WO2013146708A1 - 光学用成形体 - Google Patents
光学用成形体 Download PDFInfo
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- WO2013146708A1 WO2013146708A1 PCT/JP2013/058639 JP2013058639W WO2013146708A1 WO 2013146708 A1 WO2013146708 A1 WO 2013146708A1 JP 2013058639 W JP2013058639 W JP 2013058639W WO 2013146708 A1 WO2013146708 A1 WO 2013146708A1
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- styrene
- conjugated diene
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Classifications
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F297/00—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer
- C08F297/02—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the anionic type
- C08F297/04—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the anionic type polymerising vinyl aromatic monomers and conjugated dienes
- C08F297/044—Macromolecular compounds obtained by successively polymerising different monomer systems using a catalyst of the ionic or coordination type without deactivating the intermediate polymer using a catalyst of the anionic type polymerising vinyl aromatic monomers and conjugated dienes using a coupling agent
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2353/00—Characterised by the use of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- C08J2353/02—Characterised by the use of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers of vinyl aromatic monomers and conjugated dienes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L53/02—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
Definitions
- the present invention relates to an optical molded body.
- a polymer material having both heat resistance, flexibility, and transparency is assumed to be used, for example, as an optical molded body.
- Optical molded bodies with controlled optical anisotropy are used for liquid crystal display elements, electroluminescence elements, and the like.
- optical films there are many types of optical molded bodies.
- an optical film there is a film called a retardation film that plays a role of compensating for a phase difference of a liquid crystal of a liquid crystal display or improving a viewing angle.
- the retardation film those having positive orientation birefringence such as polycarbonate and amorphous cyclic polyolefin have been generally used.
- a further improvement in viewing angle can be achieved by laminating a film having negative orientation birefringence with a film having positive orientation birefringence.
- Patent Document 1 there is known a method of forming an optical molded article having impact resistance by block copolymerization of a styrene monomer and a conjugated diene monomer.
- examples of the block copolymer of a heat-resistant styrene monomer and a conjugated diene monomer include ⁇ -methylstyrene and a conjugated diene monomer such as those disclosed in Patent Documents 2, 3, and 4, for example.
- block copolymers of ⁇ -methylstyrene and styrene and a conjugated diene monomer such as those disclosed in Non-Patent Document 1 are known.
- JP 2006-283010 A Japanese Patent Laid-Open No. 2003-73433 JP 2003-73434 A JP 2009-84458 A L. H. Tung et al., Ance “Advances in Elastomers and Rubber Elasticity”, Lal, J. etc .; Plenum: New York, 1986, p129-142
- Patent Document 1 has no description regarding heat resistance, and is considered to be insufficient in heat resistance as an optical molded article.
- Patent Documents 2, 3, and 4 do not mention control of the phase difference expression.
- the thermal stability is low and the molding by melting cannot be tolerated.
- the vinyl bond amount of the conjugated diene monomer increases to make an optical molded body, and the appearance is not good.
- Non-Patent Document 1 does not mention control of the phase difference expression.
- An object of the present invention is to provide an optical molded article that has heat resistance, flexibility, and transparency and solves at least one of the above-mentioned conventional problems.
- the present invention provides an optical molded article having good appearance, thermal stability, and retardation development property and low photoelastic birefringence. It is another object of the present invention to provide an optical molded body suitable for obtaining a stretched film exhibiting negative orientation birefringence.
- a polymer block A comprising an ⁇ -methylstyrene unit and a styrene unit and having a glass transition temperature of 115 to 145 ° C. measured by DSC (differential scanning calorimeter), and a conjugated diene unit A block structure ABA or (AB) mX (wherein X is a residue of a coupling agent and m is an integer of 2 or more) comprising a polymer block B having 40 to 85% by volume of (a), component (b) of block structure AB and component (c) of block structure A in a total of 15 to 60% by volume, respectively, and components (a), (b) and The total of the total of (c) has a number average molecular weight of 50,000 or more, the sum of ⁇ -methylstyrene units and styrene units is 35 to 85 mol%, conjugated diene units are 15 to 65 mol%, conjugated diene units 15 ⁇
- the conjugated diene unit is, for example, a 1,3-butadiene unit.
- the optical molded body is, for example, a film having a thickness of 10 to 300 ⁇ m, such as a melt-extruded film.
- the optical molded body is a stretched film, particularly a retardation film.
- a polymer block A comprising an ⁇ -methylstyrene unit and a styrene unit and having a glass transition temperature of 115 to 145 ° C. measured by DSC (differential scanning calorimeter), and a conjugated diene A block structure ABA or (AB) mX (wherein X is a residue of a coupling agent and m is an integer of 2 or more) comprising a polymer block B having units Component (a) has a volume of 40 to 85% by volume, component (b) of block structure AB and component (c) of block structure A has a total of 15 to 60% by volume, and components (a) and (b) And (c) as a whole, the number average molecular weight is 50,000 or more, the sum of ⁇ -methylstyrene units and styrene units is 35 to 85 mol%, conjugated diene units are 15 to 65 mol%, conjugated diene units 15 to 65 mo
- the optical molded body of the present invention has good heat resistance, flexibility, transparency, appearance, thermal stability, and low photoelastic double-fold, and in particular, a retardation film, a polarizing film protective film, and a viewing angle improvement. It can be suitably used for a film, a polarizing film, an antireflection film and the like. Especially, since the retardation development property of negative birefringence is favorable, it can use especially suitably for the retardation film which shows negative orientation birefringence.
