WO2015162926A1 - メタクリル樹脂組成物およびその製造方法、成形体、フィルム並びに偏光板 - Google Patents
メタクリル樹脂組成物およびその製造方法、成形体、フィルム並びに偏光板 Download PDFInfo
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- WO2015162926A1 WO2015162926A1 PCT/JP2015/002198 JP2015002198W WO2015162926A1 WO 2015162926 A1 WO2015162926 A1 WO 2015162926A1 JP 2015002198 W JP2015002198 W JP 2015002198W WO 2015162926 A1 WO2015162926 A1 WO 2015162926A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
- C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
- C08L33/10—Homopolymers or copolymers of methacrylic acid esters
- C08L33/12—Homopolymers or copolymers of methyl methacrylate
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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
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F20/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride, ester, amide, imide or nitrile thereof
- C08F20/02—Monocarboxylic acids having less than ten carbon atoms, Derivatives thereof
- C08F20/10—Esters
- C08F20/12—Esters of monohydric alcohols or phenols
- C08F20/14—Methyl esters, e.g. methyl (meth)acrylate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L69/00—Compositions of polycarbonates; Compositions of derivatives of polycarbonates
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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
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
Definitions
- the present invention relates to a methacrylic resin composition comprising a methacrylic resin and a polycarbonate resin. Moreover, it is related with the polarizing plate which comprises the film which consists of the said methacrylic resin composition, a molded object, and the said film.
- Various kinds of resin films are used in the liquid crystal display device.
- triacetyl cellulose is mainly used for the polarizer protective film. Since a film made of triacetyl cellulose has high moisture permeability, the quality of the polarizer tends to be lowered as the film becomes thinner. Improvement of the polarizer protective film is a problem in reducing the thickness of the liquid crystal display device.
- methacrylic resin has been studied as a material for a new polarizer protective film. It is known that toughness increases when a film made of methacrylic resin is stretched (see Patent Document 1). However, when a normal methacrylic resin film is stretched, the phase difference increases, and for example, in the IPS liquid crystal system, the quality of the screen is lowered.
- Patent Documents 2 to 5 It is known that a film having a small retardation can be easily obtained by adding a resin such as a polycarbonate resin to a methacrylic resin.
- a resin such as a polycarbonate resin
- methacrylic resin compositions were not sufficiently stretchable because a polycarbonate resin having a low molecular weight was added to ensure transparency. Specifically, when it was stretched to a thinner film, it was prone to breakage, and when it was stretched at a lower temperature in order to increase the strength of the stretched film, it had a problem of being easily broken. .
- methacrylic resins with high syndiotacticity (rr) in triplet display generally have a narrow molecular weight distribution, and methacrylic resin compositions using ordinary methacrylic resins. The stretchability was not sufficient.
- the present invention has been made in view of the above background, and its object is to provide a methacrylic resin composition that has high transparency, a small retardation in the thickness direction, and is easy to stretch. .
- Another object of the present invention is to provide a film made of a methacrylic resin composition having a uniform thickness, excellent surface smoothness, high productivity and high strength.
- a methacrylic resin composition containing a methacrylic resin, a polycarbonate resin, and a polymer processing aid The methacrylic resin has a content of structural units derived from methyl methacrylate of 80% by mass or more and a weight average molecular weight of 200000 or less,
- the polycarbonate resin has a viscosity average molecular weight of 1000 or more and 32000 or less, and the content of the polycarbonate resin with respect to 100 parts by mass of the methacrylic resin is 1 part by mass or more and 4 parts by mass or less.
- the polymer processing aid has an average degree of polymerization of 3,000 or more and 40,000 or less, and the content of the polymer processing aid with respect to 100 parts by mass of the methacrylic resin is 0.3 parts by mass or more. 6 parts by mass or less,
- the methacrylic resin composition whose total amount of the said methacrylic resin and said polycarbonate resin contained in a methacrylic resin composition is 80 mass% or more.
- [2] The content of structural units derived from methyl methacrylate, wherein the methacrylic resin has a triadic syndiotacticity (rr) of 50% or more, a weight average molecular weight of 80000-200000
- [4] The methacrylic resin composition according to any one of [1] to [3], wherein the content of structural units derived from methyl methacrylate in the methacrylic resin is 99% by mass or more.
- [6] The methacrylic resin composition according to any one of [1] to [5], wherein the methacrylic resin composition has a weight average molecular weight of 70,000 to 200,000.
- [7] The methacrylic resin composition according to any one of [1] to [6], wherein the methacrylic resin composition has a molecular weight distribution of 1.2 to 2.5.
- [9] A film comprising the methacrylic resin composition according to any one of [1] to [7].
- [12] The film according to any one of [9] to [11], which is used as a polarizer protective film.
- Polycarbonate having a content of structural units derived from methyl methacrylate of 80% by mass or more and having a weight average molecular weight of 200,000 or less and a viscosity average molecular weight of 1000 or more and 32,000 or less. At least three components of 1 part by mass or more and 4 parts by mass or less of a resin and 0.3 part by mass or more and 6 parts by mass or less of a polymer processing aid having an average degree of polymerization of 3,000 or more and 40,000 or less A method for producing a methacrylic resin composition obtained by mixing.
- a methacrylic resin composition that is highly transparent, has a small retardation in the thickness direction, and is easy to stretch.
- the methacrylic resin composition of the present invention contains a methacrylic resin, a polycarbonate resin and a polymer processing aid. Moreover, the film of this invention is a film which consists of the said methacryl resin composition.
- the content of the structural unit derived from methyl methacrylate is 80% by mass or more based on the mass of the methacrylic resin, preferably 92, from the viewpoint of heat resistance of the resulting film. More preferably, it is 95 mass% or more, More preferably, it is 97 mass% or more, Especially preferably, it is 99 mass% or more, Most preferably, it is 100 mass%.
- the methacrylic resin used in the present invention may contain a structural unit other than the structural unit derived from methyl methacrylate, such as ethyl methacrylate, cyclohexyl methacrylate, t-butyl methacrylate, 2-isobornyl methacrylate, Methacrylic acid alkyl esters other than methyl methacrylate such as 8-tricyclo [5.2.1.0 2,6 ] decanyl methacrylate and 4-t-butylcyclohexyl methacrylate; methyl acrylate, ethyl acrylate, propyl acrylate Alkyl acrylates such as butyl acrylate and 2-ethylhexyl acrylate; aryl acrylates such as phenyl acrylate; cycloalkyl acrylates such as cyclohexyl acrylate and norbornenyl acrylate; acrylamide It includes structural units derived from a vinyl monomer having only one carbon-carbon
- the structural unit other than the structural unit derived from methyl methacrylate is preferably 8% by mass or less, more preferably 5% by mass or less, further preferably 3% by mass or less, particularly preferably 1% by mass or less, and most preferably 0% by mass. %.
- the lower limit of the triplet-represented syndiotacticity (rr) is preferably 50%, more preferably 55%, still more preferably 58%, even more preferably from the viewpoint of heat resistance. Preferably it is 59%, most preferably 60%.
- the upper limit of the triplet display syndiotacticity (rr) is preferably 99%, more preferably 85%, still more preferably 77%, and still more preferably 70. %, More preferably 65%, and most preferably 64%. Since the methacrylic resin having such syndiotacticity is not sufficiently stretchable due to the narrow molecular weight distribution, the addition of a polymer processing aid is more effective.
- a triplet display syndiotacticity (hereinafter sometimes simply referred to as “syndiotacticity (rr)”) is a chain of three consecutive structural units (triplet, triad).
- the two chains (doublet, dad) that are included are the ratio of racemo (denoted as rr).
- meo those having the same configuration
- racemo those opposite to each other
- m and r are expressed as m and r, respectively.
- the syndiotacticity (rr) (%) of the methacrylic resin is 0.6 to 0 when a 1 H-NMR spectrum is measured in deuterated chloroform at 30 ° C. and TMS is set to 0 ppm from the spectrum.
- the area (X) of the .95 ppm region and the area (Y) of the 0.6 to 1.35 ppm region can be measured and calculated by the formula: (X / Y) ⁇ 100.
- the methacrylic resin used in the present invention has a weight average molecular weight (hereinafter sometimes referred to as “Mw”) of 200,000 or less, preferably 80,000 to 200,000, more preferably 85,000 to 160000, and still more preferably 90000 to 120,000.
- Mw weight average molecular weight
- rr syndiotacticity
- the resulting film has high strength, is difficult to break, and is easy to stretch. Therefore, the film can be made thinner.
- Mw is 200000 or less, since the moldability of a methacrylic resin increases, the thickness of the obtained film tends to be uniform and excellent in surface smoothness.
