WO2014125985A1 - 偏光膜の製造方法 - Google Patents
偏光膜の製造方法 Download PDFInfo
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- WO2014125985A1 WO2014125985A1 PCT/JP2014/052732 JP2014052732W WO2014125985A1 WO 2014125985 A1 WO2014125985 A1 WO 2014125985A1 JP 2014052732 W JP2014052732 W JP 2014052732W WO 2014125985 A1 WO2014125985 A1 WO 2014125985A1
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- WIPO (PCT)
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- stretching
- resin
- base material
- polarizing film
- resin base
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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
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
- B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
- B29C55/14—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/023—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets using multilayered plates or sheets
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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
-
- 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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
- Y10T428/31797—Next to addition polymer from unsaturated monomers
Definitions
- the present invention relates to a method for manufacturing a polarizing film.
- polarizing films are arranged on both sides of a liquid crystal cell due to the image forming method.
- a method for producing a polarizing film for example, there is a method in which a laminate having a resin base material and a polyvinyl alcohol (PVA) resin layer is stretched and then subjected to a dyeing treatment to obtain a polarizing film on the resin base material. It has been proposed (for example, Patent Document 1). According to such a method, a polarizing film having a small thickness can be obtained, and thus has been attracting attention as being able to contribute to the recent thinning of image display devices.
- PVA polyvinyl alcohol
- the present invention has been made to solve the above-mentioned problems, and a main object of the present invention is to provide a method for producing a polarizing film having excellent production efficiency while maintaining optical characteristics.
- the method for producing a polarizing film of the present invention includes a step of stretching a resin base material in a first direction, a step of heating the resin base material, and forming and laminating a polyvinyl alcohol-based resin layer on the resin base material.
- the stretching temperature in the first direction is 70 ° C. to 150 ° C.
- the heating temperature is 70 ° C to 150 ° C.
- the resin substrate is formed from a polyethylene terephthalate resin.
- ⁇ n of the resin substrate after the heating is 0.0016 or less.
- a polarizing film is provided.
- This polarizing film is obtained by the above production method.
- an optical laminate is provided.
- This optical layered body has the polarizing film.
- a laminate is provided.
- This laminate is formed of a polyethylene terephthalate resin, and has a resin base material having an ⁇ n of 0.0016 or less, and a polyvinyl alcohol resin layer formed on the resin base material.
- a polarizing film having excellent optical properties can be produced efficiently by heating after stretching the resin substrate.
- the laminate is formed in the second direction by forming a PVA-based resin layer in a state in which the residual stress generated by stretching the resin base material in the first direction is relaxed.
- the shrinkage rate in the first direction can be reduced. As a result, manufacturing efficiency can be improved.
- FIG. 3A and FIG. 3B are schematic cross-sectional views of an optical film laminate using the polarizing film of the present invention, respectively.
- 4 (a) and 4 (b) are schematic sectional views of an optical functional film laminate using the polarizing film of the present invention, respectively.
- a method for producing a polarizing film of the present invention comprises a step of stretching a resin substrate in a first direction (first stretching step), a step of heating the resin substrate (heating step), and a resin.
- a step of forming a laminate by forming a polyvinyl alcohol (PVA) -based resin layer on the substrate (laminate preparation step), and a step of extending the laminate in the second direction (second extension step) Include in this order.
- PVA polyvinyl alcohol
- thermoplastic resin examples include ester resins such as polyethylene terephthalate resins, cycloolefin resins such as norbornene resins, olefin resins such as polypropylene, polyamide resins, polycarbonate resins, and copolymer resins thereof. Can be mentioned. Among these, amorphous (non-crystallized) polyethylene terephthalate resin is preferably used. Among these, amorphous (hard to crystallize) polyethylene terephthalate resin is particularly preferably used.
- amorphous polyethylene terephthalate resin examples include a copolymer further containing isophthalic acid as a dicarboxylic acid, and a copolymer further containing cyclohexanedimethanol as a glycol.
- the resin substrate has a water absorption rate of preferably 0.2% or more, and more preferably 0.3% or more.
- the resin base material absorbs water, and the water can be plasticized by acting as a plasticizer.
- the stretching stress can be greatly reduced, the film can be stretched at a high magnification, and the stretchability can be superior to that during air stretching.
- a polarizing film having excellent optical characteristics can be manufactured.
- the water absorption rate of the resin base material is preferably 3.0% or less, more preferably 1.0% or less.
- a resin base material By using such a resin base material, it is possible to prevent problems such as a significant decrease in dimensional stability during production and deterioration of the appearance of the resulting polarizing film. Moreover, it can prevent that a resin base material fractures
- the water absorption rate of the resin base material can be adjusted, for example, by introducing a modifying group into the constituent material. The water absorption is a value determined according to JIS K 7209.
- the glass transition temperature (Tg) of the resin base material is preferably 170 ° C. or lower.
- the stretchability of the laminate can be sufficiently ensured while suppressing crystallization of the PVA-based resin layer.
- the temperature is more preferably 120 ° C. or lower.
- the glass transition temperature of the resin substrate is preferably 60 ° C. or higher.
- the PVA resin layer can be stretched at a suitable temperature (for example, about 60 ° C.).
- a glass transition temperature lower than 60 ° C. may be used as long as the resin base material does not deform when applying and drying a coating solution containing a PVA-based resin.
- the glass transition temperature of the resin substrate can be adjusted by, for example, heating using a crystallization material that introduces a modifying group into the constituent material.
- the glass transition temperature (Tg) is a value determined according to JIS K 7121.