- An optical molded article according to an embodiment of the present invention has a block structure ABA or (AB) mX (where X is a residue of a coupling agent and m is an integer of 2 or more). And a block copolymer composition containing the component (a) of the above and the component (b) of the block structure AB and / or the component (c) of the block A.
- the polymer block A comprises ⁇ -methylstyrene units and styrene units, and has a glass transition temperature of 115 to 145 ° C. measured by DSC.
- the polymer blocks A may have a mixture of glass transition temperatures and molecular weights different from each other, or may be the same.
- the glass transition temperature can be raised to 115 ° C. or higher, and heat resistance can be obtained.
- the depolymerization seen in the ⁇ -methylstyrene homopolymer can be prevented, so that thermal stability can be obtained.
- the glass transition temperature can be controlled by adjusting the respective amounts charged in the polymerization of ⁇ -methylstyrene and styrene.
- the glass transition temperature was measured by DSC under the following measurement conditions.
- Polymer block B is a polymer block having a conjugated diene monomer unit.
- the polymer block B may be a mixture of monomer units having different types, ratios, and molecular weights, or may be the same.
- Examples of the conjugated diene compound constituting the conjugated diene unit in the polymer block B include 1,3-butadiene, isoprene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene, 1,3-hexadiene, and the like. These compounds may be used alone or in combination of two or more. Among these, 1,3-butadiene can be preferably used.
- Other monomer units may be present in the polymer block B.
- styrene monomer units are preferable, and styrene is more preferable.
- the amount of the other monomer unit is preferably 50% by mass or less because film strength can be secured. These may be introduced into the polymer block B in a random or tapered manner.
- the block copolymer composition of the present invention comprises a component of a block structure ABA or (AB) mX (where X is a residue of a coupling agent and m is an integer of 2 or more) ( 40% by volume to 85% by volume of a), and the component (b) of the block structure AB and the component (c) of the block structure A are included in a total amount of 15% by volume to 60% by volume. Flexibility can be ensured by setting the component (a) to 40% by volume or more and the components (b) and (c) to 60% by volume or less in total. Moreover, on the polymerization technique, the component (a) is 85% by volume or less, and the sum of the component (b) and the component (c) is 15% by volume or more.
- the number average molecular weight (Mn) is 50000 or more for the whole of the components (a), (b) and (c). Flexibility can be secured by setting Mn to 50000 or more.
- Mn of the present invention is Mn in terms of polystyrene measured by gel permeation chromatography (hereinafter referred to as GPC), and was measured under the following measurement conditions.
- Equipment Shimadzu GPC system (LC-20AD, CBM-20A, RID-10A, SPD-M20A, CTO-20A, SIL-20A HT , DGU-20A 3 connected)
- Detector RI (differential refractive index)
- Developing solvent Chloroform Concentration: 1% by mass
- Calibration curve Standard polystyrene (Shodex Standard SM-105)
- the attribution of each peak of components (a), (b) and (c) can be made by comparison with the measurement results of the samples collected in the process of synthesizing each component, and the volume ratio of each component Can be calculated from the respective peak area ratios.
- the total of the components (a), (b) and (c) is 35 to 85 mol% in total of ⁇ -methylstyrene units and styrene units, 15 to 65 mol% in conjugated diene units, conjugated diene.
- the 1,4-bond amount is 15 to 50 mol%
- the vinyl bond amount is 15 mol% or less. Flexibility can be ensured by setting the amount of 1,4-bond in 15 to 65 mol% of the conjugated diene unit to 15 mol% or more, and retardation development can be ensured by setting it to 50 mol% or less.
- By setting the vinyl bond amount of the conjugated diene unit to 15% or less, flexibility can be ensured, generation of gel can be suppressed, and good appearance can be secured.
- the polymerization of the block copolymer of the present invention is preferably by a production method having the steps (1), (2), (3-1), or (1), (2), (3-2): ⁇ Process (1) ⁇ -methylstyrene is mixed with a nonpolar solvent, and an organic lithium compound is used as an initiator, and polymerization is performed at a temperature of 0 to 60 ° C. while continuously adding styrene to form a living copolymer composed of block structure A.
- Process / Process (2) A process in which a conjugated diene is added to a living copolymer composed of block structure A at a temperature of 60 ° C. or lower and polymerized at a temperature of 30 to 70 ° C.
- Step (3-1) The living copolymer consisting of block structure AB is mixed by mixing ⁇ -methylstyrene with the living copolymer consisting of block structure AB and polymerizing at a temperature of 0-60 ° C. while continuously adding styrene.
