TWI556018B - 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
TWI556018B
TWI556018B TW101136871A TW101136871A TWI556018B TW I556018 B TWI556018 B TW I556018B TW 101136871 A TW101136871 A TW 101136871A TW 101136871 A TW101136871 A TW 101136871A TW I556018 B TWI556018 B TW I556018B
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Taiwan
Prior art keywords
film
bonding
active energy
energy ray
roller
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TW101136871A
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English (en)
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TW201331641A (zh
Inventor
古川淳
廣岩梓
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住友化學股份有限公司
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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
    • 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
    • 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
    • B29C65/4805—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
    • 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
    • B29C65/524—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
    • 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
    • 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
    • B29C66/7338—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
    • 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
    • B29C66/80—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
    • B29C66/83413—Roller, cylinder or drum types cooperating rollers, cylinders or drums
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
    • B29C66/934—Measuring or controlling the joining process by measuring or controlling the speed by controlling or regulating the speed
    • B29C66/93451—Measuring or controlling the joining process by measuring or controlling the speed by controlling or regulating the speed by controlling or regulating the rotational speed, i.e. the speed of revolution
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29D11/00—Producing optical elements, e.g. lenses or prisms
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    • 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
    • B29C65/02—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
    • B29C65/1403—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 type of electromagnetic or particle radiation
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/028—Non-mechanical surface pre-treatments, i.e. by flame treatment, electric discharge treatment, plasma treatment, wave energy or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/739—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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Description

偏光板之製造方法
本發明係關於一種有用於作為構成液晶顯示裝置等的光學零件之一的偏光板之製造方法。
偏光膜，係以二色性色素吸附配向於聚乙烯醇系樹脂薄膜者被廣泛使用，已知有以碘作為二色性色素之碘系偏光膜、以二色性直接染料作為二色性色素之染料系偏光膜等。該些偏光膜通常於其單面或兩面透過接合劑貼合三乙醯纖維素薄膜等的透明薄膜，而成為偏光板。