- the thickness of the resin substrate (before stretching) is preferably 20 ⁇ m to 300 ⁇ m, more preferably 50 ⁇ m to 200 ⁇ m.
- the first direction can be set to any appropriate direction depending on the desired polarizing film.
- the first direction is the width direction of the long resin base material. In this case, typically, a method of stretching using a tenter stretching machine is employed.
- the first direction is the longitudinal direction of the long resin base material. In this case, typically, a method of stretching the laminate between rolls having different peripheral speeds is employed.
- any appropriate method can be adopted as a method for stretching the resin base material. Specifically, it may be fixed end stretching or free end stretching.
- the stretching of the resin base material may be performed in one stage or in multiple stages. When performed in multiple stages, the stretch ratio of the resin base material described later is the product of the stretch ratios of the respective stages.
- stretching system in this process is not specifically limited, An air extending
- the stretching temperature of the resin base material can be set to any appropriate value depending on the forming material of the resin base material, the stretching method, and the like.
- the stretching temperature is preferably Tg-10 ° C. to Tg + 80 ° C. with respect to the glass transition temperature (Tg) of the resin substrate.
- Tg glass transition temperature
- the stretching temperature is preferably 70 ° C. to 150 ° C., more preferably 90 ° C. to 130 ° C.
- the stretching temperature is too high, the thickness of the end portion in the stretching direction of the resin base material becomes thick, and there is a possibility that the effective width of the resin base material cannot be sufficiently secured. If the stretching temperature is too low, ⁇ n described later may be increased, and the effect of heating described later may not be sufficiently obtained.
- the draw ratio of the resin base material is preferably 1.5 to 3.0 times the original length of the resin base material.
- A-2 Heating step After stretching in the first direction, the resin substrate is heated.
- the resin base material By heating the resin base material, the residual stress generated in the resin base material due to the stretching in the first direction is relaxed, and the shrinkage ratio in the first direction in the stretching in the second direction described later is reduced. Can be made. As a result, manufacturing efficiency can be improved. Furthermore, ⁇ n of the resin base material is lowered by heating.
- the heating conditions are controlled so that a predetermined ⁇ n is obtained.
- a polyethylene terephthalate resin is used as the resin substrate forming material, it is preferable to heat the resin substrate so that the ⁇ n of the resin substrate is 0.0016 or less. If it is such a range, the said shrinkage
- ⁇ n of the resin base material after heating is preferably 0 (zero) or more.
- the heating temperature is preferably Tg-10 ° C. to Tg + 80 ° C., more preferably Tg ° C. to Tg + 60 ° C. with respect to the glass transition temperature (Tg) of the resin base material.
- Tg glass transition temperature
- the heating temperature is preferably 70 ° C. to 150 ° C., more preferably 80 ° C. to 130 ° C.
- the heating time is preferably 10 to 60 seconds, more preferably 20 to 40 seconds.
- the heating step may be performed continuously or intermittently after the first stretching step, but is preferably performed continuously.
- FIG. 1 is a schematic view showing an example of the first stretching step and the heating step.
- the preheating zone 2 from the entrance side, the preheating zone 2, the first stretching zone 3, the heating zone 4 and the cooling zone 5 are provided in this order in the tenter stretching machine 1, and the long resin substrate 11 is Transport in the longitudinal direction.
- the long resin base material 11 wound in a roll shape is unwound, and the width direction end portions 11a and 11a of the resin base material 11 are gripped by gripping means (clips) 6 and 6.
- the resin base material 11 gripped by the left and right clips 6 and 6 is conveyed at a predetermined speed, led to the first stretching zone 2, and the resin base material 11 is heated to the stretching temperature.
- Arbitrary appropriate means can be employ
- heating devices such as a hot air type, a panel heater, and a halogen heater can be used.
- a hot air type is used.
- the resin substrate 11 is stretched in the width direction at the stretching temperature.
- the clips 6 and 6 holding the end portions 11a and 11a are moved outward in the width direction while conveying the resin base material 11 at a predetermined speed.
- the resin base material 11 is continuously heated to the heating temperature in the heating zone 4.
- the clips 6 and 6 are not moved substantially in the width direction but are held at the stretched width.
- substantially means that the clip is a short distance (for example, about 1% of the total width) for the purpose of suppressing film fluttering in the heating process or fine-tuning the thickness, retardation, axial direction, etc. The purpose is to allow the width to be increased or decreased by moving.
- the same heating means as in the preheating zone 2 can be adopted.
- the resin base material 11 is cooled to a predetermined temperature, and is supplied to the next step.
- Each zone substantially means a zone where the resin substrate is preheated, stretched, heated and cooled, and does not mean a mechanically and structurally independent section.
- FIG. 2 is a schematic cross-sectional view of a laminate according to a preferred embodiment of the present invention.
- the laminate 10 includes a resin base material 11 and a PVA resin layer 12, and is produced by forming the PVA resin layer 12 on the resin base material 11. Any appropriate method can be adopted as a method of forming the PVA-based resin layer.
- a PVA-based resin layer is formed by applying a coating solution containing a PVA-based resin on a resin base material and drying it.
- any appropriate resin can be adopted as the PVA resin for forming the PVA resin layer.
- Examples thereof include polyvinyl alcohol and ethylene-vinyl alcohol copolymer.
- Polyvinyl alcohol is obtained by saponifying polyvinyl acetate.
- the ethylene-vinyl alcohol copolymer can be obtained by saponifying an ethylene-vinyl acetate copolymer.