- Process and process for forming polymer (3-2) A step of performing coupling by adding a coupling agent to a living copolymer having a block structure AB at a temperature of 30 ° C. or higher.
- nonpolar solvent examples include aliphatic hydrocarbons such as cyclohexane, methylcyclohexane, n-hexane, and n-heptane, and aromatic hydrocarbons such as benzene, toluene, and xylene. These may be used alone or in combination of two or more.
- a small amount of a polar compound may be dissolved in a solvent in order to improve the efficiency of the initiator.
- the polar compounds include ethers such as tetrahydrofuran, diethylene glycol dimethyl ether and diethylene glycol dibutyl ether, amines such as triethylamine and tetramethylethylenediamine, thioethers, phosphines, phosphoramides, alkyl benzene sulfonates, potassium and sodium alkoxides.
- the preferred polar compound is tetrahydrofuran.
- the addition amount of the polar compound is preferably 500 ppm or less with respect to the nonpolar solvent because the vinyl bond amount of the conjugated diene unit can be suppressed.
- Examples of the organic lithium compound used in step (1) include lithium compounds such as n-butyllithium, sec-butyllithium and tert-butyllithium. These compounds may be used alone or in combination of two kinds. You may use above.
- the amount of the organic lithium compound used can be appropriately determined depending on the molecular weight of the desired polymer to be obtained by anionic polymerization.
- the minimum amount of organolithium compound that develops color of ⁇ -methylstyryl anion is added, and factors that deactivate the anion such as moisture, air, polymerization inhibitor, etc. in nonpolar solvent and ⁇ -methylstyrene in advance are added. It is preferable to add an organolithium compound to be used for the initiation reaction after inactivation.
- step (1) the flow rate of styrene may be changed every time.
- the polymerization temperature in step (1) is preferably 0 to 60 ° C.
- the polymerization temperature in step (1) is preferably 0 to 60 ° C.
- the polymerization rate of ⁇ -methylstyrene and styrene can be secured.
- the polymerization temperature is set to 60 ° C. or lower, it is possible to suppress the deactivation reaction at the terminal of the living copolymer to be generated, and to secure the content of the target component (a).
- step (2) it is preferable to add conjugated diene at a temperature of 60 ° C. or lower and polymerize at a temperature of 30 ° C. or higher.
- the temperature at which the conjugated diene is added 60 ° C. or less, it is possible to suppress the deactivation reaction at the end of the living copolymer to be produced.
- the polymerization temperature 30 ° C. or higher, the polymerization rate of the conjugated diene can be ensured.
- the polymerization temperature in step (3-1) is preferably 0 to 60 ° C.
- the polymerization rate of ⁇ -methylstyrene and styrene can be secured.
- the terminal of the living copolymer to be generated can suppress the deactivation reaction.
- the block copolymer having the block structure ABA is blocked.
- a polymer can be obtained.
- step (3-2) a coupling agent is added to obtain a block copolymer having a block structure (AB) mX.
- the block structure AB before coupling may be one type or a mixture of 2 types or more and m types or less.
- the coupling agent to be added a bifunctional coupling agent may be used or a polyfunctional coupling agent may be used. A plurality of types of coupling agents may be used in combination.
- the coupling agent preferably used in the present invention includes chlorosilane compounds such as silicon tetrachloride and 1,2-bis (methyldichlorosilyl) ethane, alkoxysilane compounds such as tetramethoxysilane and tetraphenoxysilane, and the like.
- Examples include tin chloride, polyhalogenated hydrocarbons, carboxylic acid esters, polyvinyl compounds, epoxidized fats and oils such as epoxidized soybean oil and epoxidized linseed oil, and epoxidized soybean oil is particularly preferred.
- the reaction temperature of the coupling agent is preferably 30 ° C. or higher because the reaction rate can be secured.
- the block copolymer composition includes a heat resistant stabilizer such as a hindered phenol compound, a lactone compound, a phosphorus compound, and a sulfur compound, and a light resistant stabilizer such as a hindered amine compound and a benzotriazole compound.
- a heat resistant stabilizer such as a hindered phenol compound, a lactone compound, a phosphorus compound, and a sulfur compound
- a light resistant stabilizer such as a hindered amine compound and a benzotriazole compound.
- Additives such as lubricants, plasticizers, colorants, antistatic agents and mineral oils may be included. The addition amount is preferably less than 1 part by mass with respect to 100 parts by mass of the copolymer resin.
- the block copolymer composition is molded into an optical molded body.
- a known molded body such as an injection molded body, a sheet or a film can be used, but it is preferably molded into a film having a thickness of 10 to 300 ⁇ m.
- a method for forming a film having such a thickness is not particularly limited, but a method of melt extrusion using a film extruder is preferred.
- the film molded as the molded article of the present invention can be used for known optical film applications such as retardation films, antireflection films, and liquid crystal protective films.
- the film molded as the molded body of the present invention can be stretched and oriented by a known method.