作為於偏光膜的單面或兩面積層透明薄膜之方法，有預先在透明薄膜的表面塗佈活性能量線硬化型樹脂後，將偏光膜與透明薄膜藉由一對貼合輥夾壓而貼合，然後照射活性能量線而接合硬化的方法(舉例而言，參照日本特開2004-245925號公報(專利文獻1)，日本特開2009-134190號公報(專利文獻2)、日本特開2011-95560號公報(專利文獻3)等)。
專利文獻3中雖然記載在以活性能量線照射活性能量線硬化型樹脂並硬化時，由於使積層體與輥之外周面一邊密合一邊硬化，藉此可抑制波浪捲曲(wave curl)等的發生，但當貼合輥以及活性能量線照射時，與積層體密合之輥之旋轉速度平衡會有不適當 之情形，所製作之偏光板會發生彎曲成波浪板狀般之外觀不良(以下將此狀態稱為「波浪板狀彎曲」。)。
[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
本發明之目的係在如上述般具備一邊於輥之外周面密合積層體一邊硬化活性能量線硬化型樹脂之步驟的方法中抑制波浪板狀彎曲的發生。
本發明係將透明薄膜貼合於偏光膜的單面或兩面所構成的偏光板之製造方法，係依順序具備：於上述透明薄膜之單面、或是上述偏光膜之單面或兩面，塗佈活性能量線硬化型接合劑之接合劑塗佈步驟；將上述透明薄膜透過上述接合劑積層於上述偏光膜的單面或兩面所構成的積層體夾於向輸送方向旋轉的一對貼合輥間，並對積層體施加壓力，藉此貼合上述透明薄膜與上述偏光膜之貼合步驟；以及上述積層體與向輸送方向旋轉之旋轉輥為密合之狀態下輸送時，對積層體照射活性能量線並硬化上述接合劑之第1活性能量線照射步驟；其中，上述一對貼合輥之至少一者為具有由橡膠所成之表面且旋轉驅動之橡膠輥，上述旋轉輥之旋轉速度比上述橡膠輥之旋轉速度快。上述旋轉輥較理想為冷卻輥。
上述本發明中，上述旋轉輥之旋轉速度較理想為上述橡膠輥之旋轉速度為100時為100.1以上且為102.0以下。
依據本發明可製作抑制波浪板狀彎曲發生且外觀良好之偏光板。因此，使用依據本發明之製造方法所得偏光板，可提供於高品質之液晶顯示裝置。
1‧‧‧偏光膜
2、3‧‧‧透明薄膜
4‧‧‧積層體(偏光板)
11、12‧‧‧接合劑塗佈裝置
13‧‧‧旋轉輥(冷卻輥)
16、17、18、31、32‧‧‧活性能量線照射裝置
19‧‧‧輸送用夾輥
20‧‧‧捲取輥
51、52‧‧‧貼合輥
第1圖係顯示本發明偏光板之製造裝置之一實施形態的概略側面圖。
本發明係將透明薄膜貼合於偏光膜的單面或兩面所構成的偏光板之製造方法，依順序具備：於透明薄膜之單面、或是偏光膜之單面或兩面，塗佈活性能量線硬化型接合劑之接合劑塗佈步驟；將透明薄膜透過前述接合劑積層於偏光膜的單面或兩面所構成的積層體夾於向輸送方向旋轉的一對貼合輥間，並對積層體施加壓力，藉此貼合透明薄膜與偏光膜之貼合步驟；以及積層體與向輸送方向旋轉之旋轉輥為密合之狀態下輸送時，對積層體照射活性能量線並硬化接合劑之第1活性能量線照射步驟。其中，上述一對貼合輥之至少一者為具有由橡膠所成之表面且旋轉驅動之橡膠輥，上述旋轉輥之旋轉速度比上述橡膠輥之旋轉速度快。
首先詳細說明用於本發明之製造方法之各要件。
(偏光膜)
本發明的偏光板之製造方法所使用的偏光膜，具體來說為二色性色素吸附配向於單軸延伸的聚乙烯醇系樹脂薄膜者。聚乙烯 醇系樹脂可藉由皂化聚乙酸乙烯酯系樹脂而得到。聚乙酸乙烯酯系樹脂除乙酸乙烯酯的單獨聚合物之聚乙酸乙烯酯外，可舉出例如乙酸乙烯酯以及可與其共聚合之其他單體的共聚物(例如乙烯-乙酸乙烯酯共聚物)等。可與乙酸乙烯酯共聚合之其他單體另外可舉出不飽和羧酸類、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。該些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。
如此聚乙烯醇系樹脂所製成之薄膜係被使用作為偏光膜的原料薄膜。聚乙烯醇系樹脂之製膜方法無特別限制，可使用以往習知適當的方法製膜。由聚乙烯醇系樹脂所構成的原料薄膜之薄膜厚度無特別限制，但例如為10至150μm的程度。通常以輥狀供給之厚度為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500至6000 mm的範圍內。
市售之聚乙烯醇系薄膜有(Vinylon VF-PS#7500、可樂麗(Kuraray)製/OPL film M-7500、日本合成製)原料厚度為75μm、(Vinylon VF-PS#6000、可樂麗製、Vinylon VF-PE#6000、可樂麗製)原料厚度為60μm等。
偏光膜，通常係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)、將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之處理後進行水洗的步驟(水洗處 理步驟)而製造。
而且，製造偏光膜時，通常將聚乙烯醇系樹脂薄膜進行單軸延伸，該單軸延伸可在染色處理步驟前進行，可在染色處理步驟中進行，亦可在染色處理步驟後進行。單軸延伸在染色處理步驟後進行的情況，該單軸延伸可在硼酸處理步驟前進行，亦可在硼酸處理步驟中進行。當然，可在該些複數階段進行單軸延伸。
單軸延伸，可在轉速相異的輥間進行單軸延伸，也可使用熱輥進行單軸延伸。而且，可為在大氣中進行延伸的乾式延伸，也可為在藉由溶劑而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倍的程度。
染色處理步驟中，聚乙烯醇系樹脂薄膜藉由二色性色素之染色，係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。二色性色素例如使用碘、二色性染料等。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於染色處理前，較理想為實施水的浸漬處理。
使用碘作為二色性色素的情況，通常採用將浸漬聚乙烯醇系樹脂薄膜浸漬於含有碘及碘化鉀的水溶液而染色之方法。該水溶液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的情況，染色所使用之水溶液的溫度通常為20至40℃，在該水溶液中的浸漬時間(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的情況，通常採 用將聚乙烯醇系樹脂薄膜浸漬於包含水溶液二色性染料的水溶液而染色之方法。該水溶液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的情況，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。