- the degree of saponification of the PVA-based resin is usually 85 mol% to 100 mol%, preferably 95.0 mol% to 99.95 mol%, more preferably 99.0 mol% to 99.93 mol%. .
- the degree of saponification can be determined according to JIS K 6726-1994. By using a PVA-based resin having such a saponification degree, a polarizing film having excellent durability can be obtained. If the degree of saponification is too high, there is a risk of gelation.
- the average degree of polymerization of the PVA resin can be appropriately selected according to the purpose.
- the average degree of polymerization is usually 1000 to 10000, preferably 1200 to 5000, and more preferably 1500 to 4500.
- the average degree of polymerization can be determined according to JIS K 6726-1994.
- the coating solution is typically a solution obtained by dissolving the PVA resin in a solvent.
- the solvent include water, dimethyl sulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, various glycols, polyhydric alcohols such as trimethylolpropane, and amines such as ethylenediamine and diethylenetriamine. These may be used alone or in combination of two or more. Among these, water is preferable.
- the concentration of the PVA resin in the solution is preferably 3 to 20 parts by weight with respect to 100 parts by weight of the solvent. With such a resin concentration, a uniform coating film in close contact with the resin substrate can be formed.
- Additives may be added to the coating solution.
- the additive include a plasticizer and a surfactant.
- the plasticizer include polyhydric alcohols such as ethylene glycol and glycerin.
- the surfactant include nonionic surfactants. These can be used for the purpose of further improving the uniformity, dyeability and stretchability of the resulting PVA-based resin layer.
- any appropriate method can be adopted as a coating method of the coating solution. Examples thereof include a roll coating method, a spin coating method, a wire bar coating method, a dip coating method, a die coating method, a curtain coating method, a spray coating method, a knife coating method (comma coating method and the like).
- the coating / drying temperature of the coating solution is preferably 50 ° C. or higher.
- the thickness of the PVA resin layer (before stretching) is preferably 3 ⁇ m to 20 ⁇ m.
- the resin substrate Before forming the PVA-based resin layer, the resin substrate may be subjected to surface treatment (for example, corona treatment), or an easy-adhesion layer may be formed on the resin substrate. By performing such a treatment, the adhesion between the resin substrate and the PVA resin layer can be improved. Moreover, arbitrary appropriate functional layers (for example, antistatic layer) may be formed in the side in which the PVA-type resin layer of the resin base material is not formed.
- surface treatment for example, corona treatment
- an easy-adhesion layer may be formed on the resin substrate.
- the said 2nd direction may be set to arbitrary appropriate directions according to a desired polarizing film.
- the second direction is orthogonal to the first direction.
- the first direction is the width direction of the long resin base material
- the second direction is preferably the longitudinal direction of the long laminate.
- the term “orthogonal” includes the case of being substantially orthogonal.
- substantially orthogonal includes the case of 90 ° ⁇ 5.0 °, preferably 90 ° ⁇ 3.0 °, more preferably 90 ° ⁇ 1.0 °.
- the second direction is substantially the absorption axis direction of the obtained polarizing film.
- Arbitrary appropriate methods can be employ
- Free-end stretching usually means a stretching method in which stretching is performed only in one direction. When the laminate is stretched in a certain direction, the laminate can shrink in a direction substantially perpendicular to the stretch direction. A method of stretching without suppressing the shrinkage is called free end stretching.
- the stretching method is not particularly limited, and an in-air stretching method or an underwater stretching method may be used, but an underwater stretching method is preferably employed.
- the resin base material and the PVA resin layer can be stretched at a temperature lower than the glass transition temperature (typically about 80 ° C.), and the crystallization of the PVA resin layer is suppressed. However, it can be stretched at a high magnification. As a result, a polarizing film having excellent optical characteristics can be manufactured.
- the stretching of the laminate may be performed in one stage or in multiple stages.
- the free end stretching and the fixed end stretching may be combined, or the underwater stretching method and the air stretching method may be combined.
- the draw ratio (maximum draw ratio) of the laminated body mentioned later is a product of the draw ratio of each step.
- the stretching temperature of the laminate can be set to any appropriate value depending on the resin base material, the stretching method, and the like.
- the stretching temperature is preferably equal to or higher than the glass transition temperature (Tg) of the resin substrate, more preferably the glass transition temperature (Tg) of the resin substrate + 10 ° C., and particularly preferably Tg + 15 ° C. That's it.
- the stretching temperature of the laminate is preferably 170 ° C. or lower.
- the liquid temperature of the stretching bath is preferably 40 ° C. to 85 ° C., more preferably 50 ° C. to 85 ° C. If it is such temperature, it can extend
- the glass transition temperature (Tg) of the resin base material is preferably 60 ° C. or higher in relation to the formation of the PVA-based resin layer.
- Tg glass transition temperature
- the stretching temperature is lower than 40 ° C., there is a possibility that the stretching cannot be satisfactorily performed even in consideration of plasticization of the resin base material with water.
- the higher the temperature of the stretching bath the higher the solubility of the PVA-based resin layer, and there is a possibility that excellent optical properties cannot be obtained.
- the immersion time of the laminate in the stretching bath is preferably 15 seconds to 5 minutes.
- the laminate When employing an underwater stretching method, it is preferable to stretch the laminate by immersing it in an aqueous boric acid solution (stretching in boric acid in water).
- an aqueous boric acid solution as the stretching bath, the PVA resin layer can be provided with rigidity that can withstand the tension applied during stretching and water resistance that does not dissolve in water.