- the stretched and oriented film generates negative orientation birefringence, and is most preferable for use as a retardation film.
- ⁇ Measurement method> (1) Method for Determining the Composition of Monomer Units Determined by the proton nuclear magnetic resonance ( 1 H-NMR) method.
- the signal shift positions necessary for quantification are as follows. Since the shift position may move depending on the solvent, temperature measurement conditions, and polymer structure, appropriate assignment is made for the entire monomer unit contained in the block copolymer composition.
- (B) 5.0 to 5.6 ppm 1,2-vinyl group (—CH ⁇ ) and butadiene 1,4-bond (double bond in the main chain) (—CH ⁇ ) by butadiene vinyl bond. It contains 1H per 1,2-vinyl group unit by vinyl bond and 2H per 1,4-bond unit.
- Example 1 (1) To a reaction vessel having a volume of 50 L, 17 kg of cyclohexane containing 150 ppm of tetrahydrofuran was added, and 5400 g of ⁇ -methylstyrene was added. (2) Next, a cyclohexane solution containing 10% by mass of n-butyllithium (initiator) was gradually added, and 50 mL was further added and the temperature was raised to 40 ° C. from the time when the color development of ⁇ -methylstyryl anion was observed. (3) While maintaining the internal temperature of the container at 40 ° C., 650 g of styrene was charged and added at a speed of 650 g / h.
- the polymerization liquid was supplied to a twin screw extruder with a vent and devolatilized to obtain a block copolymer composition.
- a 100 ⁇ m-thick film was extruded from this block copolymer composition at a cylinder temperature of 240 ° C. and a die temperature of 240 ° C. using a film extruder equipped with a T-die, and wound on a roll.
- the resulting melt-extruded film was uniaxially stretched 2.5 times at a glass transition temperature of + 10 ° C. using a tenter transverse stretching machine to obtain a stretched film.
- Table 1 shows the measurement results of the obtained block copolymer composition, melt-extruded film, and stretched film.
- Example 2 5500 g of ⁇ -methylstyrene, 750 g of styrene was added at a feed rate of 750 g / h in Step (3) of Example 1, 520 g of styrene was added at a feed rate of 520 g / h in Step (4) of Example 1, and 520 g of butadiene was added.
- a block copolymer composition, a melt-extruded film, and a stretched film were obtained in the same manner as in Example 1 except that. These measurement results are shown in Table 1.
- Example 3 4800 g of ⁇ -methylstyrene, 560 g of styrene was added at a feed rate of 560 g / h in Step (3) of Example 1, 390 g of styrene was added at a feed rate of 390 g / h in Step (4) of Example 1, and 1400 g of butadiene was added.
- a block copolymer composition, a melt-extruded film, and a stretched film were obtained in the same manner as in Example 1 except that. These measurement results are shown in Table 1.
- Example 4 5800 g of ⁇ -methylstyrene, 430 g of styrene were added at a charging rate of 430 g / h in Step (3) of Example 1, 300 g of styrene was added at a charging rate of 300 g / h in Step (4) of Example 1, and 750 g of butadiene was added.
- a block copolymer composition, a melt-extruded film, and a stretched film were obtained in the same manner as in Example 1 except that. These measurement results are shown in Table 1.
- Example 5 5,000 g of ⁇ -methylstyrene, 870 g of styrene was added at a feed rate of 870 g / h in step (3) of Example 1, 600 g of styrene was added at a feed rate of 600 g / h in step (4) of Example 1, and 760 g of butadiene was added.
- a block copolymer composition, a melt-extruded film, and a stretched film were obtained in the same manner as in Example 1 except that. These measurement results are shown in Table 1.
- Example 6 In Example 1 (1), a cyclohexane solution (initiator) containing 10% by mass of n-butyllithium was gradually added, and 72 mL was further added from the time when the color development of ⁇ -methylstyryl anion was observed. A block copolymer composition, a melt-extruded film and a stretched film were obtained in the same manner as in Example 1 except that the bean oil was changed to 7.8 g. These measurement results are shown in Table 1.
- Example 7 (1) To a reaction vessel having a volume of 50 L, 17 kg of cyclohexane containing 150 ppm of tetrahydrofuran and 5400 g of ⁇ -methylstyrene were added. (2) Next, a cyclohexane solution (initiator) containing 10% by mass of n-butyllithium was gradually added until color formation of ⁇ -methylstyryl anion was confirmed, and then 25 mL was further added and the temperature was raised to 40 ° C. (3) While maintaining the internal temperature of the container at 40 ° C., 650 g of styrene was charged and added at a speed of 650 g / h.
- Table 1 shows the measurement results of the obtained block copolymer composition, melt-extruded film, and stretched film.
- Example 3 A block copolymer composition, a melt-extruded film and a stretched film were obtained in the same manner as in Example 1 except that 7 kg of tetrahydrofuran, 10 kg of cyclohexane and 5400 g of ⁇ -methylstyrene were added in the step (1) of Example 1. . The measurement results are shown in Table 2.
