WO2013191095A1 - 積層フィルムの製造方法 - Google Patents
積層フィルムの製造方法 Download PDFInfo
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- WO2013191095A1 WO2013191095A1 PCT/JP2013/066443 JP2013066443W WO2013191095A1 WO 2013191095 A1 WO2013191095 A1 WO 2013191095A1 JP 2013066443 W JP2013066443 W JP 2013066443W WO 2013191095 A1 WO2013191095 A1 WO 2013191095A1
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- film
- adhesive
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- transparent
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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
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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
- 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
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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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/0046—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by constructional aspects of the apparatus
- B32B37/0053—Constructional details of laminating machines comprising rollers; Constructional features of the rollers
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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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
- B32B37/1207—Heat-activated adhesive
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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
- G02B5/305—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 including organic materials, e.g. polymeric layers
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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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
- B32B2037/1253—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives curable adhesive
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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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/42—Polarizing, birefringent, filtering
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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
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/08—Dimensions, e.g. volume
- B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
- B32B2309/105—Thickness
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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
- B32B2310/00—Treatment by energy or chemical effects
- B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
- B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
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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
- B32B2310/00—Treatment by energy or chemical effects
- B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
- B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
- B32B2310/0831—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using UV radiation
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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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
- B32B37/203—One or more of the layers being plastic
- B32B37/206—Laminating a continuous layer between two continuous plastic layers
Definitions
- the present invention relates to a method for producing a laminated film used for various applications such as optical components.
- Polarizing films are widely used as dichroic dyes adsorbed and oriented on polyvinyl alcohol resin films. Iodine polarizing films using iodine as a dichroic dye and dichroic direct dyes as dichroic Dye-type polarizing films used as pigments are known. These polarizing films are usually used as polarizing plates by laminating a transparent film such as a triacetyl cellulose film on one side or both sides via an adhesive.
- bubbles may be mixed between the films. This is a phenomenon that did not occur when a conventional water-based pressure-sensitive adhesive or the like was used, and is considered to be a problem peculiar to the use of an active energy ray-curable adhesive. In recent years, further thinning of laminated films has been demanded. Therefore, when trying to reduce the thickness of the active energy ray curable adhesive, there is a problem that the problem of mixing of bubbles is likely to occur.
- JP 2004-245925 A JP 2009-134190 A JP 2011-95560 A
- An object of the present invention is to suppress the mixing of bubbles between films in the production of a laminated film in which a plurality of films are bonded to each other via an active energy ray curable adhesive.
- the present invention is a method for producing a laminated film in which a plurality of films are bonded to each other via an active energy ray-curable adhesive, Among the plurality of films, an adhesive application step of applying an active energy ray-curable adhesive to one or both surfaces of at least one film; A lamination process in which the plurality of films are sandwiched between a pair of lamination rolls rotating in the transport direction in a state of being laminated so that the adhesive is interposed between adjacent films; , An active energy ray irradiating step of irradiating active energy rays to the plurality of films bonded together to cure the adhesive in this order, In the plurality of films, the surface on which the adhesive is not applied in the adhesive application step, and the surface that comes into contact with the adhesive in the bonding step is 200 nm or less. Provide a method.
- the thickness of the adhesive applied in the adhesive coating process is 2 ⁇ m or less.
- the plurality of films preferably include an optical film and a transparent film, and the laminated film is preferably a polarizing plate.
- the plurality of films are composed of one optical film and two transparent films,
- the adhesive application step the adhesive is applied to one side of each of the two transparent films,
- the bonding step the optical film and the transparent film are sandwiched between the pair of bonding rolls in a state where the adhesives of the two transparent films are in contact with both surfaces of the optical film.
- the plurality of films are composed of one optical film and one transparent film,
- the adhesive application step the adhesive is applied to one side of the transparent film,
- the bonding step the optical film and the transparent film are sandwiched between the pair of bonding rolls in a state where the adhesive of the transparent film is in contact with one surface of the optical film, It is preferable to bond each other.
- the present invention in the production of a laminated film in which a plurality of films are bonded to each other via an active energy ray-curable adhesive, it is possible to suppress air bubbles from being mixed between the films.
- FIG. 1 It is a schematic diagram which shows the structure of the whole apparatus used for the manufacturing method of Embodiment 1. It is a schematic diagram which shows the structure of the whole apparatus used for the manufacturing method of Embodiment 2. It is a schematic diagram which shows the structure of the whole apparatus used for the manufacturing method of Example 2.
- FIG. 1 It is a schematic diagram which shows the structure of the whole apparatus used for the manufacturing method of Embodiment 1. It is a schematic diagram which shows the structure of the whole apparatus used for the manufacturing method of Embodiment 2. It is a schematic diagram which shows the structure of the whole apparatus used for the manufacturing method of Example 2.
- the present invention is a method for producing a laminated film in which a plurality of films are bonded to each other via an active energy ray-curable adhesive, Among the plurality of films, an adhesive application step of applying an active energy ray-curable adhesive to one or both surfaces of at least one film; The plurality of films are bonded to each other by being sandwiched between a pair of bonding rolls that rotate in the transport direction in a state where the plurality of films are laminated so that the adhesive is interposed between adjacent films.
- An active energy ray irradiating step of irradiating active energy rays to the plurality of films bonded to each other to cure the adhesive is provided in this order.
- the surface of the surface that is not coated with the adhesive in the adhesive coating step and is in contact with the adhesive in the pasting step has a surface roughness. 200 nm or less.
- the surface roughness in the present invention means ten-point average roughness (Rzjis; where the reference length is 2.5 mm and the evaluation length is 12.5 mm) in the 2001 revised JIS B 0601, Hereinafter, it may be abbreviated as Rz.
- the unit of surface roughness (Rz) is nm.
- the surface roughness (Rz) is measured using, for example, “Handy Surf E35A” manufactured by Tokyo Seimitsu Co., Ltd. as a measuring device, with a cutoff value (reference length) of 2.5 mm and a measurement distance of 12.5 mm. The average value when the surface roughness is measured 10 times with the measuring device placed on the target film is obtained.
- the surface roughness is preferably 100 nm or less, more preferably 80 nm or less.
- the film having such a surface roughness can be selected from commercially available products.
- the surface roughness may be adjusted by coating the surface of the film with a resin or the like.
- the thickness of the adhesive applied in the adhesive coating process is 2 ⁇ m or less.
- the thickness of the adhesive to be applied is 2 ⁇ m or less, air bubbles are likely to be mixed between the films, particularly in the bonding step, so that the effect of suppressing air bubble mixing produced by the present invention becomes remarkable.
- the thickness of at least 1 adhesive is 2 micrometers or less among the adhesive agents applied to a some film, the effect of this invention is show
- Examples of the laminated film produced in the present invention include a polarizing plate.
- the plurality of films include, for example, an optical film and a transparent film.
- the optical film is, for example, a polarizing film, a retardation film, or a pattern retarder film for 3D television, and may be a single film or a laminate of a plurality of films.