- boric acid can form a tetrahydroxyborate anion in an aqueous solution and crosslink with a PVA resin by hydrogen bonding.
- rigidity and water resistance can be imparted to the PVA-based resin layer, the film can be stretched well, and a polarizing film having excellent optical properties can be produced.
- the boric acid aqueous solution is preferably obtained by dissolving boric acid and / or borate in water as a solvent.
- the boric acid concentration is preferably 1 to 10 parts by weight with respect to 100 parts by weight of water. By setting the boric acid concentration to 1 part by weight or more, dissolution of the PVA resin layer can be effectively suppressed, and a polarizing film having higher characteristics can be produced.
- an aqueous solution obtained by dissolving a boron compound such as borax, glyoxal, glutaraldehyde, or the like in a solvent can also be used.
- a dichroic substance typically iodine
- an iodide is blended in the stretching bath (boric acid aqueous solution).
- the iodide include potassium iodide, lithium iodide, sodium iodide, zinc iodide, aluminum iodide, lead iodide, copper iodide, barium iodide, calcium iodide, tin iodide, and titanium iodide.
- the concentration of iodide is preferably 0.05 to 15 parts by weight, more preferably 0.5 to 8 parts by weight with respect to 100 parts by weight of water.
- the draw ratio (maximum draw ratio) of the laminate is preferably 5.0 times or more with respect to the original length of the laminate. Such a high draw ratio can be achieved, for example, by employing an underwater drawing method (boric acid underwater drawing).
- the “maximum stretch ratio” refers to a stretch ratio immediately before the laminate is ruptured. Separately, a stretch ratio at which the laminate is ruptured is confirmed, and a value that is 0.2 lower than that value. .
- the laminate is stretched in air at a high temperature (for example, 95 ° C. or higher), and then stretched in boric acid in water and dyeing described later.
- air stretching can be positioned as preliminary or auxiliary stretching for boric acid water stretching, and is hereinafter referred to as “air-assisted stretching”.
- the laminate can be stretched at a higher magnification by combining air-assisted stretching.
- a polarizing film having more excellent optical characteristics for example, the degree of polarization
- the orientation of the resin base material is suppressed by combining the air auxiliary stretching and the boric acid water stretching rather than stretching by boric acid water stretching alone. While stretching.
- the orientation of the resin base material is improved, the stretching tension increases, and stable stretching becomes difficult or breaks. Therefore, the laminate can be stretched at a higher magnification by stretching while suppressing the orientation of the resin substrate.
- the orientation of the PVA-based resin can be improved, whereby the orientation of the PVA-based resin can be improved even after stretching in boric acid water.
- the PVA resin is easily cross-linked with boric acid during boric acid water stretching, and boric acid is a nodal point. It is presumed that the orientation of the PVA-based resin is increased even after stretching in boric acid solution by being stretched in such a state. As a result, a polarizing film having excellent optical characteristics (for example, the degree of polarization) can be manufactured.
- the stretching ratio in the air auxiliary stretching is preferably 3.5 times or less.
- the stretching temperature of the air auxiliary stretching is preferably equal to or higher than the glass transition temperature of the PVA resin.
- the stretching temperature is preferably 95 ° C to 150 ° C.
- the maximum draw ratio in the case of combining the air auxiliary stretching and the boric acid solution stretching is preferably 5.0 times or more, more preferably 5.5 times or more, and further preferably, the original length of the laminate. Is 6.0 times or more.
- the manufacturing method of the polarizing film of the present invention can include other steps in addition to the above steps.
- Examples of other processes include a dyeing process, an insolubilizing process, a crosslinking process, a washing process, and a drying process.
- the other steps can be performed at any appropriate timing.
- the dyeing step is typically a step of dyeing the PVA resin layer with a dichroic substance.
- it is performed by adsorbing a dichroic substance to the PVA resin layer.
- the adsorption method include a method of immersing a PVA resin layer (laminated body) in a staining solution containing a dichroic substance, a method of applying the staining solution to a PVA resin layer, and a method of applying the staining solution to a PVA system.
- Examples include a method of spraying on the resin layer.
- the laminate is immersed in a staining solution containing a dichroic substance. It is because a dichroic substance can adsorb
- the dichroic substance examples include iodine and dichroic dyes. Preferably, it is iodine.
- the staining solution is an iodine aqueous solution.
- the amount of iodine is preferably 0.1 to 0.5 parts by weight with respect to 100 parts by weight of water.
- an iodide is added to the aqueous iodine solution. Specific examples of the iodide are as described above.
- the blending amount of iodide is preferably 0.02 to 20 parts by weight, more preferably 0.1 to 10 parts by weight with respect to 100 parts by weight of water.
- the liquid temperature during dyeing of the dyeing liquid is preferably 20 ° C. to 50 ° C. in order to suppress dissolution of the PVA resin.
- the immersion time is preferably 5 seconds to 5 minutes in order to ensure the transmittance of the PVA resin layer.
- the staining conditions can be set so that the polarization degree or single transmittance of the finally obtained polarizing film is within a predetermined range. In one embodiment, immersion time is set so that the polarization degree of the polarizing film obtained may be 99.98% or more. In another embodiment, the immersion time is set so that the obtained polarizing film has a single transmittance of 40% to 44%.
- the insolubilization step is typically performed by immersing the PVA resin layer in an aqueous boric acid solution.
- the concentration of the boric acid aqueous solution is preferably 1 to 4 parts by weight with respect to 100 parts by weight of water.