- Example 4 A block copolymer composition, a melt-extruded film, and stretched in the same manner as in Example 1 except that 100 mL of a cyclohexane solution (initiator) containing 10% by mass of n-butyllithium and 10.8 g of epoxidized soybean oil were added. A film was obtained. The measurement results are shown in Table 2.
- Example 5 A block copolymer composition, a melt-extruded film, and a stretched film were obtained in the same manner as in Example 1 except that epoxidized soybean oil was not added. The measurement results are shown in Table 2.
- Table 2 shows the measurement results of the obtained block copolymer composition, melt-extruded film, and stretched film.
- melt-extruded film was observed using an image processing apparatus (LUZEX SE manufactured by Nireco), and the quality was judged according to the following criteria. “Excellent” and “Good” were accepted. “Excellent”: 0 film defects with a length of 50 ⁇ m or more / m 2 “Good”: 1 to 4 film defects with a length of 50 ⁇ m or more / m 2 “Not possible”: Film defects with a length of 50 ⁇ m or more are 5 pieces / m 2 or more.
- film defects appear to be uneven with the surroundings due to foreign matters, unmelted spots, etc. Refers to the part.
- the photoelastic coefficient C dRe (f) / df ⁇ w Therefore, it calculated by calculating
- the phase difference measuring device used was KOBRA-WR manufactured by Oji Scientific Co., Ltd., and stress was applied by a digital force gauge Z2S-DPU-50N manufactured by Imada. A photoelastic coefficient having an absolute value of 5 ⁇ 10 ⁇ 12 1 / Pa or less was accepted.
- the optical molded body of the present invention has good heat resistance, flexibility, transparency, appearance, thermal stability and low photoelastic birefringence, in particular, a retardation film, a polarizing film protective film, a viewing angle improving film It can be suitably used for polarizing films, antireflection films and the like. Especially, since the retardation development property of negative birefringence is favorable, it can use especially suitably for the retardation film which shows negative orientation birefringence.
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Abstract
Description
一態様では、本発明は、外観、熱安定性、位相差発現性が良好で、光弾性複屈折の低い光学用成形体を提供するものである。また、負の配向複屈折性を示す延伸フィルムを得るのに適した光学用成形体を提供することを目的とする。
重合体ブロックAは、α-メチルスチレン単位及びスチレン単位からなり、DSCから測定されるガラス転移温度が115~145℃である。重合体ブロックAはガラス転移温度や分子量がそれぞれ互いに異なっているものが混合していてもよく、また、同一であってもよい。スチレンにα-メチルスチレンを共重合することで、ガラス転移温度を115℃以上にすることが可能となり、耐熱性が得られる。ガラス転移温度145℃以下とすることでα-メチルスチレン単独重合体で見られる解重合が防げるので、熱安定性が得られる。ガラス転移温度は、α-メチルスチレンとスチレンとの重合においてそれぞれの仕込量を調節することで制御できる。