- the polarizing film used when manufacturing a polarizing plate as a laminated film is, for example, a film obtained by adsorbing and orienting a dichroic dye on a uniaxially stretched polyvinyl alcohol-based resin film.
- the polyvinyl alcohol resin can be obtained by saponifying a polyvinyl acetate resin.
- Polyvinyl acetate resins include polyvinyl acetate, which is a homopolymer of vinyl acetate, and copolymers of vinyl acetate and other monomers copolymerizable therewith (for example, ethylene-vinyl acetate copolymer). Polymer).
- polyvinyl alcohol resins may be modified. For example, polyvinyl formal modified with aldehydes, polyvinyl acetal, polyvinyl butyral, and the like may be used.
- a film obtained by forming such a polyvinyl alcohol resin is used as an original film of a polarizing film.
- the method for forming the polyvinyl alcohol-based resin is not particularly limited, and can be formed by a conventionally known appropriate method.
- the film thickness of the raw film made of polyvinyl alcohol resin is not particularly limited, but is, for example, about 10 to 150 ⁇ m. Usually, it is supplied in the form of a roll, the thickness is in the range of 20 to 100 ⁇ m, preferably in the range of 30 to 80 ⁇ m, and the industrially practical width is in the range of 1500 to 6000 mm.
- Examples of commercially available polyvinyl alcohol-based resin films include vinylon VF-PS # 7500 (manufactured by Kuraray, original fabric thickness is 75 ⁇ m), OPL film M-7500 (manufactured by Nippon Gosei, original fabric thickness is 75 ⁇ m), vinylon VF-PS # 6000 (made by Kuraray, original fabric thickness is 60 ⁇ m), vinylon VF-PE # 6000 (made by Kuraray, original fabric thickness is 60 ⁇ m), vinylon VF-PE # 5000 (made by Kuraray, original fabric thickness is 50 ⁇ m), etc. .
- the polarizing film is usually a process of dyeing a polyvinyl alcohol resin film with a dichroic dye to adsorb the dichroic dye (dyeing process), a boric acid aqueous solution of the polyvinyl alcohol resin film adsorbed with the dichroic dye And a step of washing with water after the treatment with the boric acid aqueous solution (water washing treatment step).
- the polyvinyl alcohol-based resin film is usually uniaxially stretched, but this uniaxial stretching may be performed before the dyeing treatment step or during the dyeing treatment step, It may be performed after the dyeing process.
- the uniaxial stretching may be performed before the boric acid treatment step or during the boric acid treatment step.
- uniaxial stretching can be performed in these plural stages.
- the uniaxial stretching may be performed uniaxially between rolls having different peripheral speeds, or may be performed uniaxially using a hot roll. Moreover, the dry-type extending
- the draw ratio is usually about 3 to 8 times.
- the dyeing of the polyvinyl alcohol-based resin film with the dichroic dye in the dyeing process is performed, for example, by immersing the polyvinyl alcohol-based resin film in an aqueous solution containing the dichroic dye.
- the dichroic dye for example, iodine, a dichroic dye or the like is used.
- dichroic dyes include C.I. I. Dichroic direct dyes composed of disazo compounds such as DIRECT RED 39, and dichroic direct dyes composed of compounds such as trisazo and tetrakisazo are included.
- the polyvinyl alcohol-type resin film performs the immersion process to water before a dyeing process.
- iodine When iodine is used as the dichroic dye, a method of dyeing a polyvinyl alcohol-based resin film in an aqueous solution containing iodine and potassium iodide is usually employed.
- the content of iodine in this aqueous solution is usually 0.01 to 1 part by weight per 100 parts by weight of water, and the content of potassium iodide is usually 0.5 to 20 parts by weight per 100 parts by weight of water.
- the temperature of the aqueous solution used for dyeing is usually 20 to 40 ° C.
- the immersion time (dyeing time) in this aqueous solution is usually 20 to 1800 seconds.
- a method of immersing and dyeing a polyvinyl alcohol-based resin film in an aqueous solution containing the dichroic dye is usually employed.
- the content of the dichroic dye in this aqueous solution usually, 1 ⁇ 10 -4 ⁇ 10 parts by weight per 100 parts by weight of water, preferably 1 ⁇ 10 -3 ⁇ 1 parts by weight, particularly preferably 1 ⁇ 10 - 3 to 1 ⁇ 10 ⁇ 2 parts by weight.
- This aqueous solution may contain an inorganic salt such as sodium sulfate as a dyeing assistant.
- the temperature of the dye aqueous solution used for dyeing is usually 20 to 80 ° C.
- the immersion time (dyeing time) in this aqueous solution is usually 10 to 1800 seconds. is there.
- the boric acid treatment step is performed by immersing a polyvinyl alcohol resin film dyed with a dichroic dye in a boric acid-containing aqueous solution.
- the amount of boric acid in the boric acid-containing aqueous solution is usually 2 to 15 parts by weight, preferably 5 to 12 parts by weight per 100 parts by weight of water.
- the boric acid-containing aqueous solution used in this boric acid treatment process preferably contains potassium iodide.
- the amount of potassium iodide in the boric acid-containing aqueous solution is usually 0.1 to 15 parts by weight, preferably 5 to 12 parts by weight, per 100 parts by weight of water.
- the immersion time in the boric acid-containing aqueous solution is usually 60 to 1200 seconds, preferably 150 to 600 seconds, and more preferably 200 to 400 seconds.
- the temperature of the boric acid-containing aqueous solution is usually 40 ° C. or higher, preferably 50 to 85 ° C., more preferably 55 to 75 ° C.
- the polyvinyl alcohol-based resin film after the boric acid treatment described above is washed with water, for example, by immersing it in water.
- the temperature of water in the water washing treatment is usually 4 to 40 ° C., and the immersion time is usually 1 to 120 seconds.
- a drying treatment is usually performed to obtain a polarizing film.
- the drying process is preferably performed using, for example, a hot air dryer or a far infrared heater.
- the temperature for the drying treatment is usually 30 to 100 ° C., preferably 50 to 80 ° C.
- the drying treatment time is usually 60 to 600 seconds, preferably 120 to 600 seconds.
- the polyvinyl alcohol resin film is subjected to uniaxial stretching, dyeing with a dichroic dye, boric acid treatment and water washing treatment to obtain a polarizing film.
- the thickness of this polarizing film is usually in the range of 5 to 50 ⁇ m.
- Transparent film when manufacturing a polarizing plate as a laminated
- the respective transparent films may be the same or different types of films.
- Examples of the material constituting the transparent film include cycloolefin resins, cellulose acetate resins, polyethylene terephthalate, polyethylene naphthalate, polyester resins such as polybutylene terephthalate, polycarbonate resins, acrylic resins, and polypropylene. Examples thereof include film materials that have been widely used in the field.
- the cycloolefin resin is a thermoplastic resin (also referred to as a thermoplastic cycloolefin resin) having a monomer unit made of a cyclic olefin (cycloolefin), such as norbornene or a polycyclic norbornene monomer.