硼酸處理步驟係藉由將二色性色素染色之聚乙烯醇系樹脂薄膜浸漬於含有硼酸之水溶液而進行。含有硼酸之水溶液之硼酸的量，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。於上述染色處理步驟中使用碘作為二色性色素的情況，該硼酸處理步驟所使用的含有硼酸的水溶液較理想為含有碘化鉀。於該情況，含有硼酸的水溶液中碘化鉀的量，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。在含有硼酸的水溶液中之浸漬時間通常為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75℃。
接著於水洗處理步驟，將上述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，通常實施乾燥處理以得到偏光膜。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單軸延伸、藉由二色性色素之染色、硼酸處理以及水洗處理，以得到偏光膜。該偏光膜的厚度通常為5至50μm的範圍內。
(透明薄膜)
本發明中，於上述之偏光膜之單面或兩面貼合透明薄膜。構成透明薄膜的材料可舉出例如環烯烴系樹脂、乙酸纖維素系樹脂、如聚對苯二甲酸乙二酯或聚萘二甲酸乙二酯或聚對苯二甲酸丁二酯之類之聚酯系樹脂、聚羧酸酯系樹脂、丙烯酸系樹脂、聚丙烯等，可使用本區域以往廣為使用之薄膜材料。於於偏光膜的兩面貼合透明薄膜之情況，各別的透明薄膜可為相同，亦可為不同種類的薄膜。
環烯烴系樹脂，係指具有例如降莰烯、多環降莰烯系單體之類之環狀烯烴(環烯烴)所構成單體之單元之熱塑性樹脂(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，導入極性基者亦為有效。
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的情況，鏈狀烯烴可舉出例如乙烯、丙烯等，而且作為具有乙烯基之芳香族化合物可舉出例如苯乙烯、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之單元可為50莫耳%以下(較理想為15至50莫耳%)。特別是使用環烯烴、鏈狀烯烴及具有乙烯基之芳香族化合物的三元共聚物的情況，環烯烴所構成的單體之單元可為如上述之較少的量。於 如此三元共聚物中，鏈狀烯烴所構成的單體之單元通常為5至80莫耳%，具有乙烯基之芳香族化合物所構成的單體之單元通常為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股份有限公司製)、ZEONOR(日本ZEON股份有限公司製)、ZEONEX(日本ZEON股份有限公司製)、APL(三井化學股份有限公司製)、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，適合使用溶劑鑄薄膜法、熔融擠出法等習知方法。而且，例如可使用Escena(積水化學工業股份有限公司製)、SCA40(積水化學工業股份有限公司製)、ZEONOR薄膜，(Optes股份有限公司製)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單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。延伸通常係一邊捲出薄膜捲狀物，一邊連續地進行，於加熱爐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薄膜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。
當環烯烴系樹脂薄膜為捲繞為捲狀物的狀態時，薄膜彼此接著並有容易產生結塊的傾向，故通常貼合保護薄膜後再捲成為捲狀物。而且，環烯烴系樹脂薄膜一般表面活性差，故較理想為於與偏光膜接合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。其中，適合為較易實施之電漿處理，特別是大氣壓電漿處理、電暈處理。
乙酸纖維素系樹脂係指纖維素的部分或完全酯化物，其中可舉出例如纖維素的乙酸酯、丙酸酯、丁酸酯、該些的混合酯等所構成的薄膜。更具體來說可舉出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。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(富士軟片股份有限公司製)、Fujitac TD80UF(富士軟片股份有限公司製)、Fujitac TD80UZ(富士軟片股份有限公司製)、KC8UX2M(Konica Minolta Opto股份有限公司製)、KC8UY(Konica Minolta Opto股份有限公司製)、Fujitac TD60UL(富士軟片股份有限公司製)、KC2UYW(Konica Minolta Opto股份有限公司製)、KC4UAW(Konica Minolta Opto股份有限公司製)、KC6UAW(Konica Minolta Opto股份有限公司製)等。
而且，透明薄膜也適合使用賦予相位差之乙酸纖維素系樹脂薄膜。如此賦予相位差之乙酸纖維素系樹脂薄膜之市售品可舉出例如WV BZ 438(富士軟片股份有限公司製)、KC4FR-1(Konica Minolta Opto股份有限公司製)、KC4CR-1(Konica Minolta Opto股份有限公司製)、KC4AR-1(Konica Minolta Opto股份有限公司製)等。乙酸纖維素亦稱為乙醯纖維素、纖維素乙酸酯。
該些乙酸纖維素系薄膜容易吸水，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越接近偏光板的保存環境，例如無塵室的製造產線、捲狀物的保存倉庫之平衡水分率越好，雖也與積層薄膜的構成有關，但水分率例如為2.0至3.5%的程度，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測定者，為在105℃/120分鐘後的重量變化。
本發明所使用的透明薄膜的厚度較理想為薄者，太薄時強度降低且加工性變差。另一方面，太厚時產生透明性降低、積層後所需的固化時間變長等的問題。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。
為了提高接合劑與偏光膜及/或透明薄膜的接合性，可於偏光膜及/或透明薄膜實施電暈處理、火焰處理、電漿處理、紫外線處理、底塗(primer)塗佈處理、皂化處理等的表面處理。