- the liquid temperature of the insolubilizing bath (boric acid aqueous solution) is preferably 20 ° C. to 50 ° C.
- the cross-linking step is typically performed by immersing the PVA resin layer in an aqueous boric acid solution.
- the concentration of the boric acid aqueous solution is preferably 1 to 4 parts by weight with respect to 100 parts by weight of water.
- blend iodide it is preferable to mix
- iodide By blending iodide, elution of iodine adsorbed on the PVA resin layer can be suppressed.
- the blending amount of iodide is preferably 1 to 5 parts by weight with respect to 100 parts by weight of water. Specific examples of the iodide are as described above.
- the liquid temperature of the crosslinking bath (boric acid aqueous solution) is preferably 20 ° C. to 60 ° C.
- the cleaning step is typically performed by immersing the PVA resin layer in an aqueous potassium iodide solution.
- the drying temperature in the drying step is preferably 30 ° C. to 100 ° C.
- the polarizing film of the present invention is substantially a PVA resin film in which a dichroic substance is adsorbed and oriented.
- the thickness of the polarizing film is preferably 10 ⁇ m or less, more preferably 7 ⁇ m or less, and still more preferably 5 ⁇ m or less.
- the thickness of the polarizing film is preferably 0.5 ⁇ m or more, more preferably 1.5 ⁇ m or more.
- the polarizing film preferably exhibits absorption dichroism at any wavelength of 380 nm to 780 nm.
- the single transmittance of the polarizing film is preferably 40.0% or more, more preferably 41.0% or more, further preferably 42.0% or more, and particularly preferably 42.8% or more.
- the polarization degree of the polarizing film is preferably 99.8% or more, more preferably 99.9% or more, and further preferably 99.95% or more.
- any appropriate method can be adopted as a method of using the polarizing film. Specifically, it may be used in a state integrated with the resin base material, or may be transferred from the resin base material to another member for use.
- FIG. 3A and FIG. 3B are schematic sectional views of an optical film laminate according to a preferred embodiment of the present invention.
- the optical film laminate 100 includes a resin substrate 11 ′, a polarizing film 12 ′, an adhesive layer 13, and a separator 14 in this order.
- the optical film laminate 200 includes a resin substrate 11 ′, a polarizing film 12 ′, an adhesive layer 15, an optical function film 16, an adhesive layer 13, and a separator 14 in this order.
- the resin base material is used as it is as an optical member without being peeled from the obtained polarizing film 12 ′.
- Resin base material 11 ' can function as a protective film of polarizing film 12', for example.
- optical functional film laminate 300 includes the separator 14, the pressure-sensitive adhesive layer 13, the polarizing film 12 ', the adhesive layer 15, and the optical functional film 16 in this order.
- the second optical functional film 16 ′ is provided between the polarizing film 12 ′ and the separator 14 with the adhesive layer 13 interposed therebetween.
- the resin base material is removed.
- each layer constituting the optical laminate of the present invention is not limited to the illustrated example, and any appropriate pressure-sensitive adhesive layer or adhesive layer is used.
- the pressure-sensitive adhesive layer is typically formed of an acrylic pressure-sensitive adhesive.
- the adhesive layer is typically formed of a vinyl alcohol adhesive.
- the optical functional film can function as, for example, a polarizing film protective film or a retardation film.
- Example 1 As a resin base material, an amorphous polyethylene terephthalate (A-PET) film (trade name “NOVACLEAR SH046 ”, thickness: 100 ⁇ m) was used. Using a tenter stretching machine, the resin substrate was stretched twice in the transverse direction at 105 ° C. while being conveyed in the longitudinal direction. At this time (after stretching and before heating), ⁇ n of the resin base material was 0.00249. Subsequently, the resin base material was heated at 120 ° C. for 30 seconds while being substantially held at the stretch width by the clip of the tenter stretching machine. The ⁇ n of the resin base material after heating was 0.00124.
- A-PET amorphous polyethylene terephthalate
- an aqueous solution of polyvinyl alcohol having a polymerization degree of 4200 and a saponification degree of 99.2 mol% is applied to one side of the resin base material at 60 ° C. and dried to form a PVA resin layer having a thickness of 10 ⁇ m.
- aqueous solution of polyvinyl alcohol having a polymerization degree of 4200 and a saponification degree of 99.2 mol% is applied to one side of the resin base material at 60 ° C. and dried to form a PVA resin layer having a thickness of 10 ⁇ m.
- the obtained laminate was uniaxially stretched in the longitudinal direction (longitudinal direction) twice in the longitudinal direction (longitudinal direction) between rolls having different peripheral speeds in an oven at 130 ° C. (air-assisted stretching).
- the laminate was immersed for 30 seconds in an insolubilization bath (a boric acid aqueous solution obtained by blending 4 parts by weight of boric acid with respect to 100 parts by weight of water) at a liquid temperature of 30 ° C. (insolubilization step).
- insolubilization step a boric acid aqueous solution obtained by blending 4 parts by weight of boric acid with respect to 100 parts by weight of water
- it is immersed for 60 seconds in a dyeing bath having a liquid temperature of 30 ° C.
- the laminate was immersed in a boric acid aqueous solution (an aqueous solution obtained by blending 4 parts by weight of boric acid and 5 parts by weight of potassium iodide with respect to 100 parts by weight of water) at a liquid temperature of 70 ° C.
- a boric acid aqueous solution an aqueous solution obtained by blending 4 parts by weight of boric acid and 5 parts by weight of potassium iodide with respect to 100 parts by weight of water
- uniaxial stretching was performed in the longitudinal direction (longitudinal direction) between rolls having different peripheral speeds (underwater stretching).