- the cycloolefin-based resin may be a hydrogenated product of the above-mentioned cycloolefin ring-opening polymer or a ring-opening copolymer using two or more cycloolefins, and has a cycloolefin, a chain olefin, and a vinyl group.
- An addition polymer with an aromatic compound or the like may be used. Those having a polar group introduced are also effective.
- examples of the chain olefin include ethylene and propylene
- examples of the aromatic compound having a vinyl group include Examples include styrene, ⁇ -methylstyrene, and nuclear alkyl-substituted styrene.
- the monomer unit composed of cycloolefin may be 50 mol% or less (preferably 15 to 50 mol%).
- the amount of the monomer unit composed of cycloolefin can be made relatively small as described above.
- the unit of monomer composed of a chain olefin is usually 5 to 80 mol%
- the unit of monomer composed of an aromatic compound having a vinyl group is usually 5 to 80 mol%.
- Cycloolefin-based resins may be commercially available products such as Topas (manufactured by Ticona), Arton (manufactured by JSR), ZEONOR (manufactured by Nippon Zeon), ZEONEX (manufactured by Nippon Zeon ( Co., Ltd.), Apel (manufactured by Mitsui Chemicals, Inc.), Oxis (OXIS) (manufactured by Okura Kogyo Co., Ltd.) and the like can be suitably used.
- a known method such as a solvent casting method or a melt extrusion method is appropriately used.
- cycloolefin resin films such as Essina (manufactured by Sekisui Chemical Co., Ltd.), SCA40 (manufactured by Sekisui Chemical Co., Ltd.), Zeonoa Film (manufactured by Optes Co., Ltd.), etc. You may use goods.
- the cycloolefin resin film may be uniaxially stretched or biaxially stretched.
- Stretching is usually performed continuously while unwinding a film roll, and in a heating furnace, the roll traveling direction (film longitudinal direction), the direction perpendicular to the traveling direction (film width direction), or both Stretched.
- the temperature of the heating furnace a range from the vicinity of the glass transition temperature of the cycloolefin resin to the glass transition temperature + 100 ° C. is usually employed.
- the stretching ratio is usually 1.1 to 6 times, preferably 1.1 to 3.5 times.
- the cycloolefin-based resin film When the cycloolefin-based resin film is in a roll-wound state, the films tend to adhere to each other and easily cause blocking. Therefore, the cycloolefin-based resin film is usually rolled after the protective film is bonded.
- the surface to be bonded to the optical film is subjected to surface treatment such as plasma treatment, corona treatment, ultraviolet irradiation treatment, flame (flame) treatment, and saponification treatment. Is preferred.
- plasma treatment that can be carried out relatively easily, particularly atmospheric pressure plasma treatment, and corona treatment are preferable.
- the cellulose acetate-based resin is a cellulose part or a completely esterified product, and examples thereof include a film made of cellulose acetate ester, propionate ester, butyrate ester, and mixed ester thereof. More specifically, a triacetyl cellulose film, a diacetyl cellulose film, a cellulose acetate propionate film, a cellulose acetate butyrate film, and the like can be given.
- a cellulose ester resin film As such a cellulose ester resin film, an appropriate commercially available product, for example, Fujitac TD80 (manufactured by Fuji Film Co., Ltd.), Fujitac TD80UF (manufactured by Fuji Film Co., Ltd.), Fujitac TD80UZ (manufactured by Fuji Film Co., Ltd.) KC8UX2M (manufactured by Konica Minolta Opto), KC8UY (manufactured by Konica Minolta Opto) Fujitac TD60UL (manufactured by Fuji Film), KC4UYW (manufactured by Konica Minolta Opto), KC6UAW (Konica Minolta Opto) Etc.) can be used preferably.
- Fujitac TD80 manufactured by Fuji Film Co., Ltd.
- Fujitac TD80UF manufactured by Fuji Film Co., Ltd.
- a cellulose acetate-based resin film imparted with retardation characteristics is also preferably used.
- Commercially available cellulose acetate resin films with such retardation characteristics include WV BZ 438 (Fuji Film Co., Ltd.), KC4FR-1 (Konica Minolta Opto Co., Ltd.), and KC4CR-1 (Konica Minolta). Opt Co., Ltd.), KC4AR-1 (Konica Minolta Opto Co., Ltd.) and the like.
- Cellulose acetate is also called acetyl cellulose or cellulose acetate.
- the moisture content during the production of the polarizing plate is preferably closer to the equilibrium moisture content in the storage environment of the polarizing plate, for example, a clean room production line or a roll storage warehouse, and depends on the configuration of the laminated film. About 5%, more preferably 2.5% to 3.0%.
- the numerical value of the moisture content of this polarizing plate was measured by a dry weight method, and is a change in weight before and after the treatment dried at a temperature of 105 ° C. for 120 minutes using a thermostatic bath.
- the thickness of the transparent film used in the polarizing plate of the present invention is preferably thin, but if it is too thin, the strength is lowered and the workability is poor. On the other hand, when it is too thick, problems such as a decrease in transparency and a longer curing time after lamination occur. Therefore, a suitable thickness of the transparent film is, for example, 5 to 200 ⁇ m, preferably 10 to 150 ⁇ m, more preferably 10 to 100 ⁇ m.
- the optical film and / or transparent film can be subjected to corona treatment, flame treatment, plasma treatment, ultraviolet treatment, primer coating treatment, saponification treatment, etc.
- a surface treatment may be applied.
- the transparent film may be subjected to surface treatments such as anti-glare treatment, anti-reflection treatment, hard coat treatment, antistatic treatment, and antifouling treatment individually or in combination of two or more.
- the transparent film and / or the transparent film surface protective layer may contain a UV absorber such as a benzophenone compound or a benzotriazole compound, or a plasticizer such as a phenyl phosphate compound or a phthalate compound.
- optical functions such as functions as a retardation film, function as a brightness enhancement film, function as a reflection film, function as a transflective film, function as a diffusion film, function as an optical compensation film, etc.
- a function for example, by laminating an optical functional film such as a retardation film, a brightness enhancement film, a reflection film, a transflective film, a diffusion film, and an optical compensation film on the surface of the transparent film, such a function is achieved.
- the transparent film itself can be given such a function.
- the transparent film may have a plurality of functions such as a diffusion film having the function of a brightness enhancement film.
- the above-mentioned transparent film is subjected to a stretching process described in Japanese Patent No. 2841377, Japanese Patent No. 3094113, or the like, or a process described in Japanese Patent No. 3168850 can be used as a retardation film.
- the function of can be provided.
- the retardation characteristics of the retardation film can be appropriately selected, for example, such that the front retardation value is in the range of 5 to 100 nm and the thickness direction retardation value is in the range of 40 to 300 nm.
- two or more layers having different central wavelengths of selective reflection are formed in the transparent film by forming micropores by a method as described in Japanese Patent Application Laid-Open Nos. 2002-169025 and 2003-29030. By superimposing these cholesteric liquid crystal layers, a function as a brightness enhancement film can be imparted.