而且於透明薄膜可各別單獨實施或2種以上組合實施抗眩光處理、抗反射處理、硬塗處理、抗靜電處理、抗污處理等表面處理。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、磷酸苯酯系化合物、鄰苯二甲酸酯系化合物等塑化劑。
再者，透明薄膜可具有作為相位差薄膜的功能、作為輝度提升薄膜的功能、作為反射薄膜的功能、作為半穿透反射薄膜的功能、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等之光學功能。於該情況下，例如藉由於透明薄膜的表面積層相位差薄膜、輝度提升薄膜、反射薄膜、半穿透反射薄膜、擴散薄膜、光學補償薄膜等光學功能性薄膜，除了可具有如此的功能外，也可賦予透明薄膜本身如此的功能。而且，如具有作為輝度提升薄膜的功能的擴散薄膜等般，透明薄膜可具有複數功能。
例如於上述透明薄膜實施日本專利第2841377號公報、日本專利第3094113號公報等所述之延伸處理，或實施日本專利第3168850號公報所述之處理，藉此可賦予作為相位差薄膜的功能。相位差薄膜之相位差特性，例如可適當選擇正面相位差值為5至 100nm、厚度方向位相差值為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號公報或日本特開2003-29030號公報所述之方法而形成細微孔，或者是以重疊選擇性反射的中心波長相異的2層以上的膽固醇液晶層，藉此可賦予作為輝度提升薄膜的功能。
若於上述透明薄膜以蒸鍍或濺鍍等形成金屬薄膜，則可賦予作為反射薄膜或半穿透反射薄膜的功能。於上述透明薄膜塗佈包含微粒子之樹脂溶液，藉此可賦予作為擴散薄膜之功能。而且，於上述透明薄膜塗佈圓盤型液晶性化合物等的液晶性化合物並配向，藉此賦予作為光學補償薄膜的功能。而且，於透明薄膜可含有展現相位差的化合物。再者，可使用適當的接合劑於偏光膜直接貼合各種光學功能性薄膜。光學功能性薄膜的市售品，可舉出例如DBEF(3M公司製、於日本司從住友3M股份有限公司取得)等輝度提升薄膜、WV film(富士軟片股份有限公司製)等視角改良薄膜、Arton film(JSR股份有限公司製)、ZEONOR film(Optes股份有限公司製)、Escena(積水化學工業股份有限公司製)、VA-TAC(Konica Minolta Opto股份有限公司製)、SUMICALITE(住友化學股份有限公司製)等的相位差薄膜等。
(活性能量線硬化型接合劑)
偏光膜與透明薄膜係透過活性能量線硬化型接合劑而貼合。活性能量線硬化型接合劑，以耐候性、折射率或耐久性等之觀點來看，可舉出含有藉由照射活性能量線而硬化之環氧樹脂之環氧樹脂系樹脂組成物所成之接合劑。但是並不限於此，可採用以往偏光板之製造中使用之各種活性能量線硬化型接合劑(有機溶劑 系接合劑、熱熔系接合劑、無溶劑型接合劑等)，舉例可採用丙烯醯胺、丙烯酸酯、丙烯酸胺甲酸乙酯、丙烯酸環氧酯等之丙烯酸系樹脂樹脂組成物所成之接合劑等。
環氧樹脂係指分子內具有2個以上環氧基之化合物。從耐候性、折射率、陽離子聚合性等的觀點來看，接合劑之硬化性環氧樹脂組成物所含有的環氧樹脂較理想為分子內不包含芳香環的環氧樹脂(例如參考專利文獻1)。如此的環氧樹脂可舉例如為氫化環氧樹脂、脂環式環氧樹脂、脂肪族環氧樹脂等。
可藉由將芳香族環氧樹脂的原料之聚羥基化合物在觸媒的存在下，於加壓下選擇性地進行核氫化反應而得核氫化聚羥基化合物，並將此核氫化聚羥基化合物環氧丙基醚化的方法，而得到氫化環氧樹脂。芳香族環氧樹脂可舉出例如雙酚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(phenol 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酚等多官能基型環氧樹脂等。氫化環氧樹脂中較理想為氫化雙酚A的環氧丙基醚。
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之架橋的氧原子-O-。下式中，m為2至5的整數。
除去上述式之(CH2)m中1個或複數個氫原子的形態之基鍵結於其他化學構造之化合物，可成為脂環式環氧樹脂。(CH2)m中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，由於顯示良好的接合性，較理想為使用具有氧雜二環己烷環(上述式m=3者)之環氧樹脂、具有氧雜二環庚烷環(上述式m=4者)之環氧樹脂。以下，具體地例示較理想使用的脂環式環氧樹脂，但不限於該些化合物。
(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以及R2互相獨立表示氫原子或碳數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以及R4互相獨立表示氫原子或碳數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以及R6互相獨立表示氫原子或碳數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以及R8互相獨立表示氫原子或碳數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以及R10互相獨立表示氫原子或碳數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環化合物：
(式中，R11以及R12互相獨立表示氫原子或碳數1至5之直鏈 狀烷基)。
(g)下式(VII)所示的二環氧基單螺環化合物化合物：
(式中，R13以及R14互相獨立表示氫原子或碳數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)所示的環氧基環戊基醚類：
(式中，R16以及R17互相獨立表示氫原子或碳數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故使用該些較理想。
(A)7-氧雜雙環[4.1.0]庚烷-3-羧酸與(7-氧雜-雙環[4.1.0]庚-3-基)甲醇之酯化物[式(I)中，R1=R2=H之化合物]，(B)4-甲基-7-氧雜雙環[4.1.0]庚烷-3-羧酸與(4-甲基-7-氧雜-雙環[4.1.0]庚-3-基)甲醇之酯化物[式(I)中，R1=4-CH3，R2=4-CH3之化合物]，(C)7-氧雜雙環[4.1.0]庚烷-3-羧酸與1,2-乙二醇之酯化物[式(II)中，R3=R4=H，n=2之化合物]，(D)(7-氧雜雙環[4.1.0]庚-3-基)甲醇與己二酸之酯化物[式(III)中，R5=R6=H，p=4之化合物]，(E)(4-甲基-7-氧雜雙環[4.1.0]庚-3-基)甲醇與己二酸之酯化物[式(III)中，R5=4-CH3，R6=4-CH3，p=4之化合物]，(F)(7-氧雜雙環[4.1.0]庚-3-基)甲醇與1,2-乙二醇之醚化物[式(V)中，R9=R10=H，r=2之化合物]。