- the methacrylic resin used in the present invention is a ratio of Mw to number average molecular weight (hereinafter sometimes referred to as “Mn”) (Mw / Mn: hereinafter, this value may be referred to as “molecular weight distribution”). However, it is preferably 1.2 to 2.0, more preferably 1.3 to 1.7. When the molecular weight distribution is 1.2 or more, the fluidity of the methacrylic resin is improved, and the resulting film tends to be excellent in surface smoothness. A film obtained by having a molecular weight distribution of 2.0 or less tends to be excellent in impact resistance and toughness.
- Mw and Mn are values obtained by converting a chromatogram measured by gel permeation chromatography (GPC) into a molecular weight of standard polystyrene.
- the methacrylic resin used in the present invention has a melt flow rate of preferably 0.1 to 5 g / 10 min, more preferably 0, as measured under conditions of 230 ° C. and 3.8 kg load in accordance with JIS K7210. 0.5-4 g / 10 min, most preferably 1.0-3 g / 10 min.
- the glass transition temperature of the methacrylic resin used in the present invention is preferably 110 ° C. or higher, more preferably 118 ° C. or higher, still more preferably 120 ° C. or higher, still more preferably 123 ° C. or higher, and most preferably 124 ° C. or higher.
- the upper limit of the glass transition temperature of the methacrylic resin is usually 140 ° C, preferably 130 ° C.
- the glass transition temperature can be controlled by adjusting the molecular weight and syndiotacticity (rr). When the glass transition temperature is in this range, deformation such as heat shrinkage of the obtained film is difficult to occur.
- a glass transition temperature is the midpoint glass transition temperature measured by the method as described in an Example.
- the method for producing the methacrylic resin is not particularly limited.
- Mw, syndiotacticity can be adjusted by adjusting polymerization temperature, polymerization time, type and amount of chain transfer agent, type and amount of polymerization initiator, etc.
- a methacrylic resin having properties such as city (rr) satisfying a desired range can be produced.
- the polymerization temperature is preferably 80 ° C. or lower, more preferably 70 ° C. or lower, and further preferably 60 ° C. or lower. By adjusting the temperature in this way, it is easy to increase the syndiotacticity (rr).
- alkyllithium such as n-butyllithium, sec-butyllithium, isobutyllithium, or tert-butyllithium
- organoaluminum compound coexist from a viewpoint of productivity.
- organoaluminum the following formula: AlR 1 R 2 R 3 Wherein R 1 , R 2 and R 3 are each independently an alkyl group which may have a substituent, a cycloalkyl group which may have a substituent, or an aryl which may have a substituent.
- R 2 And R 3 may be an aryleneoxy group optionally having a substituent formed by bonding each other.
- the compound shown by these is mentioned. Specifically, isobutylbis (2,6-di-tert-butyl-4-methylphenoxy) aluminum, isobutylbis (2,6-di-tert-butylphenoxy) aluminum, isobutyl [2,2′-methylenebis ( 4-methyl-6-tert-butylphenoxy)] aluminum and the like.
- an ether or a nitrogen-containing compound can coexist in order to control the polymerization reaction.
- the amount is preferably smaller than the amount of the polymerization initiator during the polymerization reaction, specifically, preferably 1 mol% to 50 mol with respect to the amount of the polymerization initiator. %, More preferably 2 mol% to 20 mol%, more preferably 5 mol% to 10 mol% of a polymerization terminator, or relative to the amount of the polymerization initiator initially added during the polymerization reaction.
- the weight average molecular weight is adjusted by adding an additional polymerization initiator, preferably 1 mol% to 50 mol%, more preferably 2 mol% to 20 mol%, and even more preferably 5 mol% to 10 mol%. it can.
- a methacrylic resin having desired characteristics such as weight average molecular weight and syndiotacticity (rr)
- desired characteristics such as weight average molecular weight and syndiotacticity (rr)
- desired characteristics characteristics, such as a weight average molecular weight, a syndiotacticity (rr)
- the mixing of a plurality of types of methacrylic resins can be carried out using a known method, for example, a melt kneading apparatus such as a kneader ruder, an extruder, a mixing roll, or a Banbury mixer.
- a melt kneading apparatus such as a kneader ruder, an extruder, a mixing roll, or a Banbury mixer.
- the temperature at the time of kneading can be appropriately adjusted according to the melting temperature of the methacrylic resin to be used, and is usually 150 to 300 ° C.
- a monomer is polymerized in the presence of a methacrylic resin that is out of the desired characteristic range to obtain a desired weight average molecular weight, syndiotacticity (rr).
- rr weight average molecular weight
- a methacrylic resin having characteristics such as) satisfying a desired range can be performed in the same manner as the radical polymerization method and the anion polymerization method described above.
- the third manufacturing method since the thermal history applied to the methacrylic resin is shortened as compared with the second manufacturing method, thermal decomposition of the methacrylic resin is suppressed, and a film with less coloring and foreign matter is easily obtained.
- a method for producing a methacrylic resin whose characteristics satisfy a desired range by an anionic polymerization method produced by an anionic polymerization method
- a method for producing a methacrylic resin whose characteristics satisfy a specified range by mixing a methacrylic resin produced by radical polymerization and a methacrylic resin produced by an anionic polymerization method and another anionic polymerization method A method of producing a methacrylic resin whose characteristics satisfy a desired range by mixing the produced methacrylic resin is preferable, and a methacrylic resin produced by anionic polymerization and a methacrylic resin produced by radical polymerization are mixed. Makes methacrylic resin whose characteristics meet the desired range How to is more preferable.
- the polycarbonate resin used in the present invention is a polymer obtained by a reaction between a polyfunctional hydroxy compound and a carbonate ester-forming compound.
- the polycarbonate resin is preferably an aromatic polycarbonate resin from the viewpoint of compatibility with a methacrylic resin and good transparency of the resulting film.
- the polycarbonate resin used in the present invention has a viscosity average molecular weight (hereinafter sometimes referred to as “Mv”) of 1000 or more, preferably 3000 from the viewpoint that the polycarbonate hardly bleeds out from the obtained methacrylic resin composition. As mentioned above, More preferably, it is 5000 or more, More preferably, it is 10,000 or more. Moreover, from a compatible viewpoint with a methacryl resin, a viscosity average molecular weight is 32000 or less, Preferably it is 22000 or less, More preferably, it is 18000 or less, More preferably, it is 17000 or less.
- Mv viscosity average molecular weight
- the viscosity average molecular weight (Mv) of the polycarbonate resin was determined by measuring the specific viscosity ⁇ sp of a solution obtained by dissolving 0.5 g of the polycarbonate resin in 100 mL of methylene chloride at 20 ° C. using a Canon-Fenske viscometer or Ubbelohde viscometer.
- the value satisfying the Schnell equation can be calculated from the intrinsic viscosity [ ⁇ ] of a 20 ° C. methylene chloride solution.
- MVR melt volume flow rate
- the polycarbonate resin used in the present invention has a weight average molecular weight (Mw) obtained by converting a chromatogram measured by gel permeation chromatography (GPC) into a molecular weight of standard polystyrene.
- Mw is preferably 1300 g / mole or more, more preferably 4700 g / mole or more, further preferably 8500 g / mole or more, and particularly preferably 19,200 g / mole or more.
- a compatible viewpoint with a methacryl resin 75000 g / mol or less is preferable, 48300 g / mol or less is more preferable, 38200 g / mol or less is further more preferable, and 35700 g / mol or less is especially preferable.
- the viscosity average molecular weight, MVR value, and weight average molecular weight of the polycarbonate resin can be adjusted by adjusting the amount of the terminal terminator or branching agent.
- the glass transition temperature of the polycarbonate resin used in the present invention is preferably 110 ° C. or higher, more preferably 125 ° C. or higher, and further preferably 140 ° C. or higher.
- the upper limit of the glass transition temperature of the polycarbonate resin is usually 180 ° C.
- the method for producing the polycarbonate resin is not particularly limited. Examples thereof include a phosgene method (interfacial polymerization method) and a melt polymerization method (transesterification method).
- the aromatic polycarbonate resin preferably used in the present invention may be obtained by subjecting a polycarbonate resin raw material produced by a melt polymerization method to a treatment for adjusting the amount of terminal hydroxy groups.
- Polyfunctional hydroxy compounds that are raw materials for producing polycarbonate resins include 4,4′-dihydroxybiphenyls optionally having substituents; bis (hydroxyphenyl) alkanes optionally having substituents Bis (4-hydroxyphenyl) ethers optionally having substituents; bis (4-hydroxyphenyl) sulfides optionally having substituents; bis optionally having substituents (4-hydroxyphenyl) sulfoxides; bis (4-hydroxyphenyl) sulfones optionally having substituents; bis (4-hydroxyphenyl) ketones optionally having substituents; Optionally substituted bis (hydroxyphenyl) fluorenes; optionally substituted dihydroxy-p-terphenyls; Dihydroxy-p-quaterphenyls which may be substituted; bis (hydroxyphenyl) pyrazines which may have a substituent; bis (hydroxyphenyl) menthanes which may have a substituent; Bis [2- (4-hydroxyphenyl) -2-propy
- Examples of the carbonate-forming compound include various dihalogenated carbonyls such as phosgene, haloformates such as chloroformate, and carbonate esters such as bisaryl carbonate.