- a function as a reflective film or a transflective film can be imparted.
- a function as a diffusion film can be imparted.
- the function as an optical compensation film can be provided by coating and aligning liquid crystalline compounds, such as a discotic liquid crystalline compound, on said transparent film.
- you may make the transparent film contain the compound which expresses retardation.
- various optical functional films may be directly bonded to the optical film using an appropriate adhesive.
- optical functional films examples include brightness enhancement films such as DBEF (manufactured by 3M, available from Sumitomo 3M Co., Ltd. in Japan), and viewing angle improvements such as WV film (manufactured by Fuji Film Co., Ltd.).
- Film, Arton Film (manufactured by JSR Corporation), Zeonoor Film (manufactured by Optes Corporation), Essina (manufactured by Sekisui Chemical Co., Ltd.), VA-TAC (manufactured by Comic Minolta Opto Corporation), Sumikalite (Sumitomo) (Chemical Co., Ltd.) etc. can be mentioned.
- the active energy ray-curable adhesive used in the present invention includes, for example, an epoxy resin composition containing an epoxy resin that is cured by irradiation with active energy rays from the viewpoint of weather resistance, refractive index, cationic polymerization, and the like.
- the adhesive which consists of is mentioned.
- the present invention is not limited to this, and various active energy ray-curable adhesives (organic solvent adhesives, hot melt adhesives, solventless adhesives) that have been used in the manufacture of polarizing plates. Etc.) can be adopted.
- An epoxy resin means a compound having two or more epoxy groups in a molecule.
- the epoxy resin contained in the curable epoxy resin composition that is an adhesive is an epoxy resin that does not contain an aromatic ring in the molecule (see, for example, Patent Document 1). It is preferable that Examples of such epoxy resins include hydrogenated epoxy resins, alicyclic epoxy resins, aliphatic epoxy resins, and the like.
- the hydrogenated epoxy resin is obtained by a method of glycidyl etherifying a nuclear hydrogenated polyhydroxy compound obtained by selectively subjecting a polyhydroxy compound, which is a raw material of an aromatic epoxy resin, to a nuclear hydrogenation reaction under pressure in the presence of a catalyst. Obtainable.
- aromatic epoxy resins include bisphenol-type epoxy resins such as bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, and bisphenol S diglycidyl ether; phenol novolac epoxy resins, cresol novolac epoxy resins, and hydroxy Examples include novolak-type epoxy resins such as benzaldehyde phenol novolac epoxy resins; glycidyl ethers of tetrahydroxyphenylmethane, glycidyl ethers of tetrahydroxybenzophenone, and polyfunctional epoxy resins such as epoxidized polyvinylphenol.
- hydrogenated epoxy resins hydrogenated bisphenol A glycidyl ether is preferred.
- the alicyclic epoxy resin means an epoxy resin having at least one epoxy group bonded to the alicyclic ring in the molecule.
- the “epoxy group bonded to an alicyclic ring” means a bridged oxygen atom —O— in the structure represented by the following formula. In the following formula, m is an integer of 2 to 5.
- a compound in which a group in the form of removing one or more hydrogen atoms in (CH 2 ) m in the above formula is bonded to another chemical structure can be an alicyclic epoxy resin.
- One or more hydrogen atoms in (CH 2 ) m may be appropriately substituted with a linear alkyl group such as a methyl group or an ethyl group.
- the alicyclic epoxy resin used preferably below is specifically illustrated, it is not limited to these compounds.
- R 1 and R 2 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms).
- R 3 and R 4 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and n represents an integer of 2 to 20).
- R 5 and R 6 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and p represents an integer of 2 to 20).
- R 7 and R 8 independently of each other represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and q represents an integer of 2 to 10).
- R 9 and R 10 independently of each other represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and r represents an integer of 2 to 20).
- R 11 and R 12 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms).
- R 13 and R 14 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms).
- R 16 and R 17 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms).
- R 18 represents a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.
- the following alicyclic epoxy resins are commercially available or their analogs, and are more preferably used because they are relatively easy to obtain.
- examples of the aliphatic epoxy resin include polyglycidyl ethers of aliphatic polyhydric alcohols or alkylene oxide adducts thereof. More specifically, 1,4-butanediol diglycidyl ether; 1,6-hexanediol diglycidyl ether; glycerin triglycidyl ether; trimethylolpropane triglycidyl ether; polyethylene glycol diglycidyl ether; propylene Diglycidyl ether of glycol; Polyether of polyether polyol obtained by adding one or more alkylene oxides (ethylene oxide or propylene oxide) to aliphatic polyhydric alcohols such as ethylene glycol, propylene glycol, and glycerin A glycidyl ether etc. are mentioned.
- the epoxy resin which comprises the adhesive agent which consists of an epoxy-type resin composition may be used individually by 1 type, and may use 2 or more types together.
- the epoxy equivalent of the epoxy resin used in this composition is usually in the range of 30 to 3,000 g / equivalent, preferably 50 to 1,500 g / equivalent.
- the epoxy equivalent is less than 30 g / equivalent, the flexibility of the composite polarizing plate after curing may be reduced, or the adhesive strength may be reduced.
- it exceeds 3,000 g / equivalent the compatibility with other components contained in the adhesive may be lowered.
- cationic polymerization is preferably used as a curing reaction of the epoxy resin from the viewpoint of reactivity. Therefore, it is preferable to mix
- the cationic polymerization initiator generates a cationic species or a Lewis acid by irradiation with active energy rays such as visible light, ultraviolet rays, X-rays, and electron beams, and initiates an epoxy group polymerization reaction.
- a cationic polymerization initiator that generates a cationic species or a Lewis acid by irradiation of active energy rays and initiates a polymerization reaction of an epoxy group is referred to as a “photo cationic polymerization initiator”.
- the method of curing the adhesive by irradiation with active energy rays using a cationic photopolymerization initiator enables curing at room temperature, reducing the need to consider the heat resistance of the optical film or distortion due to expansion, and between the films. Is advantageous in that it can be bonded well.
- the photocationic polymerization initiator acts catalytically by light, it is excellent in storage stability and workability even when mixed with an epoxy resin.
- photocationic polymerization initiator examples include aromatic diazonium salts; onium salts such as aromatic iodonium salts and aromatic sulfonium salts; iron-allene complexes and the like.
- aromatic diazonium salt examples include benzenediazonium hexafluoroantimonate, benzenediazonium hexafluorophosphate, benzenediazonium hexafluoroborate, and the like.
- aromatic iodonium salt examples include diphenyliodonium tetrakis (pentafluorophenyl) borate, diphenyliodonium hexafluorophosphate, diphenyliodonium hexafluoroantimonate, di (4-nonylphenyl) iodonium hexafluorophosphate, and the like.