而且，脂肪族環氧樹脂可舉出例如脂肪族多元醇或其環氧烷類(alkylene oxide)加成物的聚環氧丙基醚。更具體來說可舉出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；三羥甲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；於乙二醇、丙二醇及丙三醇等脂肪族多元醇加成1種或2種以上的環氧烷類(環氧乙烷、環氧丙烷)所得之聚醚多元醇的聚環氧丙基醚等。
構成由環氧系樹脂組成物所成的接合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，有硬化後的複合偏光板的可撓性降低、接合強度降低之可能性。另一方面，超過3,000 g/當量時，有與含於接合劑之其他成分的相溶性降低之可能性。
於該接合劑中，從反應性的觀點來看，環氧樹脂的硬化反應較理想為使用陽離子聚合。因此，作為活性能量線硬化型接合劑之硬化性環氧樹脂，較理想為摻配陽離子聚合起始劑。陽離子聚合起始劑係藉由可見光線、紫外線、X射線、電子線等的活性能量線之照射，而產生陽離子種或路易士酸，並引發環氧基的聚合反應。以下將藉由活性能量線之照射而產生陽離子種或路易士酸並引發環氧基的聚合反應之陽離子聚合起始劑，稱為「光陽離子聚合起始劑」。
使用光陽離子聚合起始劑並藉由活性能量線之照射而進行接合劑的硬化之方法，係可在常溫下硬化而減少考慮偏光膜的耐熱性或因膨脹而彎曲之必要，並可在薄膜間可良好地接合，此點來看係有利的。而且，光陽離子聚合起始劑係以光而進行觸媒作用，即使混合於環氧樹脂其保存安定性與操作性仍優異。
光陽離子聚合起始劑可舉出例如芳香族重氮鹽；芳香族錪鹽、芳香族鋶鹽等的鎓鹽；鐵-芳烴錯合物(iro-arene complex)等。
芳香族重氮鹽可舉出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，芳香族錪鹽可舉出例如肆(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。
芳香族鋶鹽可舉出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)二苯硫醚、雙(六氟銻酸)4,4’-雙[二(β-羥基乙氧基)苯基鋶]二苯硫醚、雙(六氟磷酸)4,4’-雙[二(β-羥基乙氧基)苯基鋶]二苯硫醚、六氟銻酸7-[二(對-甲苯基)鋶]-2-異丙基硫雜蒽酮(thioxanthone)、四(五氟苯基)硼酸7-[二(對-甲苯基)鋶]-2-異丙基硫雜蒽酮、六氟磷酸4-苯基羰基-4’-二苯基鋶-二苯硫醚、六氟銻酸4-(對-第3丁基苯基羰基)-4’-二苯基鋶-二苯硫醚、四(五氟苯基)硼酸4-(對-第三丁基苯基羰基)-4’-二(對-甲苯基)鋶-二苯硫醚等。
而且，鐵-芳烴錯合物可舉出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(xylene-cyclopentadienyliron(II)tris(trifluoromethylsulfonyl)methanide)等。
該些光陽離子聚合起始劑的市售品可容易取得，以各自的商品名舉出例如「KAYALITE PCI-220」以及「KAYALITE PCI-620」(以上係日本化藥股份有限公司製)；「UVI-6990」(聯合碳化物公司製)、「ADEKA OPTOMER SP-150」以及「ADEKA OPTOMER SP-170」(以上係ADEKA股份有限公司製)；「CI-5102」、「CIT-1370」、「CIT-1682」、「CIP-1866S」、「CIP-2048S」以及「CIP-2064S」(以上係日本曹達股份有限公司製)；「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」(以上係綠化學股份有限公司製)；「PI-2074」(Rhodia公司製)等。
光陽離子聚合起始劑可單獨只使用1種，亦可混合2種以上使用。其中，芳香族鋶鹽由於具有300nm以上的波長區域之紫外線吸收特性，硬化性理想，並可賦予具有良好的機械強度、接合強度之硬化物，所以較理想係使用芳香族鋶鹽。
光陽離子聚合起始劑的摻配量，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。光陽離子聚合起始劑的摻配量，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，有機械強度、接合強度降低之傾向。而且，光陽離子聚合起始劑的摻配量，對環氧樹脂100重量份而言超過20重量份時，因硬化物中離子性物質增加，硬化物的吸濕性變高，耐久性能有降低的可能性。
於使用光陽離子聚合起始劑的情況，硬化性環氧樹脂組成物依需要可復含有光增感劑。藉由使用光增感劑可提高陽離子聚合的反應性，提高硬化物的機械強度與接合強度。光增感劑可舉出例如羰基化合物、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、鹵化物、光還原性色素等。
光增感劑的更具體的例子可舉出例如安息香甲醚、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、鄰苯甲醯基安息香酸甲酯、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(acridone)衍生物；其他例如α,α-二乙氧基苯乙酮、二苯乙二酮、茀酮(Fluorenone)、氧雜蒽酮(Xanthone)、鈾化合物、 鹵化物等。光增感劑可單獨只使用1種，亦可併用2種以上。光增感劑較理想為於硬化性環氧樹脂組成物100重量份中含有0.1至20重量份的範圍內。
含於接合劑之環氧樹脂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兩者而硬化。於後者的情況，較理想為併用光陽離子聚合起始劑及熱陽離子聚合起始劑。