- the amount of the carbonate ester-forming compound may be appropriately adjusted in consideration of the stoichiometric ratio (equivalent) of the reaction.
- the reaction is usually performed in a solvent in the presence of an acid binder.
- acid binders include alkali metal hydroxides such as sodium hydroxide, potassium hydroxide, lithium hydroxide, and cesium hydroxide, alkali metal carbonates such as sodium carbonate and potassium carbonate, trimethylamine, triethylamine, tributylamine, Tertiary amines such as N, N-dimethylcyclohexylamine, pyridine, dimethylaniline, trimethylbenzylammonium chloride, triethylbenzylammonium chloride, tributylbenzylammonium chloride, trioctylmethylammonium chloride, tetrabutylammonium chloride, tetrabutylammonium bromide Quaternary ammonium salts, quaternary phosphonium salts such as tetrabutylphosphonium chloride, tetrabutylphosphonium bromide, etc.
- an antioxidant such as sodium sulfite or hydrosulfide may be added to this reaction system.
- the amount of the acid binder may be appropriately adjusted in consideration of the stoichiometric ratio (equivalent) of the reaction. Specifically, one equivalent or an excess amount, preferably 1 to 5 equivalents of an acid binder may be used per mole of hydroxyl group of the starting polyfunctional hydroxy compound.
- End-termination agents include p-tert-butyl-phenol, p-phenylphenol, p-cumylphenol, p-perfluorononylphenol, p- (perfluorononylphenyl) phenol, p- (perfluorohexylphenyl) phenol P-tert-perfluorobutylphenol, 1- (P-hydroxybenzyl) perfluorodecane, p- [2- (1H, 1H-perfluorotridodecyloxy) -1,1,1,3,3,3- Hexafluoropropyl] phenol, 3,5-bis (perfluorohexyloxycarbonyl) phenol, perfluorododecyl p-hydroxybenzoate, p- (1H, 1H-perfluorooctyloxy) phenol, 2H, 2H, 9H-per Fluorononanoic acid
- branching agents include phloroglysin, pyrogallol, 4,6-dimethyl-2,4,6-tris (4-hydroxyphenyl) -2-heptene, 2,6-dimethyl-2,4,6-tris (4- Hydroxyphenyl) -3-heptene, 2,4-dimethyl-2,4,6-tris (4-hydroxyphenyl) heptane, 1,3,5-tris (2-hydroxyphenyl) benzene, 1,3,5- Tris (4-hydroxyphenyl) benzene, 1,1,1-tris (4-hydroxyphenyl) ethane, tris (4-hydroxyphenyl) phenylmethane, 2,2-bis [4,4-bis (4-hydroxyphenyl) ) Cyclohexyl] propane, 2,4-bis [2-bis (4-hydroxyphenyl) -2-propyl] phenol, 2,6-bis (2-hydroxy) 5-methylbenzyl) -4-methylphenol, 2- (4-hydroxyphenyl)
- the polycarbonate resin may contain a unit having a polyester, polyurethane, polyether or polysiloxane structure in addition to the polycarbonate unit.
- Polymer processing aids are substances that contain a large amount of high molecular weight components. It is said that entanglement (network) between polymers occurs between the polymer processing aid and the resin material, and the entanglement point acts as a pseudo-crosslinking point. Therefore, when a polymer processing aid is added, the resin composition can be uniformly stretched in the same manner as when the rubber is deformed. In the case of a resin material to which no polymer processing aid is added, since this pseudo-crosslinking point does not exist, for example, if a thin part exists in the film before stretching, stress is concentrated on that part and the film is stretched locally. In some cases, such as breaking.
- the polymer processing aid used in the present invention is a polymer compound having an average degree of polymerization of 3,000 to 40,000, preferably 60% by mass or more of methyl methacrylate units and a vinyl monomer copolymerizable therewith. It consists of 40 mass% or less of body units.
- the average degree of polymerization is preferably 6,000 to 30,000, more preferably 10,000 to 25,000.
- vinyl monomers copolymerizable with methyl methacrylate include: methacrylates such as ethyl methacrylate, butyl methacrylate, cyclohexyl methacrylate, ethyl acrylate, methyl acrylate, butyl acrylate, cyclohexyl acrylate Acrylic ester such as styrene, aromatic vinyl compounds such as styrene, p-methylstyrene, o-methylstyrene, maleimide compounds such as N-propylmaleimide, N-cyclohexylmaleimide, N-o-chlorophenylmaleimide, ethylene glycol dimethacrylate , Propylene glycol dimethacrylate, triethylene glycol dimethacrylate, hexanediol dimethacrylate, ethylene glycol diacrylate, propylene glycol diacrylate, triethylene Recall diacrylate, allyl methacrylate, can be
- Examples of such a polymer processing aid include a metablene series manufactured by Mitsubishi Rayon, a paraloid series manufactured by Dow or Kureha.
- the average degree of polymerization of the polymer processing aid can be determined as a PMMA equivalent degree of polymerization by measuring at 20 ° C. using chloroform as a solvent using an automatic dilution capillary viscometer (Ubbelohde type).
- the polymerization method for producing the polymer processing aid is not particularly limited, but is preferably emulsion polymerization.
- the emulsifier that can be used in the emulsion polymerization include dialkyl sulfosuccinates such as sodium dioctyl sulfosuccinate and sodium dilauryl sulfosuccinate which are anionic emulsifiers, alkylbenzene sulfonates such as sodium dodecylbenzene sulfonate, and sodium dodecyl sulfate.
- Polyoxyethylene nonyl phenyl ether sulfate such as polyoxyethylene alkyl ether, polyoxyethylene nonyl phenyl ether as nonionic emulsifier, polyoxyethylene nonyl phenyl ether sodium sulfate as nonionic anionic emulsifier, etc.
- Polyoxyethylene alkyl ether sulfate such as sodium polyoxyethylene alkyl ether sulfate, sodium polyoxyethylene tridecyl ether acetate It may be used alkyl ether carboxylate such as um like.
- an appropriate pH adjuster can be used to prevent hydrolysis of the methacrylic acid alkyl ester and acrylic acid alkyl ester.
- the pH adjuster used is boric acid-potassium chloride-potassium hydroxide, potassium dihydrogen phosphate-disodium hydrogen phosphate, boric acid-potassium chloride-potassium carbonate, citric acid-potassium hydrogen citrate, diphosphate Potassium hydrogen-boric acid, disodium hydrogen phosphate-citric acid and the like can be used.
- the polymerization initiator may be a water-soluble initiator or an oil-soluble initiator alone, or a redox-type initiator.
- water-soluble initiators include ordinary inorganic initiators such as persulfate alone. It can also be used as a redox initiator in combination with sulfites, bisulfites, thiosulfates and the like.
- oil-soluble initiators include organic peroxides such as tert-butyl hydroperoxide, cumene hydroperoxide, benzoyl peroxide, lauroyl peroxide, azo compounds, or sodium formaldehyde sulfoxylate. Although it can also be used as a redox-type initiator in combination with, etc., it is not limited only to this specific example.
- the average degree of polymerization of the polymer processing aid can be arbitrarily adjusted by a chain transfer agent such as n-octyl mercaptan and tert-dodecyl mercaptan, polymerization conditions, and the like.
- a chain transfer agent such as n-octyl mercaptan and tert-dodecyl mercaptan, polymerization conditions, and the like.
- the average degree of polymerization of the polymer processing aid of the present invention is in the range of 3,000 to 40,000. If the average degree of polymerization of the polymer processing aid is less than 3,000, the film-forming property may not be improved when the methacrylic resin composition of the present invention is made into a film, or the stretchability is sufficiently improved when stretched. Improvement effect may not be observed. On the other hand, if the average degree of polymerization of the polymer processing aid exceeds 40,000, the transparency may decrease, or the melt tension may become too high and the melt curtain may be easily broken at both ends. .
- the compounding amount of the polymer processing aid is 0.3 to 6 parts by mass, preferably 0.5 to 3 parts by mass, with respect to 100 parts by mass of the methacrylic resin.
- the blending amount of the polymer processing aid is less than 0.3 parts by mass, the film forming property and stretchability of the methacrylic resin composition are not sufficiently improved.
- the blending amount of the polymer processing aid exceeds 6 parts by mass, the glass transition temperature of the methacrylic resin composition is lowered, the transparency is lowered, and further, the melt tension is too high. When the film is formed, both ends of the melt curtain may be easily broken.
- the content of the polycarbonate resin contained in the methacrylic resin composition of the present invention is 1 part by mass or more and 4 parts by mass or less, more preferably 2 parts by mass or more and 3 parts by mass or less with respect to 100 parts by mass of the methacrylic resin. is there.