- the laminate was immersed in a washing bath having a liquid temperature of 30 ° C.
- Example 2 A polarizing film was formed in the same manner as in Example 1 except that the heating time of the resin substrate was 40 seconds.
- Example 3 A polarizing film was formed in the same manner as in Example 1 except that the heating time of the resin substrate was 50 seconds.
- Example 4 A polarizing film was formed in the same manner as in Example 1 except that the heating temperature of the resin substrate was 125 ° C. and the heating time was 40 seconds.
- Example 5 A polarizing film was formed in the same manner as in Example 1 except that the stretching temperature of the resin substrate was 115 ° C., the heating temperature was 105 ° C., and the heating time was 40 seconds. In this example, ⁇ n of the resin base material after stretching and before heating was 0.00093.
- Example 1 A polarizing film was formed in the same manner as in Example 1 except that the stretching temperature of the resin substrate was 90 ° C. and that the resin substrate was not heated after stretching.
- Example 2 A polarizing film was formed in the same manner as in Example 1 except that the stretching temperature of the resin substrate was 100 ° C. and that the resin substrate was not heated after stretching.
- Example 3 A polarizing film was formed in the same manner as in Example 1 except that heating was not performed after stretching.
- Example 4 A polarizing film was formed in the same manner as in Example 5 except that heating was not performed after stretching.
- Example 5 A polarizing film was formed in the same manner as in Example 1 except that the resin base material was not stretched or heated.
- the width residual rate, film thickness distribution, and the optical characteristic of the polarizing film were evaluated. Evaluation methods and evaluation criteria are as follows, and the evaluation results are shown in Table 1.
- ⁇ n represents a value after heating for the examples, and a value after transverse stretching for the comparative examples. 1. Width remaining rate The width remaining rate was evaluated by measuring the width of the resin substrate after the above-described air-assisted stretching and calculating the width remaining rate with respect to the original length (width) of the resin substrate.
- Polarization degree (P) (%) ⁇ (Tp ⁇ Tc) / (Tp + Tc) ⁇ 1/2 ⁇ 100
- Ts, Tp, and Tc are Y values measured with a two-degree field of view (C light source) of JIS Z 8701 and corrected for visibility.
- the residual width ratio was high and the thickness uniformity after lateral stretching was excellent, and the effective width of the resin base material was sufficiently secured.
- the width remaining ratio is low in Comparative Examples 1, 2, 3 and 5, and in Comparative Example 4, the thickness of the end in the width direction after transverse stretching is thick, and the effective width of the resin base material cannot be sufficiently secured It was.
- the polarizing film of the present invention is a liquid crystal television, a liquid crystal display, a mobile phone, a digital camera, a video camera, a portable game machine, a car navigation system, a copier, a printer, a fax machine, a clock, a microwave oven, etc., and a reflection of an organic EL panel. It is suitably used as a prevention film.