ここで、ガラス転移温度は、下記の測定条件でDSCによって測定した。
装置名:セイコーインスツルメンツ(株)社製 Robot DSC6200
測定条件:昇温速度10℃/分、窒素気流下
装置:島津製GPCシステム(LC-20AD,CBM-20A,RID-10A,SPD-M20A,CTO-20A,SIL-20AHT、DGU-20A3を接続したもの)
カラム:昭和電工Shodex GPC KF-404HQ、KF-402.5HQの2本を直列接続
測定温度:40℃
検出器:RI(示差屈折率)
展開溶媒:クロロホルム
濃度:1質量%
検量線:標準ポリスチレン(Shodex Standard SM-105)
成分(a)、(b)及び(c)の各ピークの帰属は、各成分を合成する途中の工程において採取したサンプルの測定結果との比較によって行うことができ、また、各成分の体積比は、それぞれのピーク面積比から算出することができる。
本発明のブロック共重合体の重合は、工程(1)、(2)、(3-1)、もしくは(1)、(2)、(3-2)を有する製造方法によるのが好ましい:
・工程(1)
非極性溶媒にα-メチルスチレンを混合し、有機リチウム化合物を開始剤として用い、スチレンを連続的に加えながら0~60℃の温度で重合させてブロック構造Aからなるリビング共重合体を形成する工程
・工程(2)
ブロック構造Aからなるリビング共重合体に対し、60℃以下の温度で共役ジエンを加え、30~70℃の温度にて重合させてブロック構造A-Bからなるリビング共重合体を形成する工程
・工程(3-1)
ブロック構造A-Bからなるリビング共重合体に対し、α-メチルスチレンを混合し、スチレンを連続的に加えながら0~60℃の温度で重合させてブロック構造A-B-Aからなるリビング共重合体を形成する工程
・工程(3-2)
ブロック構造A-Bからなるリビング共重合体に対し、30℃以上の温度でカップリング剤を添加しカップリングを行う工程
有機リチウム化合物の使用量は、アニオン重合により得ようとする所望の重合体の分子量によって適宜決定することができる。また、α-メチルスチリルアニオンの発色がみられる最少量の有機リチウム化合物を添加し、非極性溶媒及びα-メチルスチレン中の、水分、空気、重合禁止剤等のアニオンを失活させる要因を事前に不活性化してから、開始反応に使用する有機リチウム化合物を追加するのが好ましい。
ブロック共重合体組成物は、光学用成形体に成形される。光学用成形体の形状としては、射出成形体、シート、フィルム等公知の成形体で使用できるが、好ましくは、厚み10~300μmのフィルムに成形される。このような厚みのフィルムを成形する方法は特に制限はないが、フィルム押出機を用いて溶融押出する方法が好ましい。
(1)単量体単位の組成の決定方法
プロトン核磁気共鳴(1H-NMR)法によって求めた。
装置:JEOL-ECX400(分解能400MHz)
溶媒:重水素化クロロホルム
リファレンス:TMS又はクロロホルム
温度:20℃
(a)4.8~5.0ppm
ブタジエンビニル結合(=CH2)。ビニル結合による1,2-ビニル基1ユニットあたり2Hを含む。
ブタジエンビニル結合による1,2-ビニル基(-CH=)及びブタジエン1,4-結合(主鎖中の2重結合)(-CH=)。ビニル結合による1,2-ビニル基1ユニットあたり1Hと、1,4-結合1ユニットあたり2Hを含む。
α-メチルスチレン、スチレン中のベンゼン環H。α-メチルスチレン及びスチレン1ユニットあたり5Hを含む。標準としてクロロホルムを用いた場合、この範囲(7.2ppm)にクロロホルム中のH1つを含む。
(a)、(b)、(c)の範囲の積分値をそれぞれIa、Ib、Ic、クロロホルムの積分値をIchとした場合、ブタジエンビニル結合量のモル%Mx、ブタジエン1,4-結合のモル%My、α-メチルスチレンとスチレンとの総和のモル%Mzは、それぞれ、次の数式によって計算できる。
(1)容積50Lの反応容器に150ppmのテトラヒドロフランを含むシクロヘキサン17kgを添加し、α-メチルスチレン5400gを添加した。
(2)次いでn-ブチルリチウムを10質量%含むシクロヘキサン溶液(開始剤)を徐々に添加し、α-メチルスチリルアニオンの発色が観察された時点から、更に50mL添加し40℃まで昇温した。
(3)容器内温を40℃に保ちながらスチレン650gを仕込み速度650g/hで添加した。
(4)内温を40℃に保ちながらスチレン450gを仕込み速度450g/hで添加した。
(5)ブタジエン760gを一括添加した。添加終了後、50℃まで内温を上げ、1時間攪拌した。
(6)エポキシ化大豆油(アデカ社製)5.4gを60mLのシクロヘキサンで希釈した溶液を添加し、30分攪拌した。
(7)メタノール10gを添加し、重合活性末端を失活させて、重合液を得た。
(8)重合液をベント付き二軸押出機に供給し、脱揮してブロック共重合体組成物を得た。
このブロック共重合体組成物を、Tダイを付したフィルム押出成形機を用いシリンダー温度240℃、ダイ温度240℃で、厚さ100μmのフィルムを押し出し、ロールに巻き取った。得られた溶融押出フィルムを、テンター横延伸機を用い、ガラス転移温度+10℃で2.5倍に一軸延伸し、延伸フィルムを得た。
得られたブロック共重合体組成物、溶融押出フィルム及び延伸フィルムの測定結果を表1に示した。
α-メチルスチレンを5500g、実施例1の工程(3)においてスチレン750gを仕込み速度750g/hで添加、実施例1の工程(4)においてスチレン520gを仕込み速度520g/hで添加、ブタジエンを520gとした以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表1に示した。
α-メチルスチレンを4800g、実施例1の工程(3)においてスチレン560gを仕込み速度560g/hで添加、実施例1の工程(4)においてスチレン390gを仕込み速度390g/hで添加、ブタジエンを1400gとした以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表1に示した。