- the total amount of the methacrylic resin and the polycarbonate resin contained in the methacrylic resin composition of the present invention is 80% by mass or more, preferably 90% by mass or more, more preferably 94% by mass or more, and further preferably 96% by mass or more. is there.
- the upper limit of the amount is not particularly limited as long as the polymer processing aid can be contained in the methacrylic resin composition of the present invention as long as the effects of the present invention can be obtained.
- the methacrylic resin composition of the present invention may contain a filler as necessary within a range not impairing the effects of the present invention.
- the filler include calcium carbonate, talc, carbon black, titanium oxide, silica, clay, barium sulfate, and magnesium carbonate.
- the amount of filler that can be contained in the methacrylic resin composition of the present invention is preferably 3% by mass or less, more preferably 1.5% by mass or less.
- the methacrylic resin composition of the present invention may contain other polymers as long as the effects of the present invention are not impaired.
- Other polymers include polyolefin resins such as polyethylene, polypropylene, polybutene-1, poly-4-methylpentene-1 and polynorbornene; ethylene ionomers; polystyrene, styrene-maleic anhydride copolymer, high impact polystyrene, Styrenic resins such as AS resin, ABS resin, AES resin, AAS resin, ACS resin and MBS resin; methyl methacrylate-styrene copolymer; polyester resin such as polyethylene terephthalate and polybutylene terephthalate; nylon 6, nylon 66, polyamide elastomer Polyamide such as polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene-vinyl alcohol copolymer, polyacetal, polyvinylidene fluoride, polyurethane,
- an antioxidant in the methacrylic resin composition of the present invention, an antioxidant, a thermal degradation inhibitor, an ultraviolet absorber, a light stabilizer, a lubricant, a mold release agent, an antistatic agent, a flame retardant, and the like within a range not impairing the effects of the present invention. It may contain additives such as dyes and pigments, light diffusing agents, organic dyes, matting agents, impact resistance modifiers, and phosphors.
- the antioxidant alone has an effect of preventing oxidative deterioration of the resin in the presence of oxygen.
- Examples thereof include phosphorus antioxidants, hindered phenol antioxidants, and thioether antioxidants.
- phosphorus-based antioxidants and hindered phenol-based antioxidants are preferable, and the combined use of phosphorus-based antioxidants and hindered phenol-based antioxidants is more preferable.
- a phosphorus antioxidant and a hindered phenol antioxidant are used in combination, it is preferable to use a phosphorus antioxidant / hindered phenol antioxidant at a mass ratio of 0.2 / 1 to 2/1. It is preferable to use 0.5 / 1 to 1/1.
- Examples of phosphorus antioxidants include 2,2-methylenebis (4,6-di-tert-butylphenyl) octyl phosphite (manufactured by ADEKA; trade name: ADK STAB HP-10), tris (2,4-di- tert-butylphenyl) phosphite (manufactured by BASF; trade name: IRGAFOS168), 3,9-bis (2,6-di-tert-butyl-4-methylphenoxy) -2,4,8,10-tetraoxa 3,9-diphosphaspiro [5.5] undecane (manufactured by ADEKA; trade name: ADK STAB PEP-36) is preferable.
- pentaerythrityl-tetrakis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate] (manufactured by BASF; trade name IRGANOX1010)
- octadecyl-3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate (manufactured by BASF; trade name IRGANOX1076) is preferred.
- the thermal degradation inhibitor can prevent thermal degradation of the resin by trapping polymer radicals that are generated when exposed to high heat in a substantially oxygen-free state.
- the thermal degradation inhibitor include 2-tert-butyl-6- (3′-tert-butyl-5′-methyl-hydroxybenzyl) -4-methylphenyl acrylate (manufactured by Sumitomo Chemical Co., Ltd .; trade name Sumilizer GM), 2,4-ditert-amyl-6- (3 ′, 5′-di-tert-amyl-2′-hydroxy- ⁇ -methylbenzyl) phenyl acrylate (manufactured by Sumitomo Chemical Co., Ltd .; trade name Sumilyzer GS) is preferable. .
- the ultraviolet absorber is a compound having an ability to absorb ultraviolet rays, and is mainly said to have a function of converting light energy into heat energy.
- the ultraviolet absorber include benzophenones, benzotriazoles, triazines, benzoates, salicylates, cyanoacrylates, succinic anilides, malonic esters, formamidines, and the like.
- benzotriazoles, triazines, or ultraviolet absorbers having a maximum molar extinction coefficient ⁇ max at a wavelength of 380 to 450 nm of 100 dm 3 ⁇ mol ⁇ 1 cm ⁇ 1 or less are preferable.
- Benzotriazoles are preferable as ultraviolet absorbers used when the film of the present invention is applied to optical applications because it has a high effect of suppressing deterioration of optical properties such as coloring due to ultraviolet irradiation.
- benzotriazoles include 2- (2H-benzotriazol-2-yl) -4- (1,1,3,3-tetramethylbutyl) phenol (manufactured by BASF; trade name TINUVIN329), 2- (2H- Benzotriazol-2-yl) -4,6-bis (1-methyl-1-phenylethyl) phenol (manufactured by BASF; trade name TINUVIN234), 2,2′-methylenebis [6- (2H-benzotriazole-2) -Yl) -4-tert-octylphenol] (manufactured by ADEKA; LA-31), 2- (5-octylthio-2H-benzotriazol-2-yl) -6-tert-butyl
- an ultraviolet absorber having a maximum molar extinction coefficient ⁇ max at wavelengths of 380 to 450 nm of 1200 dm 3 ⁇ mol ⁇ 1 cm ⁇ 1 or less can suppress discoloration of the resulting film.
- ultraviolet absorbers include 2-ethyl-2′-ethoxy-oxalanilide (manufactured by Clariant Japan; trade name Sundebore VSU).
- benzotriazoles are preferably used from the viewpoint of suppressing resin degradation due to ultraviolet irradiation.
- a triazine UV absorber is preferably used.
- examples of such an ultraviolet absorber include 2,4,6-tris (2-hydroxy-4-hexyloxy-3-methylphenyl) -1,3,5-triazine (manufactured by ADEKA; LA-F70), Hydroxyphenyl triazine-based UV absorbers (manufactured by BASF; TINUVIN477 and TINUVIN460), 2,4-diphenyl-6- (2-hydroxy-4-hexyloxyphenyl) -1,3,5-triazine Is mentioned.
- the light stabilizer is a compound that is said to have a function of capturing radicals generated mainly by oxidation by light.
- Suitable light stabilizers include hindered amines such as compounds having a 2,2,6,6-tetraalkylpiperidine skeleton.
- lubricant examples include stearic acid, behenic acid, stearamide acid, methylene bisstearamide, hydroxystearic acid triglyceride, paraffin wax, ketone wax, octyl alcohol, and hardened oil.
- the mold release agent is a compound having a function of facilitating mold release from a mold.
- the release agent include higher alcohols such as cetyl alcohol and stearyl alcohol; glycerin higher fatty acid esters such as stearic acid monoglyceride and stearic acid diglyceride.
- the mass ratio of higher alcohols / glycerin fatty acid monoester is preferably 2.5 / 1 to 3.5 / 1, and preferably 2.8. More preferably, it is used in the range of / 1 to 3.2 / 1.
- the impact modifier examples include a core-shell type modifier containing acrylic rubber or diene rubber as a core layer component; a modifier containing a plurality of rubber particles, and the like.
- the organic dye a compound having a function of converting ultraviolet rays that are harmful to the resin into visible light is preferably used.
- the light diffusing agent and matting agent include glass fine particles, polysiloxane-based crosslinked fine particles, crosslinked polymer fine particles, talc, calcium carbonate, and barium sulfate.
- the phosphor examples include a fluorescent pigment, a fluorescent dye, a fluorescent white dye, a fluorescent brightener, and a fluorescent bleach.
- additives may be used alone or in combination of two or more. Moreover, these additives may be added to the polymerization reaction liquid when producing a methacrylic resin or a polycarbonate resin, or may be added to the produced methacrylic resin or the polycarbonate resin, or a methacrylic resin composition may be added. It may be added during preparation.
- the total amount of additives contained in the methacrylic resin composition used in the present invention is preferably 7% by mass or less, more preferably 5% by mass or less, based on the methacrylic resin, from the viewpoint of suppressing poor appearance of the film. More preferably, it is 4 mass% or less.
- the method for preparing the methacrylic resin composition is not particularly limited. Examples thereof include a method of polymerizing a monomer mixture containing methyl methacrylate in the presence of a polycarbonate resin to produce a methacrylic resin, a method of melt-kneading a methacrylic resin and a polycarbonate resin, and the like. Among these, the melt-kneading method is preferable because the process is simple. When melt-kneading, other polymers and additives may be mixed as necessary, methacrylic resin may be mixed with other polymers and additives, and then mixed with polycarbonate resin. The resin may be mixed with methacrylic resin after being mixed with other polymers and additives.
