip is cut into a width of 300 to 400 mm, and the plurality of small pieces thus obtained are taken as one For the sample, the small pieces were suspended in a constant temperature/humidifier adjusted to 60 ° C × 90% RH in a state of not contacting each other for 500 hours. Light was transmitted through the light box, and the light leakage was evaluated by visual comparison with a polarizing plate not placed in the thermostat/humidifier. The decolorization evaluation test was performed on four samples cut at any position of the polarizing plate, and the case where no light leakage occurred in all of the four samples was set to "OK", and one or more samples of the four samples were used. When the light leakage occurred, it was set to "NG", and the results are shown in the column of "Decolorization Evaluation Results" in Table 1. The numerical values in the brackets of the column indicate the number of samples in the four samples that cause light leakage.
如表1所示,未設置控制步驟(E)之比較例1及2中,紫外線之分光輻射照度之積分值大幅降低,隨此,所獲得之偏光板於嚴酷環境下出現脫色,相對於此,設置控制步驟(E)且於特定波長區域之求得之分光輻射照度之積分值X與設定之分光輻射照度之積分值Y相比降低5%以上時改變紫外線之照射輸出之實施例1與2中,與設定之分光輻射照度之積分值Y相比,求得之分光輻射照度之積分值X之平均值(分光輻射照度之積分值之偏移)之變動被抑制於5%以內,可製造於嚴酷環境下不會脫色之偏光板。 As shown in Table 1, in Comparative Examples 1 and 2 in which the control step (E) was not provided, the integral value of the ultraviolet spectroscopy illuminance was greatly reduced, and accordingly, the obtained polarizing plate was decolored in a severe environment, and accordingly, When the control step (E) is set and the integral value X of the astigmatism illuminance obtained in the specific wavelength region is reduced by 5% or more compared with the integrated value Y of the set spectroscopy illuminance, the embodiment 1 and the ultraviolet ray irradiation output are changed. In the case of 2, the variation of the integral value X of the integrated illuminance of the astigmatism illuminance (the offset of the integrated value of the astigmatism illuminance) is suppressed to be less than 5%, compared with the integral value Y of the set illuminance of the astigmatism. A polarizing plate that does not discolor in harsh environments.
1‧‧‧偏光膜 1‧‧‧ polarizing film
2‧‧‧第一光學膜 2‧‧‧First optical film
3‧‧‧第二光學膜 3‧‧‧Second optical film
4‧‧‧偏光板 4‧‧‧Polar plate
10‧‧‧第一塗佈機 10‧‧‧First coater
11‧‧‧凹版輥 11‧‧‧ gravure roll
12‧‧‧第二塗佈機 12‧‧‧Second coating machine
13‧‧‧凹版輥 13‧‧‧ gravure roll
14‧‧‧第一膜厚計 14‧‧‧First film thickness gauge
15‧‧‧第二膜厚計 15‧‧‧Second film thickness gauge
16‧‧‧紫外線照射裝置 16‧‧‧UV irradiation device
17‧‧‧分光輻射照度計 17‧‧‧Splitting illuminance meter
20、21‧‧‧貼合用夾輥 20, 21‧‧‧ nip rollers for lamination
22、23‧‧‧捲取前夾輥 22, 23‧‧‧ Rolling front nip rollers
24‧‧‧導輥 24‧‧‧guide roller
26‧‧‧照射用捲繞輥 26‧‧‧Ring winding roller
30‧‧‧捲取輥 30‧‧‧Winding roller
圖1係表示適用於本發明之製造裝置之配置例之概略側視圖。 Fig. 1 is a schematic side view showing an arrangement example of a manufacturing apparatus to which the present invention is applied.
圖2係表示本發明之各步驟間之關係之一之方塊圖。 Figure 2 is a block diagram showing one of the relationships between the steps of the present invention.
圖3係表示實施例中使用之製造裝置之配置之概略側視圖。 Fig. 3 is a schematic side view showing the configuration of a manufacturing apparatus used in the embodiment.
1‧‧‧偏光膜 1‧‧‧ polarizing film
2‧‧‧第一光學膜 2‧‧‧First optical film
3‧‧‧第二光學膜 3‧‧‧Second optical film
4‧‧‧偏光板 4‧‧‧Polar plate
10‧‧‧第一塗佈機 10‧‧‧First coater
11‧‧‧凹版輥 11‧‧‧ gravure roll
12‧‧‧第二塗佈機 12‧‧‧Second coating machine
13‧‧‧凹版輥 13‧‧‧ gravure roll
14‧‧‧第一膜厚計 14‧‧‧First film thickness gauge
15‧‧‧第二膜厚計 15‧‧‧Second film thickness gauge
16‧‧‧紫外線照射裝置 16‧‧‧UV irradiation device
17‧‧‧分光輻射照度計 17‧‧‧Splitting illuminance meter
20、21‧‧‧貼合用夾輥 20, 21‧‧‧ nip rollers for lamination
22、23‧‧‧捲取前夾輥 22, 23‧‧‧ Rolling front nip rollers
24‧‧‧導輥 24‧‧‧guide roller
30‧‧‧捲取輥 30‧‧‧Winding roller
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