α-メチルスチレンを5800g、実施例1の工程(3)においてスチレン430gを仕込み速度430g/hで添加、実施例1の工程(4)においてスチレン300gを仕込み速度300g/hで添加、ブタジエンを750gとした以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表1に示した。
α-メチルスチレンを5000g、実施例1の工程(3)においてスチレン870gを仕込み速度870g/hで添加、実施例1の工程(4)においてスチレン600gを仕込み速度600g/hで添加、ブタジエンを760gとした以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表1に示した。
実施例1の(1)においてn-ブチルリチウムを10質量%含むシクロヘキサン溶液(開始剤)を徐々に添加し、α-メチルスチリルアニオンの発色が観察された時点から、更に72mL添加、エポキシ化大豆油を7.8gとした以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表1に示した。
(1)容積50Lの反応容器に150ppmのテトラヒドロフランを含むシクロヘキサン17kg、α-メチルスチレン5400gを添加した。
(2)次いでn-ブチルリチウムを10質量%含むシクロヘキサン溶液(開始剤)を、α-メチルスチリルアニオンの発色が確認できるまで徐々に添加した後、更に25mL添加し40℃まで昇温した。
(3)容器内温を40℃に保ちながらスチレン650gを仕込み速度650g/hで添加した。
(4)ブタジエン760gを一括添加した。添加終了後、50℃まで内温を上げ、1時間攪拌した。内温を40℃に下げた。
(5)内温を40℃に保ちながらスチレン450kgを仕込み速度450g/hで添加した。
(7)重合活性末端をメタノールにより失活させて、重合液を得た。
(8)反応液をベント付き二軸押出機に供給し、脱揮して共重合樹脂を得た。
この樹脂を、Tダイを付したフィルム押出成形機を用いシリンダー温度240℃、ダイ温度240℃で、厚さ100μmのフィルムを押し出し、ロールに巻き取った。得られたフィルムを、テンター横延伸機を用い、ガラス転移温度+10℃で2.5倍に一軸延伸し、延伸された光学フィルムを得た。
得られたブロック共重合体組成物、溶融押出フィルム及び延伸フィルムの測定結果を表1に示した。
(1)容積50Lの反応容器に150ppmのテトラヒドロフランを含むシクロヘキサン17kg、α-メチルスチレン6100gを添加した。
(2)次いでn-ブチルリチウムを10質量%含むシクロヘキサン溶液(開始剤)を、α-メチルスチリルアニオンの発色が確認できるまで徐々に添加した後、更に26mL添加し40℃まで昇温した。
(3)容器内温を40℃に保ちながらスチレン700gを仕込み速度700g/hで添加した。
(4)内温を40℃に保ちながらスチレン490kgを仕込み速度490g/hで添加した。
(5)重合活性末端をメタノールにより失活させて、重合液を得た。
(6)反応液をベント付き二軸押出機に供給し、脱揮して共重合樹脂を得た。
この樹脂を、Tダイを付したフィルム押出成形機を用いシリンダー温度240℃、ダイ温度240℃で、厚さ100μmのフィルムを押し出し、ロールに巻き取った。得られたフィルムを、テンター横延伸機を用い、ガラス転移温度+10℃で2.5倍に一軸延伸し、延伸された光学フィルムを得た。
得られたブロック共重合体組成物、溶融押出フィルム及び延伸フィルムの測定結果を表2に示した。
α-メチルスチレンを5900g、実施例1の工程(3)においてスチレン690gを仕込み速度690g/hで添加、実施例1の工程(4)においてスチレン480gを仕込み速度480g/hで添加、ブタジエンを250gとした以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表2に示した。
実施例1の工程(1)において、テトラヒドロフラン7kg、シクロヘキサン10kg、α-メチルスチレンを5400g添加した以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表2に示した。
n-ブチルリチウムを10質量%含むシクロヘキサン溶液(開始剤)を100mL、エポキシ化大豆油を10.8g添加した以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表2に示した。
エポキシ化大豆油を添加しなかった以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表2に示した。
(1)容積50Lの反応容器に、容器内温を-40℃に保ちながらテトラヒドロフラン7kg、シクロヘキサン10kg、α-メチルスチレン2300g、スチレン500gを添加した。
(2)次いでn-ブチルリチウムを10質量%含むシクロヘキサン溶液(開始剤)を、α-メチルスチリルアニオンの発色が確認できるまで徐々に添加した後、更に60mLを添加し、3時間攪拌した。
(3)40℃に昇温し、ブタジエン740gを一括添加した。添加終了後、50℃まで内温を上げ、1時間攪拌した。
(4)60Lのシクロヘキサンで希釈したエポキシ化大豆油(アデカ社製)7.5g添加し、1時間攪拌した。
(5)重合活性末端をメタノールにより失活させて、重合液を得た。
(6)反応液をベント付き二軸押出機に供給し、脱揮してブロック共重合体組成物を得た。
この樹脂を、Tダイを付したフィルム押出成形機を用いシリンダー温度240℃、ダイ温度240℃で、厚さ100μmのフィルムを押し出し、ロールに巻き取った。得られたフィルムを、テンター横延伸機を用い、ガラス転移温度+10℃で2.5倍に一軸延伸し、延伸フィルムを得た。
得られたブロック共重合体組成物、溶融押出フィルム及び延伸フィルムの測定結果を表2に示した。