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- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
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- Liquid Crystal (AREA)
- Shaping By String And By Release Of Stress In Plastics And The Like (AREA)
Abstract
Description
1つの実施形態においては、上記第1の方向への延伸温度は70℃~150℃である。
1つの実施形態においては、上記加熱温度は70℃~150℃である。
1つの実施形態においては、上記樹脂基材は、ポリエチレンテレフタレート系樹脂から形成されている。
1つの実施形態においては、上記加熱後の樹脂基材のΔnは0.0016以下である。
本発明の別の局面によれば、偏光膜が提供される。この偏光膜は、上記製造方法により得られる。
本発明のさらに別の局面によれば、光学積層体が提供される。この光学積層体は、上記偏光膜を有する。
本発明のさらに別の局面によれば、積層体が提供される。この積層体は、ポリエチレンテレフタレート系樹脂から形成され、Δnが0.0016以下の樹脂基材と、該樹脂基材上に形成されたポリビニルアルコール系樹脂層とを有する。
本発明の偏光膜の製造方法は、樹脂基材を第1の方向に延伸する工程(第1の延伸工程)と、樹脂基材を加熱する工程(加熱工程)と、樹脂基材上にポリビニルアルコール(PVA)系樹脂層を形成して積層体を作製する工程(積層体作製工程)と、積層体を第2の方向に延伸する工程(第2の延伸工程)とを、この順で含む。以下、各々の工程について説明する。
上記樹脂基材の形成材料としては、任意の適切な熱可塑性樹脂が採用され得る。熱可塑性樹脂としては、例えば、ポリエチレンテレフタレート系樹脂等のエステル系樹脂、ノルボルネン系樹脂等のシクロオレフィン系樹脂、ポリプロピレン等のオレフィン系樹脂、ポリアミド系樹脂、ポリカーボネート系樹脂、これらの共重体樹脂等が挙げられる。これらの中でも、非晶質の(結晶化していない)ポリエチレンテレフタレート系樹脂が好ましく用いられる。中でも、非晶性の(結晶化しにくい)ポリエチレンテレフタレート系樹脂が特に好ましく用いられる。非晶性のポリエチレンテレフタレート系樹脂の具体例としては、ジカルボン酸としてイソフタル酸をさらに含む共重合体や、グリコールとしてシクロヘキサンジメタノールをさらに含む共重合体が挙げられる。
Δn=R0/d ・・・・・(1)
R0:23℃における波長590nmの光で測定した樹脂基材の正面位相差(nm)
d:樹脂基材の厚み(nm)
上記第1の方向への延伸後、樹脂基材を加熱する。樹脂基材を加熱することにより、上記第1の方向への延伸により樹脂基材に生じた残存応力を緩和し、後述の第2の方向への延伸における第1の方向への縮率を低下させることができる。その結果、製造効率を向上させることができる。さらに、加熱によって樹脂基材のΔnが低下する。
図2は、本発明の好ましい実施形態による積層体の概略断面図である。積層体10は、樹脂基材11とPVA系樹脂層12とを有し、樹脂基材11上に、PVA系樹脂層12を形成することにより作製される。PVA系樹脂層の形成方法としては、任意の適切な方法が採用され得る。好ましくは、樹脂基材上に、PVA系樹脂を含む塗布液を塗布し、乾燥することにより、PVA系樹脂層を形成する。
上記第2の方向は、所望の偏光膜に応じて、任意の適切な方向に設定され得る。好ましくは、第2の方向は、上記第1の方向と直交する。例えば、上記第1の方向が長尺状の樹脂基材の幅方向である場合、第2の方向は、好ましくは、長尺状の積層体の長手方向である。なお、本明細書において、「直交」とは、実質的に直交する場合も包含する。ここで、「実質的に直交」とは、90°±5.0°である場合を包含し、好ましくは90°±3.0°、さらに好ましくは90°±1.0°である。また、第2の方向が、実質的に、得られる偏光膜の吸収軸方向となる。
本発明の偏光膜の製造方法は、上記工程以外に、その他の工程を含み得る。その他の工程としては、例えば、染色工程、不溶化工程、架橋工程、洗浄工程、乾燥工程等が挙げられる。その他の工程は、任意の適切なタイミングで行い得る。
本発明の偏光膜は、実質的には、二色性物質が吸着配向されたPVA系樹脂膜である。偏光膜の厚みは、好ましくは10μm以下であり、より好ましくは7μm以下、さらに好ましくは5μm以下である。一方、偏光膜の厚みは、好ましくは0.5μm以上、より好ましくは1.5μm以上である。偏光膜は、好ましくは、波長380nm~780nmのいずれかの波長で吸収二色性を示す。偏光膜の単体透過率は、好ましくは40.0%以上、より好ましくは41.0%以上、さらに好ましくは42.0%以上、特に好ましくは42.8%以上である。偏光膜の偏光度は、好ましくは99.8%以上、より好ましくは99.9%以上、さらに好ましくは99.95%以上である。
本発明の光学積層体は、上記偏光膜を有する。図3(a)および図3(b)はそれぞれ、本発明の好ましい実施形態による光学フィルム積層体の概略断面図である。光学フィルム積層体100は、樹脂基材11’と偏光膜12’と粘着剤層13とセパレータ14とをこの順で有する。光学フィルム積層体200は、樹脂基材11’と偏光膜12’と接着剤層15と光学機能フィルム16と粘着剤層13とセパレータ14とをこの順で有する。本実施形態では、上記樹脂基材を得られた偏光膜12’から剥離せずに、そのまま光学部材として用いている。樹脂基材11’は、例えば、偏光膜12’の保護フィルムとして機能し得る。
1.厚み
デジタルマイクロメーター(アンリツ社製、製品名「KC-351C」)を用いて測定した。
2.ガラス転移温度(Tg)
JIS K 7121に準じて測定した。
3.吸水率
JIS K 7209に準じて測定した。
4.正面位相差(R0)
Axometrics社製のAxoscanを用いて測定した。測定波長は590nm、測定温度は23℃であった。
樹脂基材として、長尺状で、吸水率0.35%、Tg75℃のシクロヘキサンジメタノールを共重合成分として含む非晶質ポリエチレンテレフタレート(A-PET)フィルム(三菱化学社製、商品名「ノバクリアー SH046」、厚み:100μm)を用いた。テンター延伸機を用いて、この樹脂基材を長手方向に搬送しながら、105℃で横方向に2倍に延伸した。この時点(延伸後かつ加熱前)での樹脂基材のΔnは0.00249であった。
続いて、テンター延伸機のクリップで実質的に延伸幅に保持された状態で、樹脂基材を120℃で30秒間加熱した。加熱後の樹脂基材のΔnは0.00124であった。
次に、樹脂基材の片面に、重合度4200、ケン化度99.2モル%のポリビニルアルコールの水溶液を60℃で塗布および乾燥して、厚み10μmのPVA系樹脂層を形成し、積層体を作製した。
次いで、積層体を、液温30℃の不溶化浴(水100重量部に対して、ホウ酸を4重量部配合して得られたホウ酸水溶液)に30秒間浸漬させた(不溶化工程)。