- the kneading can be performed using, for example, a known mixing apparatus or kneading apparatus such as a kneader ruder, an extruder, a mixing roll, or a Banbury mixer. Of these, a twin screw extruder is preferred.
- the temperature at the time of mixing and kneading can be appropriately adjusted according to the melting temperature of the methacrylic resin and polycarbonate resin used, but is preferably 110 to 300 ° C.
- the methacrylic resin composition prepared by the above method can be formed into a film in any form such as pellets, granules, and powders.
- the glass transition temperature of the methacrylic resin composition of the present invention is preferably 120 ° C. or higher, more preferably 123 ° C. or higher, and still more preferably 124 ° C. or higher.
- the upper limit of the glass transition temperature of the methacrylic resin composition is not particularly limited, but is preferably 140 ° C, more preferably 130 ° C.
- the Mw determined by measuring the methacrylic resin composition of the present invention by GPC is preferably 70000-200000, more preferably 72000-16000, and further preferably 75000-120000.
- the molecular weight distribution determined by measuring the methacrylic resin composition used in the present invention by GPC is preferably 1.2 to 2.5, more preferably 1.3 to 2.0. When the Mw and molecular weight distribution are in this range, the moldability of the methacrylic resin composition becomes good, and it becomes easy to obtain a molded article excellent in impact resistance and toughness.
- the melt flow rate determined by measuring the methacrylic resin composition of the present invention at 230 ° C. and a load of 3.8 kg is preferably 0.1 to 6 g / 10 minutes, more preferably 0.5 to 5 g / 10. Min, most preferably 1.0 to 3 g / 10 min.
- the methacrylic resin composition of the present invention has a 1.0 mm thickness haze of preferably 1.0% or less, more preferably 0.7% or less, and even more preferably 0.5% or less.
- the film of the present invention is not particularly limited by the production method.
- the film of the present invention can be obtained, for example, by forming the methacrylic resin composition by a known method such as a solution casting method, a melt casting method, an extrusion molding method, an inflation molding method, or a blow molding method. it can. Of these, the extrusion method is preferred. According to the extrusion method, a film having excellent transparency, improved toughness, excellent handleability, and excellent balance between toughness, surface hardness, and rigidity can be obtained.
- the temperature of the methacrylic resin composition discharged from the extruder is preferably set to 160 to 270 ° C., more preferably 220 to 260 ° C.
- the methacrylic resin composition is extruded from a T-die in a molten state, and then it is applied to two or more specular surfaces.
- a method including forming by sandwiching with a roll or a mirror belt is preferable.
- the mirror roll or the mirror belt is preferably made of metal.
- the linear pressure between the pair of mirror rolls or the mirror belt is preferably 10 N / mm or more, more preferably 30 N / mm or more.
- the surface temperature of the mirror roll or the mirror belt is preferably 130 ° C. or less.
- the pair of mirror rolls or mirror belts preferably have at least one surface temperature of 60 ° C. or higher. When such a surface temperature is set, the methacrylic resin composition discharged from the extruder can be cooled at a faster rate than natural cooling, and the film of the present invention having excellent surface smoothness and low haze is produced. Easy to do.
- the film of the present invention may be subjected to a stretching treatment.
- the stretching treatment By the stretching treatment, a film that has high mechanical strength and is difficult to crack can be obtained.
- the stretching method is not particularly limited, and examples thereof include uniaxial stretching, simultaneous biaxial stretching, sequential biaxial stretching, and tuber stretching.
- the temperature during stretching is preferably from 100 to 200 ° C., more preferably from 120 to 160 ° C., from the viewpoint that uniform stretching can be performed and a high-strength film can be obtained.
- a lower temperature is preferable, for example, 110 to 150 ° C. is preferable, and 125 to 140 ° C. is more preferable.
- the draw ratio There is no limitation on the draw ratio, but the area ratio is usually
- the amount of the methacrylic resin contained therein is preferably 78 to 98.7% by mass, more preferably 85 to 97% by mass, from the viewpoint of transparency and small retardation in the thickness direction. It is.
- the amount of the polycarbonate resin contained therein is preferably 1 to 3.8% by mass, more preferably 2 to 2.9% by mass from the viewpoint that the retardation in the thickness direction is small. %.
- the amount of the polymer processing aid contained therein is preferably 0.3 to 5.6% by mass, more preferably 0.5 to 2.9, from the viewpoint of stretchability. % By mass.
- the thickness of the film of the present invention is not particularly limited, but when used as an optical film, the thickness is preferably 1 to 300 ⁇ m, more preferably 10 to 50 ⁇ m, and still more preferably 15 to 40 ⁇ m.
- the film of the present invention has a haze at a thickness of 50 ⁇ m, preferably 0.2% or less, more preferably 0.1% or less. Thereby, it is excellent in surface glossiness and transparency. Further, in optical applications such as a liquid crystal protective film and a light guide film, the use efficiency of the light source is preferably increased. Furthermore, it is preferable because it is excellent in shaping accuracy when performing surface shaping.
- the film of the present invention has an in-plane retardation Re for light having a wavelength of 590 nm and a film thickness of 40 ⁇ m, it is preferably 5 nm or less, more preferably 4 nm or less, still more preferably 3 nm or less, particularly preferably 2 nm or less, Most preferably, it is 1 nm or less.
- the thickness direction retardation Rth for light having a wavelength of 590 nm is preferably ⁇ 10 nm or more and 10 nm or less, more preferably ⁇ 5 nm or more and 5 nm or less, even more preferably when the film thickness is 40 ⁇ m.
- the in-plane direction phase difference Re and the thickness direction phase difference Rth are values defined by the following equations, respectively.
- nx is the refractive index in the slow axis direction of the film
- ny is the refractive index in the fast axis direction of the film
- nz is the refractive index in the thickness direction of the film
- d (nm) is the film. Is the thickness.
- the slow axis refers to the direction in which the in-plane refractive index is maximized
- the fast axis refers to the direction perpendicular to the slow axis in the plane.
- the film of the present invention has high transparency, high heat resistance, small retardation, and thin, it is suitable for a polarizer protective film and various films described later.
- the polarizing plate of the present invention is obtained by laminating at least one polarizer protective film comprising the film of the present invention.
- a polarizer formed from a polyvinyl alcohol-based resin and the polarizer protective film of the present invention are laminated via an adhesive layer.
- the polarizing plate includes an adhesive layer 12, an easy-adhesion layer 13, and the polarizer protective film 14 of the present invention on one surface of a polarizer 11.
- the adhesive layer 15 and the optical film 16 are laminated in this order on the other surface of the polarizer 11.
- the polarizer formed from the polyvinyl alcohol resin is obtained by, for example, dyeing a polyvinyl alcohol resin film with a dichroic substance (typically iodine or a dichroic dye) and uniaxially stretching the film.
- the polyvinyl alcohol-based resin film is formed by any suitable method (for example, casting method, casting method, extrusion method for casting a solution obtained by dissolving a resin in water or an organic solvent). Can be obtained.
- the degree of polymerization of the polyvinyl alcohol resin is preferably 100 to 5000, and more preferably 1400 to 4000.
- the thickness of the polyvinyl alcohol-based resin film used for the polarizer can be appropriately set according to the purpose and application of the LCD in which the polarizing plate is used, but is typically 5 to 80 ⁇ m.
- the adhesive layer that can be provided on the polarizing plate of the present invention is not particularly limited as long as it is optically transparent.
- an adhesive constituting the adhesive layer for example, a water-based adhesive, a solvent-based adhesive, a hot-melt adhesive, an active energy ray-curable adhesive, or the like can be used. Of these, water-based adhesives and active energy ray-curable adhesives are suitable.
- the form of the water-based adhesive may be an aqueous solution or latex.
- an aqueous adhesive For example, a vinyl polymer type
- a catalyst such as a crosslinking agent, other additives, and an acid can be blended as necessary.
- an adhesive containing a vinyl polymer is preferably used, and the vinyl polymer is preferably a polyvinyl alcohol resin.
- the polyvinyl alcohol-based resin can contain a water-soluble crosslinking agent such as boric acid, borax, glutaraldehyde, melamine, or oxalic acid.
- a water-soluble crosslinking agent such as boric acid, borax, glutaraldehyde, melamine, or oxalic acid.
- an adhesive containing a polyvinyl alcohol resin it is preferable from the viewpoint of adhesiveness to use an adhesive containing a polyvinyl alcohol resin.
- an adhesive containing a polyvinyl alcohol-based resin having an acetoacetyl group is more preferable from the viewpoint of improving durability.
- the aqueous adhesive is usually used as an adhesive composed of an aqueous solution, and usually contains 0.5 to 60% by mass of a solid content.