α-メチルスチレンを2700g、実施例1の工程(3)においてスチレン310gを仕込み速度310g/hで添加、実施例1の工程(4)においてスチレン210gを仕込み速度210g/hで添加、ブタジエンを1500gとした以外は、実施例1と同様にしてブロック共重合体組成物、溶融押出フィルム及び延伸フィルムを得た。これらの測定結果を表2に示した。
(1)柔軟性
柔軟性として溶融押出フィルムの耐折強度の測定を以下の条件下で行い、下記基準によって判断した。折り曲げ回数200回以上を合格とした。
測定条件
測定器:MIT-D FOLDING ENDURANCE TESTER(東洋精機社製)
荷重(張力):500g重
折り曲げ速度:175回/分
折り曲げ角度:左右各45度
折り曲げ装置先端半径:0.38mm
試験片幅:15mm
折り曲げ方向:フィルム押出方向
サンプル点数:5点(折り曲げ回数1000回以上のものは2点)
(2)透明性
ASTM D1003に基づき、ヘーズメーター(日本電色工業社製NDH-1001DP型)を用いてフィルムのヘーズ(単位:%)を測定した。2%以下を合格とした。
(3)外観
溶融押出フィルムについて、画像処理装置(ニレコ社製LUZEX SE)を用いて観測し、下記基準にて良否を判断した。「優」、「良」を合格とした。
「優」:長さ50μm以上のフィルム欠陥が0個/m2
「良」:長さ50μm以上のフィルム欠陥が1~4個/m2
「不可」:長さ50μm以上のフィルム欠陥が5個/m2以上
ここで、「フィルム欠陥」とは、異物の混入や、未溶融ブツの発生等により、周囲とは不均一になって見える部分を指す。
(4)熱安定性
セイコー電子工業社製TG/DTA 220TGAを用いて、以下の条件で加熱重量減少を測定した。5%重量減少した際の温度が320℃以上のものを合格とした。
フローガス;N2 100ml/分
昇温条件:30℃より400℃まで10℃/分
(5)光弾性複屈折
光弾性複屈折を表す指標である光弾性係数を、溶融押出フィルムに引張応力をかけた状態で位相差測定装置にてリタデーション(単位:nm)を測定することによって求めた。荷重fが加わった状態でのリタデーションをRe(f)、試験片幅をwとすると、光弾性係数Cは
C=dRe(f)/df×w
となるので、試験片に加えた荷重に対するリタデーションの値の傾きを求めることで算出した。位相差測定装置は王子計測社製KOBRA-WRを使用し、応力は、イマダ社製、デジタルフォースゲージZ2S-DPU-50Nによって加えた。光弾性係数の絶対値が5×10-121/Pa以下のものを合格とした。
(6)位相差発現性
位相差測定装置(王子計測社製KOBRA-WR)を用いて、延伸フィルムのリタデーション(単位:nm)を測定した。リタデーションの絶対値が100nm以上を合格とした。また、位相差顕微鏡で観察することで、配向複屈折の符号は、実施例と比較例中の全てのサンプルについて負であることを確認した。
Claims (6)
- α-メチルスチレン単位及びスチレン単位からなり、DSC(示差走査熱量計)によって測定されるガラス転移温度が115~145℃である重合体ブロックAと、共役ジエン単位を有する重合体ブロックBとから構成されてなるブロック構造A-B-A又は(A-B)m-X(ここで、Xはカップリング剤の残基、mは2以上の整数)の成分(a)を40~85体積%、ブロック構造A-Bの成分(b)及びブロック構造Aの成分(c)を総和で15~60体積%それぞれ有し、成分(a)、(b)及び(c)を合わせた全体について、数平均分子量が50000以上であり、α-メチルスチレン単位とスチレン単位との総和が35~85モル%、共役ジエン単位が15~65モル%、共役ジエン単位15~65モル%のうち1,4-結合量が15~50モル%、ビニル結合量が15モル%以下であるブロック共重合体組成物を成形してなる、光学用成形体。
- 共役ジエン単位が1,3-ブタジエン単位であるブロック共重合体組成物を成形してなる請求項1記載の光学用成形体。
- 厚さ10~300μmのフィルムであることを特徴とする請求項1又は2記載の光学用成形体。
- フィルムが、溶融押出フィルムであることを特徴とする請求項3記載の光学用成形体。
- フィルムが、延伸フィルムであることを特徴とする請求項3又は4記載の光学用成形体。
- 延伸フィルムが位相差フィルムであることを特徴とする請求項5に記載の光学用成形体。
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WO2017119245A1 (ja) * | 2016-01-05 | 2017-07-13 | 富士フイルム株式会社 | 偏光板および液晶表示装置 |
JP2017167514A (ja) * | 2016-01-05 | 2017-09-21 | 富士フイルム株式会社 | 偏光板および液晶表示装置 |
WO2017135059A1 (ja) * | 2016-02-05 | 2017-08-10 | 富士フイルム株式会社 | 積層体および液晶表示装置 |
JP2017215562A (ja) * | 2016-02-05 | 2017-12-07 | 富士フイルム株式会社 | 積層体および液晶表示装置 |
KR20180099759A (ko) * | 2016-02-05 | 2018-09-05 | 후지필름 가부시키가이샤 | 적층체 및 액정 표시 장치 |
KR102091095B1 (ko) | 2016-02-05 | 2020-03-19 | 후지필름 가부시키가이샤 | 적층체 및 액정 표시 장치 |
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KR20140146110A (ko) | 2014-12-24 |
JPWO2013146708A1 (ja) | 2015-12-14 |
JP5952386B2 (ja) | 2016-07-13 |
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