- aromatic sulfonium salt examples include triphenylsulfonium hexafluorophosphate, triphenylsulfonium hexafluoroantimonate, triphenylsulfonium tetrakis (pentafluorophenyl) borate, 4,4′-bis (diphenylsulfonio) diphenyl sulfide bis ( Hexafluorophosphate), 4,4′-bis [di ( ⁇ -hydroxyethoxy) phenylsulfonio] diphenyl sulfide, bis (hexafluoroantimonate), 4,4′-bis [di ( ⁇ -hydroxyethoxy) phenylsulfonio ] Diphenyl sulfide bis (hexafluorophosphate), 7- [di (p-toluyl) sulfonio] -2-isopropylthioxanthone hexafluor
- iron-allene complex examples include xylene-cyclopentadienyl iron (II) hexafluoroantimonate, cumene-cyclopentadienyl iron (II) hexafluorophosphate, xylene-cyclopentadienyl iron (II). -Tris (trifluoromethylsulfonyl) methanide and the like.
- photocationic polymerization initiators can be easily obtained.
- “Kayarad PCI-220” and “Kayarad PCI-620” Nippon Kayaku Co., Ltd. )
- “UVI-6990” manufactured by Union Carbide
- “Adekaoptomer SP-150” and “Adekaoptomer SP-170” manufactured by ADEKA Corporation
- “CI-5102”, “ “CIT-1370”, “CIT-1682”, “CIP-1866S”, “CIP-2048S” and “CIP-2064S” aboveve, Nippon Soda Co., Ltd.
- the photocationic polymerization initiator may be used alone or in combination of two or more.
- aromatic sulfonium salts are preferably used because they have ultraviolet absorption characteristics even in a wavelength region of 300 nm or more, and thus can provide a cured product having excellent curability and good mechanical strength and adhesive strength.
- the amount of the cationic photopolymerization initiator is usually 0.5 to 20 parts by weight, preferably 1 part by weight or more, and preferably 15 parts by weight or less based on 100 parts by weight of the epoxy resin.
- the blending amount of the cationic photopolymerization initiator is less than 0.5 parts by weight with respect to 100 parts by weight of the epoxy resin, curing becomes insufficient, and mechanical strength and adhesive strength tend to decrease.
- the compounding quantity of a photocationic polymerization initiator exceeds 20 weight part with respect to 100 weight part of epoxy resins, the hygroscopic property of hardened
- the curable epoxy resin composition may further contain a photosensitizer as necessary.
- a photosensitizer By using a photosensitizer, the reactivity of cationic polymerization is improved, and the mechanical strength and adhesive strength of the cured product can be improved.
- the photosensitizer include carbonyl compounds, organic sulfur compounds, persulfides, redox compounds, azo and diazo compounds, halogen compounds, and photoreductive dyes.
- photosensitizers include, for example, benzoin derivatives such as benzoin methyl ether, benzoin isopropyl ether, and ⁇ , ⁇ -dimethoxy- ⁇ -phenylacetophenone; benzophenone, 2,4-dichlorobenzophenone, o Benzophenone derivatives such as methyl benzoylbenzoate, 4,4′-bis (dimethylamino) benzophenone, and 4,4′-bis (diethylamino) benzophenone; thioxanthone derivatives such as 2-chlorothioxanthone and 2-isopropylthioxanthone; 2 Anthraquinone derivatives such as chloroanthraquinone and 2-methylanthraquinone; acridone derivatives such as N-methylacridone and N-butylacridone; other ⁇ , ⁇ -diethoxyacetophenone, ben Examples include zil, fluorenone
- the epoxy resin contained in the adhesive is cured by photocationic polymerization, but may be cured by both photocationic polymerization and thermal cationic polymerization. In the latter case, it is preferable to use a photocationic polymerization initiator and a thermal cationic polymerization initiator in combination.
- thermal cationic polymerization initiator examples include benzylsulfonium salt, thiophenium salt, thiolanium salt, benzylammonium, pyridinium salt, hydrazinium salt, carboxylic acid ester, sulfonic acid ester, and amine imide.
- thermal cationic polymerization initiators can be easily obtained as commercial products. For example, “Adeka Opton CP77” and “Adeka Opton CP66” (manufactured by ADEKA Corporation), “CI” are available under the trade names.
- the active energy ray-curable adhesive may further contain a compound that promotes cationic polymerization, such as oxetanes and polyols.
- Oxetanes are compounds having a 4-membered ring ether in the molecule, such as 3-ethyl-3-hydroxymethyloxetane, 1,4-bis [(3-ethyl-3-oxetanyl) methoxymethyl] benzene, 3 -Ethyl-3- (phenoxymethyl) oxetane, di [(3-ethyl-3-oxetanyl) methyl] ether, 3-ethyl-3- (2-ethylhexyloxymethyl) oxetane, phenol novolac oxetane and the like. These oxetanes can be easily obtained as commercial products.
- polyols those having no acidic groups other than phenolic hydroxyl groups are preferable.
- polyol compounds having no functional groups other than hydroxyl groups polyester polyol compounds, polycaprolactone polyol compounds, polyol compounds having phenolic hydroxyl groups, polycarbonates A polyol etc. can be mentioned.
- the molecular weight of these polyols is usually 48 or more, preferably 62 or more, more preferably 100 or more, and preferably 1,000 or less.
- These polyols are usually contained in the curable epoxy resin composition in a proportion of 50% by weight or less, preferably 30% by weight or less.
- Active energy ray-curable adhesives include ion trapping agents, antioxidants, chain transfer agents, tackifiers, thermoplastic resins, fillers, flow regulators, leveling agents, plasticizers, antifoaming agents, etc. Additives can be blended.
- the ion trapping agent include powdered bismuth-based, antimony-based, magnesium-based, aluminum-based, calcium-based, titanium-based, and mixed inorganic compounds.
- the antioxidant is a hindered phenol-based antioxidant. Etc.
- Active energy ray-curable adhesives can be used as solventless adhesives that are substantially free of solvent components, but each coating method has an optimum viscosity range, A solvent may be included.
- the solvent it is preferable to use a solvent that dissolves the epoxy resin composition and the like well without degrading the optical performance of the optical film.
- hydrocarbons typified by toluene
- esters typified by ethyl acetate, and the like.
- the viscosity of the active energy ray-curable adhesive used in the present invention is, for example, in the range of about 5 to 1000 mPa ⁇ s, preferably 10 to 200 mPa ⁇ s, and more preferably 20 to 100 mPa ⁇ s.
- the laminated film is manufactured from one optical film and two transparent films.
- the adhesive coating step the adhesive is applied to one side of each of the two transparent films, and in the bonding step, the adhesive of the two transparent films on both sides of the optical film.
- the optical film and the transparent film are bonded to each other by sandwiching the optical film and the transparent film between the pair of bonding rolls.
- FIG. 1 is a schematic diagram showing the configuration of the entire apparatus used in the manufacturing method of the present embodiment.
- the adhesive coating apparatuses 11 and 12 for applying an adhesive to one side of the transparent films 2 and 3, the transparent films 2 and 3, and the optical film 1 are bonded.