- the active energy ray-curable adhesive a compound having a monofunctional or bifunctional (meth) acryloyl group or a compound having a vinyl group is used as a curable component, and an epoxy compound, an oxetane compound, a photoacid generator, It is also possible to use a photocationic curing component mainly composed of As the active energy ray, an electron beam or an ultraviolet ray can be used.
- the adhesive may contain a metal compound filler. With the metal compound filler, the fluidity of the adhesive layer can be controlled, the film thickness can be stabilized, and a polarizing plate having a good appearance, uniform in-plane and no adhesive variation can be obtained.
- the method for forming the adhesive layer is not particularly limited. For example, it can be formed by applying the adhesive to an object and then heating or drying.
- coating of an adhesive agent may be performed with respect to the polarizer protective film or optical film of this invention, and may be performed with respect to a polarizer.
- the polarizer protective film or the optical film and the polarizer can be pressed together to laminate them. In the lamination, a roll press machine or a flat plate press machine can be used.
- the heating and drying temperature and drying time are appropriately determined according to the type of adhesive.
- the thickness of the adhesive layer is preferably 0.01 to 10 ⁇ m, more preferably 0.03 to 5 ⁇ m in the dry state.
- the easy-adhesion layer that can be provided on the polarizing plate of the present invention improves the adhesion of the surface where the polarizer protective film and the polarizer are in contact.
- the easy adhesion layer can be provided by an easy adhesion treatment or the like. Examples of the easy adhesion treatment include surface treatment such as corona treatment, plasma treatment, and low-pressure UV treatment.
- the easy adhesion layer can be provided by a method of forming an anchor layer or a combination of the surface treatment and the method of forming an anchor layer. Among these, a corona treatment, a method of forming an anchor layer, and a method of using these in combination are preferable.
- the anchor layer examples include a silicone layer having a reactive functional group.
- the material of the silicone layer having a reactive functional group is not particularly limited.
- an isocyanate group-containing alkoxysilanol, an amino group-containing alkoxysilanol, a mercapto group-containing alkoxysilanol, a carboxy-containing alkoxysilanol, and an epoxy group examples include alkoxysilanols, vinyl unsaturated group-containing alkoxysilanols, halogen group-containing alkoxysilanols, and isocyanate group-containing alkoxysilanols. Of these, amino silanols are preferred.
- the adhesive strength can be strengthened.
- other additives include tackifiers such as terpene resins, phenol resins, terpene-phenol resins, rosin resins, and xylene resins; stabilizers such as ultraviolet absorbers, antioxidants, and heat stabilizers.
- the layer which consists of what saponified cellulose acetate butyrate resin as an anchor layer is also mentioned.
- the anchor layer is formed by coating and drying by a known technique.
- the thickness of the anchor layer is preferably 1 to 100 nm, more preferably 10 to 50 nm in a dry state.
- the anchor layer forming chemical may be diluted with a solvent.
- the dilution solvent is not particularly limited, and examples thereof include alcohols.
- the dilution concentration is not particularly limited, but is preferably 1 to 5% by mass, more preferably 1 to 3% by mass.
- the optical film 16 may be the polarizer protective film of the present invention, or any other appropriate optical film.
- the optical film used is not particularly limited, and examples thereof include films made of cellulose resin, polycarbonate resin, cyclic polyolefin resin, methacrylic resin, and the like.
- Cellulose resin is an ester of cellulose and fatty acid.
- Specific examples of the cellulose ester resin include cellulose triacetate, cellulose diacetate, cellulose tripropionate, and cellulose dipropionate. Among these, cellulose triacetate is particularly preferable.
- Many products of cellulose triacetate are commercially available, which is advantageous in terms of availability and cost. Examples of commercially available cellulose triacetate products are trade names “UV-50”, “UV-80”, “SH-80”, “TD-80U”, “TD-TAC”, “UZ-” manufactured by FUJIFILM Corporation. TAC ”,“ KC series ”manufactured by Konica Minolta, and the like.
- the cyclic polyolefin resin is a general term for resins that are polymerized using a cyclic olefin as a polymerization unit, and is described in, for example, JP-A-1-240517, JP-A-3-14882, JP-A-3-122137, and the like. Resins that are included. Specific examples include cyclic olefin ring-opening (co) polymers, cyclic olefin addition polymers, cyclic olefins and ⁇ -olefins such as ethylene and propylene (typically random copolymers), And graft polymers obtained by modifying them with an unsaturated carboxylic acid or a derivative thereof, and hydrides thereof. Specific examples of the cyclic olefin include norbornene monomers.
- cyclic polyolefin resins As specific examples, trade names “ZEONEX” and “ZEONOR” manufactured by ZEON Corporation, “ARTON” manufactured by JSR, “TOPAS” manufactured by Polyplastics, and “Product Name” manufactured by Mitsui Chemicals, Inc. APEL ".
- any appropriate methacrylic resin can be adopted as long as the effects of the present invention are not impaired.
- polymethacrylate such as polymethylmethacrylate, methyl methacrylate- (meth) acrylic acid copolymer, methyl methacrylate- (meth) acrylic acid ester copolymer, methyl methacrylate-acrylic acid ester- (meth) Acrylic acid copolymer, (meth) methyl acrylate-styrene copolymer (MS resin, etc.), polymer having alicyclic hydrocarbon group (for example, methyl methacrylate- methacrylic acid cyclohexyl copolymer, methyl methacrylate) -(Meth) acrylic acid norbornyl copolymer).
- the methacrylic resin used in the optical film such as the optical film 16 include, for example, methyl methacrylate described in Mitsubishi Rayon Co., Ltd. Acrypet VH and Acrypet VRL20A, JP2013-033237A and WO2013 / 005634.
- Tg glass transition temperature
- a methacrylic resin having a lactone ring structure can also be used as the methacrylic resin. It is because it has high mechanical strength by high heat resistance, high transparency, and biaxial stretching.
- Examples of the methacrylic resin having the lactone ring structure include JP 2000-230016, JP 2001-151814, JP 2002-120326, JP 2002-254544, and JP 2005-146084. And a methacrylic resin having a lactone ring structure.
- the polarizing plate of the present invention can be used for an image display device.
- the image display device include a self-luminous display device such as an electroluminescence (EL) display, a plasma display (PD), and a field emission display (FED), and a liquid crystal display device.
- the liquid crystal display device includes a liquid crystal cell and the polarizing plate disposed on at least one side of the liquid crystal cell.
- the methacrylic resin composition of the present invention is highly transparent because the methacrylic resin and the polycarbonate resin are compatible with each other, and the retardation in the thickness direction is small even when stretched. Moreover, the film obtained has a high stretchability. Therefore, according to the methacrylic resin composition of the present invention, a thin film having excellent in-plane uniformity and high surface smoothness can be obtained. In addition, the film can be stretched at a low temperature, and a film having high strength can be obtained. Furthermore, by setting the syndiotacticity (rr) of the methacrylic resin to a specific value, it is possible to provide a film having high heat resistance and a small heat shrinkage rate.
- GPC device manufactured by Tosoh Corporation, HLC-8320 Detector: Differential refractive index detector Column: TSKgel SuperMultipore HZM-M manufactured by Tosoh Corporation and Superhz4000 connected in series were used. Eluent: Tetrahydrofuran Eluent flow rate: 0.35 mL / min Column temperature: 40 ° C Calibration curve: Created using 10 standard polystyrene data
- Glass transition temperature Tg Glass transition temperature Tg
- the methacrylic resin, polycarbonate resin and methacrylic resin composition were heated to 230 ° C. once using a differential scanning calorimeter (manufactured by Shimadzu Corporation, DSC-50 (product number)) in accordance with JIS K7121, and then at room temperature. Then, the DSC curve was measured under the condition that the temperature was raised from room temperature to 230 ° C. at a rate of 10 ° C./min.
- the midpoint glass transition temperature obtained from the DSC curve measured at the second temperature rise was defined as the glass transition temperature in the present invention.
- the methacrylic resin which is the raw material of the methacrylic resin composition used in the production of the film in each Example and Comparative Example, was measured under conditions of 230 ° C., 3.8 kg load, and 10 minutes in accordance with JIS K7210.
- MFR Melt Mass Flow Rate
- MVR Melt volume flow rate
- the polycarbonate resin which is the raw material of the methacrylic resin composition used in the production of the film in each Example and Comparative Example, was measured under the conditions of 300 ° C., 1.2 kg load, and 10 minutes in accordance with JIS K7210.
- Total light transmittance A test piece of 50 mm ⁇ 50 mm was cut out from the biaxially stretched film obtained in each Example and Comparative Example, and the total light beam was measured using a haze meter (manufactured by Murakami Color Research Laboratory, HM-150) according to JIS K7361-1. The transmittance was measured.
- the methacrylic resin composition was evaluated by molding a 1.0 mm-thick molded body with a hot press and measuring the total light transmittance.