熱陽離子聚合起始劑可舉出例如苄基鋶鹽、噻吩鹽(thiophenium)、四氫噻吩鹽(thiolanium)、苄基銨、吡啶鹽、聯胺鹽(hydrazinium)、羧酸酯、磺酸酯、胺醯亞胺等。該些熱陽離子聚合起始劑，作為市售品可容易取得，以各自的商品名可舉出例如「Adeka opton CP77」以及「Adeka opton CP66」(以上係ADEKA股份有限公司製)、「CI-2639」以及「CI-2624」(以上係日本曹達股份有限公司式會公司製)、「Sunaid SI-60L」及「Sunaid SI-80L」以及「Sunaid SI-100L」(以上係三新化學工業股份有限公司式會公司製)等。
活性能量線硬化型的接合劑可復含有氧雜環丁烷類、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員環醚的化合物可舉出例如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。該些氧雜環丁烷類，作為市售品可容易取得，可舉例為以分別的商品名為「Aron oxetane OXT-101」、「Aron oxetane OXT-121」、「Aron oxetane OXT-211」、「Aron oxetane OXT-221」以及「Aron oxetane OXT-212」(以上東亞合成股份有限公司製)等。該些氧雜環丁烷類，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。
多元醇類較理想為不存在酚性羥基以外的酸性基者，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。該些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。該些多元醇類，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的接合劑中，可再摻配離子捕捉劑、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、整平劑、塑化劑、消泡劑等添加劑。離子捕捉劑可舉出例如粉末狀的鉍系、銻系、鎂系、鋁系、鈣系、鈦系及該些混合系等的無機化合物，抗氧化劑可舉出例如受阻酚系抗氧化劑等。
於活性能量線硬化型的接合劑可使用作為實質上不含有溶劑成分之無溶劑型接合劑，為了於各種塗佈方式為分別適合的黏度範圍，而可含有用以調整黏度之溶劑。溶劑較理想為使用不降低偏光膜的光學特性、可良好地溶解環氧樹脂組成物者，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。本發明使用之活性能量線硬化型接合劑之黏度例如為5至1000mPa‧s左右的範圍，較理想為10至200mPa‧s，更理想為20至100mPa‧s。
<偏光板之製造方法>
接下來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圖為表示關於本發明的偏光板之製造裝置的一實施態樣的概略圖。
第1圖所示偏光板之製造裝置係沿著輸送方向依序設置：用以於透明薄膜2、3的單面塗佈接合劑之接合劑塗佈裝置11、12；用以貼合透明薄膜2、3與偏光膜1而得積層體4之貼合輥(夾輥)51、52；使積層體4密合之旋轉輥13；設置於相對該旋轉輥13的外圓周面的位置之第1活性能量線照射裝置31、32；復於第1活性能量線照射裝置31、32之輸送方向之下游側設置之第2活性能量線照射裝置16至18；以及輸送用夾輥19。
首先，從卷為捲狀物的狀態連續拉出的透明薄膜2、3的單面，藉由接合劑塗佈裝置11、12塗佈活性能量線硬化型接合劑(接合劑塗佈步驟)。
然後，在卷為捲狀物的狀態連續拉出的偏光膜1的兩面透過接合劑積層塗佈有接合劑之透明薄膜2、3而成為積層體，在將該積層體夾於朝輸送方向旋轉的一對貼合輥51、52間的狀態下，使至少一方之貼合輥朝另一方之貼合輥之方向擠壓並對積層體加以壓力，使偏光膜1與透明薄膜2、3貼合並形成積層體4(貼合步驟)。
然後，在一邊使此積層體4與旋轉輥13之外周面密合一邊輸送的過程中，自第1活性能量線照射裝置31、32向旋轉輥13之外周面照射活性能量線，並使接合劑聚合硬化(第1活性能量線照射步驟)。
另外，配置於輸送方向下游側之第2以後的活性能量線照射裝置16至18係使接合劑完全聚合硬化(第2活性能量線照射步驟)之裝置，依據需要可將之追加/省略。最後，積層體4通過輸送用 夾輥19而作為偏光板捲取於捲取輥20，作為偏光板。以下詳細說明各步驟。
(接合劑塗佈步驟)
對透明薄膜2、3塗佈接合劑之方法無特別限定，但例如可利用刮刀(doctor blade)、線棒、狹縫塗佈法、缺角輪塗佈法(comma coater)、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、廣泛的對應等，接合劑塗佈裝置11、12較理想為冠狀輥。。
於使用冠狀輥作為接合劑塗依裝置11、12並進行接合劑的塗佈之情況，塗佈的接合劑之厚度(塗佈厚度)較理想為約0.1至10 μm，更理想為0.2 μm至4μm。接合劑的塗佈厚度係根據冠狀輥的速度對透明薄膜的線速度(line speed)的比之牽引比調整。一般而言，牽引比(冠狀輥的速度/線速度)調整為0.5至10，可調整接合劑的塗佈厚度為約0.1至10μm。更具體來說，使透明薄膜2、3之線速度為10至100m/分，冠狀輥係與透明薄膜2、3的輸送方向相反方向地旋轉，冠狀輥的速度為5至1000m/分，藉此可調整接合劑的塗佈厚度為約0.1至10μm。
接合劑調製後，通常在15至40℃的範圍內之既定溫度±5℃(例如既定的溫度為30℃的情況則為30℃±5℃)，較理想為±3℃，更理想為調整為±1℃的環境下塗佈。
(貼合步驟)
於本步驟中，於從卷為卷狀物之狀態連續地拉出之偏光膜1的兩面，透過接合劑而積層藉由上述步驟塗佈接合劑之透明薄膜2、3。在該積層體夾於朝輸送方向旋轉的一對貼合輥51、52間的 狀態下，例如將貼合輥51朝貼合輥52的方向擠壓，藉此使偏光膜1與透明薄膜2、3貼合，而形成積層體4。此時，貼合輥間輸送偏光膜係與垂直貼合輥擠壓方向的面成為±3°的範圍內的角度，較理想為±1°的範圍內的角度，特別理想為與垂直擠壓方向的面重疊。藉此，使偏光膜與透明薄膜在貼合輥前接觸而不會產生氣泡。
另外，於第1圖表示於透明薄膜2、3的單面均勻塗佈接合劑，且將透明薄膜2、3的接合劑塗佈面與偏光膜1重疊並藉由貼合輥51、52貼合之方法，但亦可於偏光膜1的兩面均勻塗佈接合劑，且將偏光膜1的接合劑塗佈面與透明薄膜2、3重疊並藉由貼合輥51、52貼合。
貼合輥51、52之材質可舉出金屬輥或表面由橡膠所成之橡膠輥。一對貼合輥51、52之至少一者為具有由橡膠所成之表面且旋轉驅動之橡膠輥。第1圖所示製造裝置中，例如下側之輥52可為橡膠輥。通常，旋轉驅動之橡膠輥之旋轉速度與通過一對貼合輥間之積層體之線速度一致。另一側貼合輥較理想為使用金屬輥，其可與積層體的線動作隨動，或使其旋轉驅動。橡膠輥之旋轉速度例如為10至50m/分。