- Bonding rolls (nip rolls) 51 and 52 for obtaining the laminate 4 a roll 13 for bringing the transparent films 2 and 3 and the optical film 1 into close contact with each other in the laminate 4, and relative to the outer peripheral surface of the roll 13.
- the first active energy ray irradiation devices 14 and 15 installed at the position where the second active energy ray irradiation devices 16 to 18 are installed downstream of the first active energy ray irradiation devices 14 and 15 and the conveyance nip roll 19. are provided in order along the transport direction.
- an active energy ray-curable adhesive is applied to one side of the transparent films 2 and 3 that are continuously drawn out from a rolled state by an adhesive application device 11 or 12 ⁇ Adhesive coating Construction process>.
- coated are laminated
- the optical film 1 and the transparent films 2 and 3 are pasted by pressing at least one pasting roll in the direction of the other pasting roll while being sandwiched between a pair of pasting pasting rolls 51 and 52.
- the laminated body 4 is formed ⁇ bonding step>.
- the active energy rays are irradiated from the first active energy ray irradiating devices 14, 15 toward the outer peripheral surface of the roll 13, and bonded.
- the agent is polymerized and cured ⁇ active energy ray irradiation step>.
- the second and subsequent active energy ray irradiation devices 16 to 18 arranged on the downstream side in the transport direction are devices for completely polymerizing and curing the adhesive, and can be added or omitted as necessary.
- the laminate 4 passes through the conveyance nip roll 19 and is taken up by the take-up roll 20 as a laminated film.
- the method for applying the adhesive to the transparent films 2 and 3 is not particularly limited, and various coating methods such as a doctor blade, a wire bar, a die coater, a comma coater, and a gravure coater can be used. Of these, taking into consideration the thin film coating, the degree of freedom of the pass line, the wideness, etc., gravure rolls are preferable as the adhesive coating apparatuses 11 and 12.
- the thickness of the applied adhesive is preferably about 0.1 to 10 ⁇ m, more preferably 0.2 ⁇ m to 4 ⁇ m.
- the coating thickness of the adhesive is adjusted by the draw ratio, which is the speed ratio of the gravure roll to the line speed of the transparent film. Generally, by adjusting the draw ratio (gravure roll speed / line speed) to 0.5 to 10, the coating thickness of the adhesive can be adjusted to about 0.1 to 10 ⁇ m.
- the line speed of the transparent films 2 and 3 is set to 10 to 100 m / min
- the gravure roll is rotated in the direction opposite to the conveying direction of the transparent films 2 and 3
- the speed of the gravure roll is set to 5 to 1000 m / min.
- the adhesive is usually at a predetermined temperature ⁇ 5 ° C. within the range of 15 to 40 ° C. (for example, 30 ° C. ⁇ 5 ° C. when the predetermined temperature is 30 ° C.), preferably ⁇ 3 ° C., more preferably It is applied in an environment adjusted to ⁇ 1 ° C.
- the transparent films 2 and 3 to which the adhesive is applied by the above-described steps are laminated on both surfaces of the optical film 1 continuously drawn out from the state wound in a roll shape via the adhesive.
- the optical film 1 and the transparent film are pressed by pressing the laminating roll 51 in the direction of the laminating roll 52, for example, in a state where the laminated body is sandwiched between a pair of laminating rolls 51 and 52 rotating in the transport direction. 2 and 3 are bonded together to form a laminate 4.
- the adhesive is uniformly applied to one side of the transparent films 2, 3, and the optical film 1 is overlapped on the surface of the transparent films 2, 3 applied with the bonding rolls 51, 52.
- the adhesive agent is apply
- the pressure applied to the laminate by pressing is not particularly limited. However, when a metal roll and a rubber roll are used, the instantaneous pressure in the two-sheet type press case made of Fuji Film is 0.2 to 3.0 MPa. Is more preferable, and 0.5 to 2.3 MPa is more preferable.
- the external force of the press with respect to this bonding roll is normally applied with respect to the bearing member of the both ends of a bonding roll.
- a pair of bonding rolls may have a difference in peripheral speed between one bonding roll and the other bonding roll.
- the peripheral speed of the bonding roll (1st bonding roll) installed in the surface side bonded to the liquid crystal panel of the laminated body 4 is the opposite side of the bonding roll (2nd bonding roll). It is preferably faster than the peripheral speed.
- the polarizing plate When the obtained polarizing plate is curled (reverse curl) so that the surface to be bonded to the liquid crystal panel is concave and the opposite surface is convex, the polarizing plate is bonded to the liquid crystal cell. When it does, it will become easy to produce malfunctions, such as a bubble biting in a center part. In this case, it is preferable to use a metal roll as the first laminating roll and a rubber roll as the second laminating roll.
- the ratio of the peripheral speeds of the first laminating roll is more preferably 1.0050 to 1.0200.
- the peripheral speed of the first laminating roll is faster than this range, the curl amount of the positive curl becomes too large, causing problems such as entrapment of bubbles at the end when laminating the polarizing plate to the liquid crystal cell. This is because, when placed in a harsh environment, the positive curl is further promoted and the end of the polarizing plate may be peeled off from the liquid crystal cell.
- the roll 13 constitutes a convex curved surface whose outer peripheral surface is mirror-finished, and the laminate 4 is conveyed while closely contacting the surface, and the adhesive is polymerized and cured by the active energy ray irradiation devices 14 and 15 in the process. .
- the diameter of the roll 13 is not particularly limited when the adhesive is polymerized and cured and the laminate 4 is sufficiently adhered.
- the laminated body 4 in which the adhesive is in an uncured state is preferably irradiated with active energy rays so that the cumulative amount of light while passing through the roll 13 is 10 mJ / cm 2 or more.
- the roll 13 may be driven or rotated according to the movement of the line of the laminate 4 or may be fixed so that the laminate 4 slides on the surface.
- the roll 13 may act as a cooling roll for dissipating heat generated in the laminate 4 at the time of polymerization and curing by irradiation with active energy rays.
- the surface temperature of the cooling roll is preferably set to 20 to 30 ° C.
- the laminated film is manufactured from one optical film and one transparent film. And in the adhesive coating step, the adhesive is applied to one side of the transparent film, and in the bonding step, the optical film is laminated so that the adhesive of the transparent film is in contact with one side of the optical film. Then, the optical film and the transparent film are bonded to each other by being sandwiched between the pair of bonding rolls.
- FIG. 2 is a schematic diagram showing a configuration of the entire apparatus used in the manufacturing method of the present embodiment.
- an adhesive coating apparatus 11 for applying an adhesive to one side of the transparent film 2, the transparent film 2, and the optical film 1 are bonded to obtain a laminated body 4.
- Active energy ray irradiating devices 14 and 15, further second and subsequent active energy ray irradiating devices 16 to 18 installed downstream in the conveying direction, and a nip roll 19 for conveying are provided in order along the conveying direction. It has been.