- a test piece of 40 mm ⁇ 40 mm was cut out from the biaxially stretched film obtained in each example and comparative example. This test piece was subjected to three-dimensional refraction using an automatic birefringence meter (KOBRA-WR manufactured by Oji Scientific Co., Ltd.) at a temperature of 23 ⁇ 2 ° C. and a humidity of 50 ⁇ 5% from a phase difference value at a wavelength of 590 nm and a tilt angle of 40 °. The rates nx, ny, and nz were obtained, and the thickness direction phase difference Rth and the in-plane direction phase difference Re were calculated from the above-described equations.
- KOBRA-WR automatic birefringence meter
- the thickness d (nm) of the test piece was measured using a digimatic indicator (manufactured by Mitutoyo Corporation), and the refractive index n was measured by a digital precision refractometer (KPR-20 manufactured by Kalnew Optical Industry Co., Ltd.).
- the obtained solution was diluted by adding 1500 g of toluene. Next, the diluted solution was poured into 100 kg of methanol to obtain a precipitate. The obtained precipitate was dried at 80 ° C. and 140 Pa for 24 hours.
- the Mw was 96100, the molecular weight distribution was 1.07, the syndiotacticity (rr) was 83%, and the glass transition temperature was 133 ° C.
- the ratio of the structural unit derived from methyl methacrylate was 100 mass%, and the methacryl resin [PMMA1] was obtained.
- the diluted solution was poured into 100 kg of methanol to obtain a precipitate.
- the obtained precipitate was dried at 80 ° C. and 140 Pa for 24 hours.
- the Mw was 81400
- the molecular weight distribution was 1.08
- the syndiotacticity (rr) was 73%
- the glass transition temperature was 131 ° C.
- a methacrylic resin [PMMA2] having a content of structural units derived from methyl methacrylate of 100% by mass was obtained.
- the polymerization reaction was started in a batch mode while maintaining the temperature at 140 ° C.
- the raw material liquid is supplied from the autoclave to the tank reactor at a flow rate of an average residence time of 150 minutes, and the reaction liquid is supplied at a flow rate corresponding to the supply flow rate of the raw material liquid. It was extracted from the tank reactor, maintained at a temperature of 140 ° C., and switched to a continuous flow polymerization reaction. After switching, the polymerization conversion in the steady state was 55% by mass.
- the reaction liquid extracted from the tank reactor in a steady state was heated by supplying it to a multi-tubular heat exchanger having an internal temperature of 230 ° C. at a flow rate with an average residence time of 2 minutes.
- the heated reaction liquid was introduced into a flash evaporator, and volatile components mainly composed of unreacted monomers were removed to obtain a molten resin.
- the molten resin from which volatile components have been removed is supplied to a twin-screw extruder having an internal temperature of 260 ° C., discharged into a strand shape, cut with a pelletizer, pellet-shaped, Mw is 82,000, and the molecular weight distribution is 1.85.
- a methacrylic resin [PMMA3] having a syndiotacticity (rr) of 52%, a glass transition temperature of 120 ° C. and a content of structural units derived from methyl methacrylate of 100% by mass was obtained.
- MMA means a structural unit derived from methyl methacrylate
- BA means a structural unit derived from butyl acrylate.
- B1 Metablene P570A manufactured by Mitsubishi Rayon Co., Ltd. (average polymerization degree: 2384, MMA 53 mass% / BA 47 mass%)
- B2 Metablene P550A manufactured by Mitsubishi Rayon Co., Ltd. (average polymerization degree: 7734, MMA 88 mass% / BA 12 mass%)
- B3 Paraloid K125P manufactured by Kureha Co., Ltd.
- B4 Metablene P530A manufactured by Mitsubishi Rayon Co., Ltd. (average polymerization degree: 24455, MMA 80 mass% / BA 20 mass%)
- B5 Metablene P531A manufactured by Mitsubishi Rayon Co., Ltd. (average polymerization degree: 37162, MMA 80 mass% / BA 20 mass%)
- Example 1 100 parts by weight of methacrylic resin [PMMA1], 2.5 parts by weight of polycarbonate resin [PC1] and 2 parts by weight of processing aid [B2] are mixed together and a twin-screw extruder (manufactured by Technobel, trade name: KZW20TW-45MG-NH). -600) and kneaded and extruded at 250 ° C. to produce a methacrylic resin composition [1].
- the obtained methacrylic resin composition [1] was subjected to hot press molding to form a plate-like molded body of 50 mm ⁇ 50 mm ⁇ 1.0 mm, and the total light transmittance, haze and glass transition temperature were measured.
- Table 3 shows the physical properties of the methacrylic resin composition [1].
- the methacrylic resin composition [1] was dried at 80 ° C. for 12 hours. Using a 20 mm ⁇ single-screw extruder (OCS), the methacrylic resin composition [1] is extruded from a 150 mm wide T-die at a resin temperature of 260 ° C., and is taken up by a roll having a surface temperature of 85 ° C. An unstretched film having a thickness of 110 mm and a thickness of 160 ⁇ m was obtained.
- OCS 20 mm ⁇ single-screw extruder
- the unstretched film obtained by the above-described method is cut into 100 mm ⁇ 100 mm, and stretched at a glass transition temperature + 10 ° C., 500% / min in one direction by a pantograph type biaxial stretching tester (manufactured by Toyo Seiki Co., Ltd.)
- the film was sequentially biaxially stretched at a stretching speed and a stretching ratio of 2 times in one direction (4 times in area ratio), cooled to 100 ° C. or lower over 2 minutes, and a biaxially stretched film having a thickness of 40 ⁇ m was obtained.
- Methacrylic resin compositions [2] to [18] were produced in the same manner as in Example 1 except that the formulations shown in Tables 3 and 4 were used.
- the obtained methacrylic resin compositions [2] to [18] were subjected to hot press molding to form a plate-like molded body of 50 mm ⁇ 50 mm ⁇ 1.0 mm, and the total light transmittance, haze and glass transition temperature were measured.
- Tables 3 and 4 show the physical properties of the methacrylic resin compositions [2] to [18].
- a biaxially stretched film was obtained in the same manner as in Example 1 except that the methacrylic resin compositions [2] to [18] were used instead of the methacrylic resin composition [1].
- the evaluation results are shown in Table 3 and Table 4.
- polarizer protective film A The biaxially stretched film of Example 8 was used as the polarizer protective film A.
- Polyester urethane (Daiichi Kogyo Seiyaku Co., Ltd., trade name: Superflex 210, solid content: 33%) 16.8 g, crosslinking agent (oxazoline-containing polymer, product of Nippon Shokubai Co., Ltd., trade name: Epocross WS-700, solid content: 25%) 4.2 g, 2.0 g of 1 mass% ammonia water, 0.42 g of colloidal silica (manufactured by Fuso Chemical Industries, Quattron PL-3, solid content: 20 mass%) and 76.6 g of pure water were mixed.
- An easy-adhesive composition was obtained.
- the resulting easy-adhesive composition was applied to the corona discharge treated surface of the biaxially stretched film of Example 8 subjected to corona discharge treatment with a bar coater so that the thickness after drying was 100 nm. Thereafter, the film was put into a hot air dryer (110 ° C.), and the easy-adhesive composition was dried for about 5 minutes to form an easy-adhesion layer on the biaxially stretched film of Example 8.
- N-hydroxyethylacrylamide manufactured by Kojin Co., Ltd.
- tripropylene glycol diacrylate trade name: Aronix M-220, manufactured by Toagosei Co., Ltd.
- acryloylmorpholine 38.3 parts of Kojin Co., Ltd.
- a photopolymerization initiator trade name: KAYACURE DETX-S, diethylthioxanthone, Nippon Kayaku Co., Ltd.
- the active energy ray-curable adhesive was applied to the easy-adhesion layer side of the polarizer protective film A so that the thickness after drying was 500 nm. Thereafter, one polarizer protective film A was laminated on each side of the above polarizer using a small laminator via an active energy ray curable adhesive. From both sides of the bonded polarizer protective film A, heat to 50 ° C. using an IR heater and irradiate both sides with ultraviolet rays with an integrated irradiation amount of 1000 mJ / cm 2 to cure the active energy ray-curable adhesive. A polarizing plate X having a transparent polarizer protective film A on both sides of the polarizer was obtained. When the produced polarizing plate X was put into a constant temperature and humidity machine at 80 ° C. and 90% RH and the degree of deterioration of the polarizer after 100 hours was visually observed, no deterioration was observed.
- polarizing plate Y A 40 ⁇ m thick triacetylcellulose film was immersed in a 10% aqueous sodium hydroxide solution (60 ° C.) for 30 seconds to saponify, and then washed with water for 60 seconds to obtain a polarizer protective film B.
- An acetoacetyl group-containing polyvinyl alcohol resin (average polymerization degree: 1200, saponification degree: 98.5 mol%, acetoacetyl group modification degree: 5 mol%) is 100 parts by mass, and 20 parts by mass of methylolmelamine is 30 ° C. It was dissolved in pure water under temperature conditions to obtain an aqueous solution with a solid content concentration of 0.5%. The obtained aqueous solution was used as an adhesive composition under a temperature condition of 30 ° C.