金屬製輥的母材可使用各種習知的材質，較理想為SUS304，更理想為於金屬製輥的表面實施鉻電鍍處理。此外，橡膠輥之材質無特別限定，但可舉出EPDM，NBR(腈橡膠)、胺甲酸乙酯、泰坦(Titan)、聚矽氧等。橡膠輥之硬度無特別限定，通常為60至100°，更理想為85至95°。另外，橡膠製輥之硬度可用根據JISK6253之硬度計測定。市售的硬度計係例如使用ASKA公司製橡膠硬度 計「A型」等。具體而言，係用棒狀物按壓表面時，以硬度計測定橡膠輥的表面阻力。
因金屬輥與橡膠輥擠壓施加於積層體之壓力，較理想為富士軟片製兩片式按壓箱(超低壓用)之瞬間壓力為0.5至3.0MPa，更理想為0.7至2.3MPa。貼合輥51、52之直徑無特別限定，通常為50至400mm。此外，二隻(一對)貼合輥51、52之直徑可為相同或相異。
(第1活性能量線照射步驟)
旋轉輥13之外圓周面係構成為鏡面之凸曲面，其表面一邊與積層體4密接，一邊輸送，並在該過程藉由活性能量線照射裝置31、32使接合劑聚合硬化。只要使接合劑聚合硬化並使積層體4充分密接，則旋轉輥13的直徑無特別限制。旋轉輥13以比一對貼合輥51、52之旋轉驅動之橡膠輥之旋轉速度更快之旋轉速度而驅動。一對貼合輥51、52之旋轉驅動之橡膠輥之旋轉速度為100時，旋轉輥13之旋轉速度較理想為100.1以上且為102.0以下，更理想為100.1至101.5。未達100.1時積層體容易發生波浪捲曲。另一方面，超過102.0時薄膜與輥之間有滑動並產生損傷等之可能性。
旋轉輥13之旋轉速度為例如10至50m/分。旋轉輥13之旋轉速度不需控制為一定，例如可對應薄膜之種類與輥表面之滑性等，一邊確認波浪板狀彎曲的發生狀況一邊適宜地控制。
此外，在藉由照射活性能量線而聚合硬化時，旋轉輥13可作用為用以使積層體4產生之熱放熱之冷卻輥。此時，冷卻輥之表面溫度為較理想為設定為4至30℃。
以活性能量線的照射進行接合劑的聚合硬化所使用的光源無 特別限制，但較理想為具有波長400 nm以下的發光分佈之光源。如此的光源可舉出例如低壓水銀燈、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。第1活性能量線照射步驟中，活性能量線的照射較理想為分成複數次進行。第1圖中係表示將活性能量線的照射分2次進行，亦即沿著積層體之輸送方向配置有2個光源(活性能量線照射裝置31、32)。
對活性能量線硬化型接著劑之光照射強度由每一接合劑的組成決定，無特別限制，較理想為10至5000mW/cm2。對樹脂組成物之光照射強度未達10mW/cm2時，反應時間變得太長，超過5000mW/cm2時，則因從燈輻射之熱及組成物聚合時的發熱而可能產生接合劑的構成材料之環氧樹脂組成物等的黃變、偏光膜的劣化。再者，照射強度較理想為可使光陽離子聚合起始劑活性化的波長區域之強度，更理想為波長400nm以下之波長區域之強度，又更理想為波長280至320nm之波長區域之強度。
活性能量線為紫外線之情況，對積層體4照射活性能量線之步驟中，較理想為於積層體4之長度方向(輸送方向)一邊施加100至800N/m之張力，一邊以使照射時間為0.1秒以上的線速度而輸送積層體4。
(第2活性能量線照射步驟)
活性能量線照射裝置31、32之活性能量線的累積光量為不充分的情況，較理想為進一步設置第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而促進積層體4的接合劑之硬化。加上第1活性能量線照射步驟，全步驟之累積光量設定為 10mJ/cm2以上，特別較理想為10至5,000mJ/cm2。對上述接合劑之累積光量未達10mJ/cm2時，來自起始劑的活性種的發生不充份，使接合劑之硬化變得不充分。另一方面當累積光量超過5000mJ/cm2時，照射時間變得非常長，不利於提高生產性。此時，隨著使用的薄膜、接合劑種類的組合等，所需之何種波長區域(UVA(320至390nm)或UVB(280至320nm)等)的累積光量也不同。
為了確實進行偏光板(積層體)端部之接合劑的硬化，可舉例如將無電極D燈泡之FUSION製「Light Hammer10」，以相對薄膜的移動而橫跨之方式而排列的方法等。
活性能量線硬化型樹脂硬化之比例，亦即反應率，較理想為90%以上，更理想為95%以上。
(偏光板卷取步驟)
捲繞積層體(偏光板)4之張力為30 N/cm2至150 N/cm2。較理想為30 N/cm2至120 N/cm2。未達30 N/cm2時，由於移動長條的捲狀物時會引起捲繞差異，所以不理想。大於150 N/cm2的情況，捲繞緊張度強而容易產生鬆弛。
另外，由於卷取長度愈長則在相同張力愈容易引起捲取緊張(拉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。即使在如此所謂漸低地降低張力之方法中，此時的張力為150N/cm2以下。
捲取於捲芯之偏光板的長度無特別限制，較理想為100 m以上4000 m以下。
圓筒狀的捲芯之直徑較理想為6吋至12吋。捲芯之直徑愈大愈好，更理想為11英吋、12英吋等，惟進一步地過大時則難以 移動及保管。
因在無塵室使用，故圓筒狀的捲芯之材質只要是其自體發塵困難，並可確保在適當的強度下捲取寬度寬的偏光板則無特別限制，但可選擇FRP(玻璃纖維強化塑膠)等。
[實施例]
以下舉出實施例更詳細地說明本發明，但本發明不限於該些實施例。
[實施例1] (偏光膜之製作)
聚乙烯醇的原料薄膜係使用聚合度2400、皂化度99.9莫耳%、厚度75μm、寬3000mm之長條聚乙烯醇薄膜「OPL薄膜M-7500(日本合成製)」。對處理槽前後的驅動夾輥賦予圓周速度差而進行延伸。
首先，以使原料薄膜不鬆弛之方式保持薄膜的緊張狀態，於放入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，入口與出口的輥速度比為1.2。在夾輥進行除水後，於放入30℃的純水之水浸漬槽中浸漬160秒。在該槽中，機械方向的延伸倍率為1.09倍。
然後，浸漬於放入碘/碘化鉀/水之重量比為0.02/2.0/100的水溶液之染色槽，同時以延伸倍率約1.5倍進行單軸延伸。然後，在放入碘化鉀/硼酸/水之重量比為12/3.7/100的水溶液之硼酸槽中，於55.5℃浸漬130秒，同時進行單軸延伸使原料的累積延伸倍率成為5.7倍為止。然後，在放入碘化鉀/硼酸/水之重量比為9/2.4/100的水溶液之硼酸槽中，於40℃浸漬60秒。
進一步地，於水洗槽以8℃的純水進行洗淨約16秒，然後依序通過約60℃的乾燥爐、約85℃的乾燥爐，在該些乾燥爐的滯留時間合計為160秒而進行乾燥。如此而得碘吸附配向之厚度28μm的偏光膜。
(偏光板之製作)