- an active energy ray-curable adhesive is applied to one side of the transparent film 2 that is continuously drawn out from a rolled state by an adhesive application device 11 ⁇ adhesive application process>.
- coated is laminated
- the optical film 1 and the transparent film 2 are bonded and laminated by pressing at least one bonding roll in the direction of the other bonding roll in a state of being sandwiched between the bonding rolls 51 and 52.
- the body 4 is formed ⁇ bonding step>.
- the active energy rays are irradiated from the first active energy ray irradiating devices 14, 15 toward the outer peripheral surface of the roll 13, and bonded.
- the agent is polymerized and cured ⁇ active energy ray irradiation step>.
- the second and subsequent active energy ray irradiation devices 16 to 18 arranged on the downstream side in the transport direction are devices for completely polymerizing and curing the adhesive, and can be added or omitted as necessary. The details of each process are the same as those in the first embodiment, and thus are omitted.
- Example 1 a laminated film in which two films were bonded was prepared using the apparatus shown in FIG. 2 described in the second embodiment.
- a 60 ⁇ m thick cycloolefin resin film “ZEONOR” (manufactured by ZEON Corporation) and a 80 ⁇ m thick triacetyl cellulose film “KC8UX2MW” (manufactured by Konica Minolta) were prepared.
- the surface roughness (Rz) of the cycloolefin-based resin film was 30 nm when measured by “Handy Surf E35A” manufactured by Tokyo Seimitsu Co., Ltd.
- this value is an average value when the measurement distance is set to 12.5 mm, the surface roughness is measured 10 times by placing the measurement apparatus on the target film.
- the laminate in which the cycloolefin-based resin film is laminated so as to be in contact with the adhesive applied to the triacetyl cellulose film is sandwiched between a pair of nip rolls (bonding rolls) each having a diameter of 250 mm, and 1.0 MPa
- the cycloolefin resin film and the triacetylcellulose film were bonded together by pressing with pressure.
- the laminate on which the two kinds of films are bonded is transferred at a line speed of 25 m / min while applying a tension of 600 N / m in the longitudinal direction, and the total integrated light amount (of the light irradiation intensity in the wavelength region of wavelengths 280 to 320 nm).
- the laminated body was irradiated with ultraviolet rays (UVB) having an integrated amount) of about 250 mJ / cm 2 (measuring device: measured value by UV Power Pack II manufactured by FusionUV) to obtain a laminated film.
- UVB ultraviolet rays
- Example 2 a laminated film in which two films were bonded was produced using an apparatus as shown in FIG.
- the apparatus shown in FIG. 3 is obtained by omitting the cooling roll 13 and the like in the apparatus shown in FIG. Note that the reference numerals in FIG. 3 have the same meaning as in FIG.
- a 40 ⁇ m thick triacetyl cellulose film “KC4CR-1” (manufactured by Konica Minolta Co., Ltd.) and a 135 ⁇ m thick composite film laminate were prepared.
- the surface roughness (Rz) of KC4CR-1 was measured with “Handy Surf E35A” manufactured by Tokyo Seimitsu and found to be 50 nm.
- this value is an average value when the measurement distance is set to 12.5 mm, the surface roughness is measured 10 times by placing the measurement apparatus on the target film.
- the laminate on which the two kinds of films are bonded is transferred at a line speed of 25 m / min while applying a tension of 600 N / m in the longitudinal direction, and the total integrated light amount (of the light irradiation intensity in the wavelength region of wavelengths 280 to 320 nm).
- the laminated body was irradiated with ultraviolet rays (UVB) having an integrated amount) of about 250 mJ / cm 2 (measuring device: measured value by UV Power Pack II manufactured by FusionUV) to obtain a laminated film.
- UVB ultraviolet rays
- Example 1 and Example 1 were used except that a polyvinyl alcohol film having a surface roughness (Rz) of 280 nm (Vinylon VF-PS # 7500, manufactured by Kuraray, original thickness is 75 ⁇ m) was used instead of the cycloolefin film.
- Rz surface roughness
- a laminated film was produced in the same manner. About the obtained laminated
- the surface on which the adhesive is not applied in the adhesive coating step and the surface that comes into contact with the adhesive in the bonding step is 200 nm or less.
- Example 1 it can be seen that bubbles are not mixed between the films, and in Comparative Example 1 using a film having a surface roughness outside the range of the present invention, bubbles are mixed between the films.