次いで、液温30℃の染色浴(水100重量部に対して、ヨウ素を0.2重量部配合し、ヨウ化カリウムを1.0重量部配合して得られたヨウ素水溶液)に60秒間浸漬させた(染色工程)。
次いで、液温30℃の架橋浴(水100重量部に対して、ヨウ化カリウムを3重量部配合し、ホウ酸を3重量部配合して得られたホウ酸水溶液)に30秒間浸漬させた(架橋工程)。
その後、積層体を、液温70℃のホウ酸水溶液(水100重量部に対して、ホウ酸を4重量部配合し、ヨウ化カリウムを5重量部配合して得られた水溶液)に浸漬させながら、周速の異なるロール間で縦方向(長手方向)に一軸延伸を行った(水中延伸)。ここで、積層体が破断する直前まで延伸した(最大延伸倍率は6.0倍)。
その後、積層体を液温30℃の洗浄浴(水100重量部に対して、ヨウ化カリウムを4重量部配合して得られた水溶液)に浸漬させた後、60℃の温風で乾燥させた(洗浄・乾燥工程)。
こうして、樹脂基材上に、厚み4.5μmの偏光膜を形成した。
樹脂基材の加熱時間を40秒としたこと以外は、実施例1と同様にして偏光膜を形成した。
樹脂基材の加熱時間を50秒としたこと以外は、実施例1と同様にして偏光膜を形成した。
樹脂基材の加熱温度を125℃、加熱時間を40秒としたこと以外は、実施例1と同様にして偏光膜を形成した。
樹脂基材の延伸温度を115℃としたこと、加熱温度を105℃、加熱時間を40秒としたこと以外は、実施例1と同様にして偏光膜を形成した。本実施例において、延伸後かつ加熱前の樹脂基材のΔnは0.00093であった。
樹脂基材の延伸温度を90℃としたこと、延伸後に加熱しなかったこと以外は、実施例1と同様にして偏光膜を形成した。
樹脂基材の延伸温度を100℃としたこと、延伸後に加熱しなかったこと以外は、実施例1と同様にして偏光膜を形成した。
延伸後に加熱しなかったこと以外は、実施例1と同様にして偏光膜を形成した。
延伸後に加熱しなかったこと以外は、実施例5と同様にして偏光膜を形成した。
樹脂基材に対し、延伸・加熱を行わなかったこと以外は、実施例1と同様にして偏光膜を形成した。
1.幅残存率
上記空中補助延伸後の樹脂基材の幅を計測し、樹脂基材の元長(幅)に対する幅残存率を算出することにより幅残存率を評価した。
(評価基準)
良好:120%以上
不良:120%未満
2.膜厚分布
樹脂基材延伸後、幅方向両端部を除いた幅方向中央部(85%)における膜厚を測定し、最大値と最小値との差を算出することにより膜厚分布を評価した。
(評価基準)
良好:10μm未満
不良:10μm以上
3.光学特性
紫外可視分光光度計(日本分光社製、製品名「V7100」)を用いて、偏光膜の単体透過率(Ts)、平行透過率(Tp)および直交透過率(Tc)を測定し、偏光度(P)を次式により求めた。
偏光度(P)(%)={(Tp-Tc)/(Tp+Tc)}1/2×100
なお、上記Ts、TpおよびTcは、JIS Z 8701の2度視野(C光源)により測定し、視感度補正を行ったY値である。
(評価基準)
良好:単体透過率99.99%における偏光度が42.8%以上
不良:単体透過率99.99%における偏光度が42.8%未満
Claims (8)
- 樹脂基材を第1の方向に延伸する工程と、
前記樹脂基材を加熱する工程と、
前記樹脂基材上にポリビニルアルコール系樹脂層を形成して積層体を作製する工程と、
前記積層体を第2の方向に延伸する工程と
をこの順で含む、偏光膜の製造方法。 - 前記第1の方向への延伸温度が70℃~150℃である、請求項1に記載の製造方法。
- 前記加熱温度が70℃~150℃である、請求項1に記載の製造方法。
- 前記樹脂基材が、ポリエチレンテレフタレート系樹脂から形成されている、請求項1に記載の製造方法。
- 前記加熱後の樹脂基材のΔnが0.0016以下である、請求項4に記載の製造方法。
- 請求項1に記載の製造方法により得られた、偏光膜。
- 請求項6に記載の偏光膜を有する、光学積層体。
- ポリエチレンテレフタレート系樹脂から形成され、Δnが0.0016以下の樹脂基材と、
該樹脂基材上に形成されたポリビニルアルコール系樹脂層と
を有する、積層体。
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CN103620452B (zh) * | 2011-06-17 | 2016-03-02 | 帝人株式会社 | 反射偏振膜、由其形成的液晶显示装置用光学部件和液晶显示装置 |
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2013
- 2013-02-15 JP JP2013027505A patent/JP2014157212A/ja active Pending
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2014
- 2014-02-06 CN CN201480008469.8A patent/CN105026964B/zh active Active
- 2014-02-06 US US14/767,345 patent/US20150369964A1/en not_active Abandoned
- 2014-02-06 KR KR1020157022059A patent/KR101738801B1/ko active IP Right Grant
- 2014-02-06 WO PCT/JP2014/052732 patent/WO2014125985A1/ja active Application Filing
- 2014-02-13 TW TW106136196A patent/TWI647495B/zh not_active IP Right Cessation
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JP2006241446A (ja) * | 2005-02-02 | 2006-09-14 | Mitsubishi Gas Chem Co Inc | ポリエステルフィルム、及びその製造方法、ならびにその用途 |
JP2012078796A (ja) * | 2010-09-09 | 2012-04-19 | Nitto Denko Corp | 薄型偏光膜の製造方法 |
JP2012159665A (ja) * | 2011-01-31 | 2012-08-23 | Nippon Zeon Co Ltd | 位相差フィルムの製造方法 |
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TWI619972B (zh) | 2018-04-01 |
CN105026964B (zh) | 2018-04-03 |
TWI647495B (zh) | 2019-01-11 |
KR101738801B1 (ko) | 2017-05-22 |
JP2014157212A (ja) | 2014-08-28 |
TW201805666A (zh) | 2018-02-16 |
KR20150109403A (ko) | 2015-10-01 |
TW201443494A (zh) | 2014-11-16 |
US20150369964A1 (en) | 2015-12-24 |
CN105026964A (zh) | 2015-11-04 |
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