準備作為透明薄膜之厚度40μm的賦予相位差特性之乙酸纖維素系樹脂薄膜「KC4FR-1(Konica Minolta Opto股份有限公司製)」以及厚度80μm之三乙醯纖維素薄膜「KC8UX2MW」(Konica Minolta Opto公司製)。
使用如上述般準備之偏光膜與透明薄膜，藉由第1圖所示裝置製作偏光板。首先，於上述賦予相位差特性之乙酸纖維素系樹脂薄膜「KC4CR-1」之單面，使用接合劑塗佈裝置(Micro Chamber Doctor：富士機械公司製)塗佈紫外線硬化型接合劑之環氧樹脂樹脂組成物「KR系列」(ADEKA公司製)。此外，於上述三乙醯纖維素薄膜「KC8UX2MW」之單面，使用相同之接合劑塗佈裝置塗佈紫外線硬化型接合劑之環氧樹脂樹脂組成物「KR系列」(ADEKA公司製)。此時，接合劑塗佈裝置中，偏光膜積層體之線速度為25m/分，使乙酸纖維素系樹脂薄膜「KC4CR-1」上之接合劑層之厚度約4.0μm，三乙醯纖維素薄膜、「KC8UX2MW」上之接合劑層之厚度約3.3μm(合計約7.3μm)。
接著，以使上述偏光膜之兩面與上述乙酸纖維素系樹脂薄膜「KC4CR-1」、三乙醯纖維素薄膜「KC8UX2MW」接合之方式，於驅動旋轉之橡膠輥與金屬輥之間輸送夾壓，並透過上述環氧樹脂組成物(紫外線硬化型接合劑)貼合(貼合步驟)。
將貼合上述2種透明薄膜之偏光膜，於長度方向施加600N/m之張力，並一邊與冷卻輥密合一邊以線速度(line speed)25m/分移動，通過於來自2盞金屬鹵化物燈(GS-YUASA公司製，1盞之電力量為130W/cm)照射之紫外線而進行第1活性能量線照射步驟，並通過來自其後設置之3盞無電極D燈泡(Fusion公司製「Light Hammer10」，1盞之電力量為216mW/cm)照射紫外線而進行第2活性能量線照射步驟，並製作偏光板。
上述3盞無電極D燈泡，係將排列於薄膜的寬度方向之6台無電極D燈泡所構成的單元於薄膜的長度方向配置成3列者。
通過金屬鹵化物燈時，將貼合於上述薄膜之三乙醯纖維素薄膜「KC8UX2MW」與設定為23℃之冷卻輥之外周面接觸，並由乙酸纖維素系樹脂薄膜「KC4CR-1」側照射紫外線。貼合步驟中驅動旋轉之橡膠輥之旋轉速度設為25.00m/分，冷卻輥之旋轉速度設為25.23m/分。亦即，橡膠輥之旋轉速度為100時，冷卻輥之旋轉速度為100.9。
本實施例之第1活性能量線照射步驟以及第2活性能量線照射步驟合計之累積光量為468mJ/cm2。在此之累積光量為波長280至320nm之波長區域(UVB)中，根據光照射強度測定器(FusionUV公司製UV Power PuckII)所得之測定值。
(外觀評價)
如上述製作之實施例1之偏光板中，對著螢光燈藉由反射檢查觀察外觀時，未確認到波浪板狀彎曲的發生。
[實施例2]
除了透明薄膜使用厚度60μm之環烯烴系樹脂薄膜「ZEONOR」 (日本ZEON股份有限公司製)取代乙酸纖維素系樹脂薄膜「KC4CR-1」之點以外，以相同於實施例1之方式製作實施例2之偏光板。
(外觀評價)
如上述製作之實施例2之偏光板中，以相同於實施例1之方式觀察外觀時，未確認到波浪板狀彎曲的發生。
[實施例3]
透明薄膜係使用厚度25μm之環烯烴系樹脂薄膜「ZEONOR」(日本ZEON股份有限公司製)取代乙酸纖維素系樹脂薄膜「KC4CR-1」、使用厚度25μm之三乙醯纖維素薄膜「K2UAW」(Konica Minolta Opto公司製)取代三乙醯纖維素薄膜「KC8UX2MW」，並使貼合步驟中驅動旋轉之橡膠輥之旋轉速度設為25.00m/分，冷卻輥之旋轉速度設為25.08m/分。亦即，橡膠輥之旋轉速度為100時，冷卻輥之旋轉速度為100.3。除了該等點以外，以相同於實施例1之方式製作實施例3之偏光板。
(外觀評價)
如上述製作之實施例3之偏光板中，以相同於實施例1之方式觀察外觀時，未確認到波浪板狀彎曲的發生。
[實施例4]
透明薄膜係使用厚度50μm之環烯烴系樹脂薄膜「ZEONOR」(日本ZEON股份有限公司製)取代乙酸纖維素系樹脂薄膜「KC4CR-1」、使用厚度60μm之三乙醯纖維素薄膜「TD60UL」(富士軟片股份有限公司製)取代三乙醯纖維素薄膜「KC8UX2MW」，並使貼合步驟中驅動旋轉之橡膠輥之旋轉速度設為25.00m/分，冷 卻輥之旋轉速度設為25.28m/分。亦即，橡膠輥之旋轉速度為100時，冷卻輥之旋轉速度為101.1。除了該等點以外，以相同於實施例1之方式製作實施例4之偏光板。
(外觀評價)
如上述製作之實施例4之偏光板中，以相同於實施例1之方式觀察外觀時，未確認到波浪板狀彎曲的發生。
[實施例5]
除了設定使相對於貼合步驟中驅動旋轉之橡膠輥之旋轉速度100時，冷卻輥之旋轉速度為102.2以外，以相同於實施例1之方式製作偏光板。
(外觀評價)
如上述製作之實施例5之偏光板中，觀察外觀時雖然未確認到波浪板狀彎曲的發生，但卻確認到擦傷的發生。
[比較例1]
除了使相對於貼合步驟中驅動旋轉之橡膠輥之旋轉速度100時，冷卻輥之旋轉速度為100，亦即旋轉速度為相同之點以外，以相同於實施例1之方式製作比較例1之偏光板。
(外觀評價)
如上述製作之比較例1之偏光板中，觀察外觀時確認到波浪板狀彎曲的發生。
[產業上之利用可能性]
本發明之偏光板係可有效適用於以液晶顯示裝置為首之各種顯示裝置。
1‧‧‧偏光膜
2、3‧‧‧透明薄膜
4‧‧‧積層體(偏光板)
11，12‧‧‧接合劑塗佈裝置
13‧‧‧旋轉輥(冷卻輥)
16、17、18、31、32‧‧‧活性能量線照射裝置
19‧‧‧輸送用夾輥
20‧‧‧卷取輥
51、52‧‧‧貼合輥

Claims (3)

  1. 一種偏光板之製造方法，該偏光板係將透明薄膜貼合於偏光膜的單面或兩面而成，該製造方法依順序具備：於前述透明薄膜之單面、或是前述偏光膜之單面或兩面，塗佈活性能量線硬化型接合劑之接合劑塗佈步驟；將前述透明薄膜透過前述接合劑積層於前述偏光膜的單面或兩面所構成的積層體夾於向輸送方向旋轉的一對貼合輥間，並對前述積層體施加壓力，藉此貼合前述透明薄膜與前述偏光膜之貼合步驟；以及前述積層體與向輸送方向旋轉之旋轉輥為密合之狀態下輸送時，對前述積層體照射活性能量線並硬化前述接合劑之第1活性能量線照射步驟；其中，前述一對貼合輥之至少一者為具有由橡膠所成之表面且旋轉驅動之橡膠輥，且前述旋轉輥之旋轉速度比前述橡膠輥之旋轉速度快。
  2. 如申請專利範圍第1項所述之偏光板之製造方法，其中，前述旋轉輥係冷卻輥。
  3. 如申請專利範圍第1或2項所述之偏光板之製造方法，其中，前述橡膠輥之旋轉速度為100時，前述旋轉輥之旋轉速度為100.1以上且為102.0以下。
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