- Example 1 a cycloolefin film was used as a film having a surface roughness of 30 nm, and a polyvinyl alcohol film was used as a film having a surface roughness of 280 nm in the comparative example. Since films having different surface roughness were selected, films having different materials were only used. That is, even when films made of the same material but different only in surface roughness are compared, it is considered that the same effect difference is observed. Therefore, in this invention, each film which comprises a laminated film is not limited to the material described in the said Example, A laminated film can be manufactured using the film which consists of various materials.
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Abstract
Description
前記複数のフィルムのうち、少なくとも1枚のフィルムの片面または両面に、活性エネルギー線硬化型の接着剤を塗工する接着剤塗工工程と、
隣り合うフィルムの間に前記接着剤が介在するように積層した状態で、前記複数のフィルムを、搬送方向に回転する一対の貼合ロールの間に挟むことで、互いに貼合する貼合工程と、
互いに貼合された前記複数のフィルムに、活性エネルギー線を照射して前記接着剤を硬化させる活性エネルギー線照射工程とをこの順で備え、
前記複数のフィルムにおいて、前記接着剤塗工工程において前記接着剤が塗工されなかった面であって、前記貼合工程において前記接着剤と接することとなる面の表面粗さが200nm以下である方法を提供する。
前記接着剤塗工工程において、2枚の前記透明フィルムそれぞれの片面に前記接着剤を塗工し、
前記貼合工程において、前記光学フィルムの両面に2枚の前記透明フィルムの前記接着剤が接するように積層した状態で、前記光学フィルムおよび前記透明フィルムを、前記一対の貼合ロールの間に挟むことで、互いに貼合することが好ましい。
前記接着剤塗工工程において、前記透明フィルムの片面に前記接着剤を塗工し、
前記貼合工程において、前記光学フィルムの片面に前記透明フィルムの前記接着剤が接するように積層した状態で、前記光学フィルムおよび前記透明フィルムを、前記一対の貼合ロールの間に挟むことで、互いに貼合することが好ましい。
前記複数のフィルムのうち、少なくとも1枚のフィルムの片面または両面に、活性エネルギー線硬化型の接着剤を塗工する接着剤塗工工程と、
前記複数のフィルムを、隣り合うフィルムの間に前記接着剤が介在するように積層した状態で、搬送方向に回転する一対の貼合ロールの間に挟むことで、前記複数のフィルムを互いに貼合する貼合工程と、
互いに貼合された前記複数のフィルムに、活性エネルギー線を照射して前記接着剤を硬化させる活性エネルギー線照射工程とをこの順で備える。
光学フィルムとは、例えば偏光フィルムや位相差フィルム、3Dテレビ用のパターンリターダーフィルムであり、1枚のフィルムであってもよく、複数のフィルムの積層体であってもよい。
本発明において、積層フィルムとして偏光板を製造する場合、上述した光学フィルムの片面または両面には透明フィルムが貼合される。光学フィルムの両面に透明フィルムが貼合される場合、各々の透明フィルムは同じものであってもよく、異なる種類のフィルムであってもよい。
本発明で用いられる活性エネルギー線硬化型の接着剤としては、耐候性や屈折率、カチオン重合性などの観点から、例えば、活性エネルギー線の照射により硬化するエポキシ樹脂を含有するエポキシ系樹脂組成物からなる接着剤が挙げられる。ただし、これに限定されるものではなく、従来から偏光板の製造に使用されている各種の活性エネルギー線硬化型の接着剤(有機溶剤系接着剤、ホットメルト系接着剤、無溶剤型接着剤など)が採用可能である。
(i)次式(IX)で示されるエポキシシクロペンチルエーテル類:
上記例示した脂環式エポキシ樹脂の中でも、次の脂環式エポキシ樹脂は、市販されているか、またはその類似物であって、入手が比較的容易である等の理由からより好ましく用いられる。
(B)4-メチル-7-オキサビシクロ[4.1.0]ヘプタン-3-カルボン酸と(4-メチル-7-オキサ-ビシクロ[4.1.0]ヘプト-3-イル)メタノールとのエステル化物[式(I)において、R1=4-CH3、R2=4-CH3の化合物]、
(C)7-オキサビシクロ[4.1.0]ヘプタン-3-カルボン酸と1,2-エタンジオールとのエステル化物[式(II)において、R3=R4=H、n=2の化合物]、
(D)(7-オキサビシクロ[4.1.0]ヘプト-3-イル)メタノールとアジピン酸とのエステル化物[式(III)において、R5=R6=H、p=4の化合物]、
(E)(4-メチル-7-オキサビシクロ[4.1.0]ヘプト-3-イル)メタノールとアジピン酸とのエステル化物[式(III)において、R5=4-CH3、R6=4-CH3、p=4の化合物]、
(F)(7-オキサビシクロ[4.1.0]ヘプト-3-イル)メタノールと1,2-エタンジオールとのエーテル化物[式(V)において、R9=R10=H、r=2の化合物]。
(実施形態1)
本実施形態において、積層フィルムは、1枚の光学フィルムおよび2枚の透明フィルムから製造される。そして、前記接着剤塗工工程において、2枚の前記透明フィルムそれぞれの片面に前記接着剤を塗工し、前記貼合工程において、前記光学フィルムの両面に2枚の前記透明フィルムの前記接着剤が接するように積層した状態で、前記光学フィルムおよび前記透明フィルムを、前記一対の貼合ロールの間に挟むことで、互いに貼合する。
透明フィルム2,3への接着剤の塗工方法は特に限定されないが、例えば、ドクターブレード、ワイヤーバー、ダイコーター、カンマコーター、グラビアコーターなど、種々の塗工方式が利用できる。このうち、薄膜塗工、パスラインの自由度、幅広への対応などを考慮すると、接着剤塗工装置11,12としてはグラビアロールが好ましい。
本工程では、ロール状に巻回された状態から連続的に繰り出された光学フィルム1の両面に、上記工程により接着剤が塗布された透明フィルム2,3が接着剤を介して積層される。この積層体を、搬送方向に回転する一対の貼合ロール51,52の間に挟んだ状態で、例えば貼合ロール51を貼合ロール52の方向に押圧することで、光学フィルム1と透明フィルム2,3とが貼合され、積層体4が形成される。
本実施形態において、積層フィルムは、1枚の光学フィルムおよび1枚の透明フィルムから製造される。そして、前記接着剤塗工工程において、前記透明フィルムの片面に前記接着剤を塗工し、前記貼合工程において、前記光学フィルムの片面に前記透明フィルムの前記接着剤が接するように積層した状態で、前記光学フィルムおよび前記透明フィルムを、前記一対の貼合ロールの間に挟むことで、互いに貼合する。
本実施例では、上記実施形態2で説明した図2に示すような装置を用いて、2枚のフィルムが貼合された積層フィルムを作製した。
<実施例2>
本実施例では、図3に示すような装置を用いて、2枚のフィルムが貼合された積層フィルムを作製した。図3に示す装置は、上記実施形態2で説明した図2に示す装置において冷却ロール13等が省略されたものであり、詳細説明は省略する。なお、図3における参照符号は、図2と同じ意味で用いている。
<比較例1>
シクロオレフィン系フィルムの代わりに、表面粗さ(Rz)が280nmであるポリビニルアルコール系フィルム(クラレ製のビニロンVF-PS#7500、原反厚みは75μm)を用いたこと以外は、実施例1と同様にして積層フィルムを作製した。得られた積層フィルムについて、フィルムの間に目視で気泡が観察された。
Claims (5)
- 複数のフィルムが活性エネルギー線硬化型の接着剤を介して互いに貼合された積層フィルムの製造方法であって、
前記複数のフィルムのうち、少なくとも1枚のフィルムの片面または両面に、活性エネルギー線硬化型の接着剤を塗工する接着剤塗工工程と、
隣り合うフィルムの間に前記接着剤が介在するように積層した状態で、前記複数のフィルムを、搬送方向に回転する一対の貼合ロールの間に挟むことで、互いに貼合する貼合工程と、
互いに貼合された前記複数のフィルムに、活性エネルギー線を照射して前記接着剤を硬化させる活性エネルギー線照射工程とをこの順で備え、
前記複数のフィルムにおいて、前記接着剤塗工工程において前記接着剤が塗工されなかった面であって、前記貼合工程において前記接着剤と接することとなる面の表面粗さが200nm以下である方法。 - 前記接着剤塗工工程において塗工される前記接着剤の厚みが2μm以下である、請求項1に記載の方法。
- 前記複数のフィルムは、光学フィルムおよび透明フィルムを含み、前記積層フィルムは偏光板である、請求項1または2に記載の方法。
- 前記複数のフィルムは、1枚の光学フィルムおよび2枚の透明フィルムからなり、
前記接着剤塗工工程において、2枚の前記透明フィルムそれぞれの片面に前記接着剤を塗工し、
前記貼合工程において、前記光学フィルムの両面に2枚の前記透明フィルムの前記接着剤が接するように積層した状態で、前記光学フィルムおよび前記透明フィルムを、前記一対の貼合ロールの間に挟むことで、互いに貼合する、請求項3に記載の方法。 - 前記複数のフィルムは、1枚の光学フィルムおよび1枚の透明フィルムからなり、
前記接着剤塗工工程において、前記透明フィルムの片面に前記接着剤を塗工し、
前記貼合工程において、前記光学フィルムの片面に前記透明フィルムの前記接着剤が接するように積層した状態で、前記光学フィルムおよび前記透明フィルムを、前記一対の貼合ロールの間に挟むことで、互いに貼合する、請求項3に記載の方法。
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