- the above-mentioned adhesive composition 30 minutes after the preparation was applied to the polarizer protective film B so that the thickness after drying was 50 nm. Thereafter, a polarizer protective film B is laminated on each side of the polarizer described above via an adhesive composition using a small laminator, put into a hot air dryer (70 ° C.), dried for 5 minutes, and polarized. Plate Y was obtained. When the produced polarizing plate Y was put into a constant temperature and humidity chamber of 80 ° C. and 90% RH and the degree of deterioration of the polarizer after 100 hours was visually observed, deterioration was recognized on the entire surface.
- the methacrylic resin composition of the present invention has high transparency, small retardation in the thickness direction, high heat resistance, and can be stretched thinly. Therefore, a polarizer protective film, a retardation film, a liquid crystal protective plate, and portable information It is suitable for a surface material of a terminal, a display window protective film for a portable information terminal, a light guide film, a transparent conductive film coated with silver nanowires or carbon nanotubes on the surface, and a front plate for various displays. In particular, since the film of the present invention has a small retardation, it is suitable for a polarizer protective film.
- the film of the present invention has high transparency and heat resistance, IR cut film, crime prevention film, anti-scattering film, decorative film, metal decorative film, solar cell back sheet, flexible solar, etc. can be used for applications other than optical applications. It can be used for a battery front sheet, a shrink film, and an in-mold label film.
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Abstract
Description
前記メタクリル樹脂は、メタクリル酸メチル由来の構造単位の含有量が80質量%以上であって、重量平均分子量が200000以下であり、
前記ポリカーボネート樹脂は、1000以上、32000以下の粘度平均分子量を有しており、前記メタクリル樹脂100質量部に対する前記ポリカーボネート樹脂の含有量が1質量部以上、4質量部以下であり、
前記高分子加工助剤は、3,000以上、40,000以下の平均重合度を有しており、前記メタクリル樹脂100質量部に対する前記高分子加工助剤の含有量が0.3質量部以上、6質量部以下であり、
メタクリル樹脂組成物中に含有される前記メタクリル樹脂と前記ポリカーボネート樹脂との合計量が、80質量%以上であるメタクリル樹脂組成物。
〔3〕:前記メタクリル樹脂のシンジオタクティシティ(rr)が、58%以上、85%以下である〔1〕または〔2〕に記載のメタクリル樹脂組成物。
〔4〕:前記メタクリル樹脂のメタクリル酸メチル由来の構造単位の含有量が、99質量%以上である〔1〕~〔3〕のいずれかひとつに記載のメタクリル樹脂組成物。
〔5〕:前記ポリカーボネート樹脂が、5000以上、18000以下の粘度平均分子量を有する〔1〕~〔4〕のいずれかひとつに記載のメタクリル樹脂組成物。
〔6〕:前記メタクリル樹脂組成物の重量平均分子量が70000~200000である〔1〕~〔5〕のいずれかひとつに記載のメタクリル樹脂組成物。
〔7〕:前記メタクリル樹脂組成物の分子量分布が1.2~2.5である〔1〕~〔6〕のいずれかひとつに記載のメタクリル樹脂組成物。
〔9〕:〔1〕~〔7〕のいずれかひとつに記載のメタクリル樹脂組成物からなるフィルム。
〔10〕:厚さが10~50μmである、〔9〕に記載のフィルム。
〔11〕:面積比で1.5~8倍に二軸延伸された〔9〕または〔10〕に記載のフィルム。
〔12〕:偏光子保護フィルムとして用いられる〔9〕~〔11〕のいずれかひとつに記載のフィルム。
〔13〕:〔12〕に記載のフィルムが少なくとも1枚積層された偏光板。
〔14〕:メタクリル酸メチル由来の構造単位の含有量が80質量%以上であって、重量平均分子量が200000以下であるメタクリル樹脂100質量部と、1000以上、32000以下の粘度平均分子量を有するポリカーボネート樹脂1質量部以上、4質量部以下と、3,000以上、40,000以下の平均重合度を有する高分子加工助剤0.3質量部以上、6質量部以下と、の少なくとも3成分を混合してなるメタクリル樹脂組成物の製造方法。
メタクリル樹脂のシンジオタクティシティ(rr)(%)は、重水素化クロロホルム中、30℃で、1H-NMRスペクトルを測定し、そのスペクトルからTMSを0ppmとした際の、0.6~0.95ppmの領域の面積(X)と0.6~1.35ppmの領域の面積(Y)とを計測し、式:(X/Y)×100にて算出することができる。
AlR1R2R3
(式中、R1、R2およびR3はそれぞれ独立して置換基を有してもよいアルキル基、置換基を有していてもよいシクロアルキル基、置換基を有してもよいアリール基、置換基を有していてもよいアラルキル基、置換基を有してもよいアルコキシル基、置換基を有してもよいアリールオキシ基またはN,N-二置換アミノ基を表す。R2およびR3は、それぞれが結合してなる、置換基を有していてもよいアリーレンジオキシ基であってもよい。)
で示される化合物が挙げられる。具体的には、イソブチルビス(2,6-ジ-tert-ブチル-4-メチルフェノキシ)アルミニウム、イソブチルビス(2,6-ジ-tert-ブチルフェノキシ)アルミニウム、イソブチル〔2,2’-メチレンビス(4-メチル-6-tert-ブチルフェノキシ)〕アルミニウム等が挙げられる。
また、アニオン重合法においては、重合反応を制御するために、エーテルや含窒素化合物などを共存させることもできる。
ηsp /c=[η]+0.45×[η]2 c
(但し[η]は極限粘度、上記条件ではc=0.5)
[η]=1.23×10- 4 Mv0 . 8 3
なお、ポリカーボネート樹脂の粘度平均分子量、MVR値や重量平均分子量は末端停止剤や分岐剤の量を調整することによって行うことができる。
リン系酸化防止剤とヒンダードフェノール系酸化防止剤とを併用する場合、リン系酸化防止剤/ヒンダードフェノール系酸化防止剤を質量比で0.2/1~2/1で使用するのが好ましく、0.5/1~1/1で使用するのがより好ましい。
該熱劣化防止剤としては、2-tert-ブチル-6-(3’-tert-ブチル-5’-メチル-ヒドロキシベンジル)-4-メチルフェニルアクリレート(住友化学社製;商品名スミライザーGM)、2,4-ジtert-アミル-6-(3’,5’-ジ-tert-アミル-2’-ヒドロキシ-α-メチルベンジル)フェニルアクリレート(住友化学社製;商品名スミライザーGS)などが好ましい。
紫外線吸収剤としては、ベンゾフェノン類、ベンゾトリアゾール類、トリアジン類、ベンゾエート類、サリシレート類、シアノアクリレート類、蓚酸アニリド類、マロン酸エステル類、ホルムアミジン類などが挙げられる。これらの中でも、ベンゾトリアゾール類、トリアジン類、または波長380~450nmにおけるモル吸光係数の最大値εmaxが100dm3・mol-1cm-1以下である紫外線吸収剤が好ましい。
これら紫外線吸収剤の中、紫外線被照による樹脂劣化が抑えられるという観点からベンゾトリアゾール類が好ましく用いられる。
εmax=[Amax/(10×10-3)]×MUV
有機色素としては、樹脂に対しては有害とされている紫外線を可視光線に変換する機能を有する化合物が好ましく用いられる。
光拡散剤や艶消し剤としては、ガラス微粒子、ポリシロキサン系架橋微粒子、架橋ポリマー微粒子、タルク、炭酸カルシウム、硫酸バリウムなどが挙げられる。
蛍光体として、蛍光顔料、蛍光染料、蛍光白色染料、蛍光増白剤、蛍光漂白剤などが挙げられる。
また、本発明のフィルムは、その中に含まれるポリカーボネート樹脂の量が、厚さ方向の位相差が小さいという観点から、好ましくは1~3.8質量%、より好ましくは2~2.9質量%である。
また、本発明のフィルムは、その中に含まれる高分子加工助剤の量が、延伸性の観点から、好ましくは0.3~5.6質量%、より好ましくは0.5~2.9質量%である。
本発明のフィルムは、波長590nmの光に対する厚さ方向位相差Rthが、フィルムの厚さ40μmの時に、-10nm以上10nm以下であることが好ましく、より好ましくは-5nm以上、5nm以下、さらに好ましくは-4nm以上、4nm以下、さらにより好ましくは-3nm以上、3nm以下、特に好ましくは-2nm以上、2nm以下、最も好ましくは-1nm以上、1nm以下である。
面内方向位相差および厚さ方向位相差がこのような範囲であれば、位相差に起因する画像表示装置の表示特性への影響が顕著に抑制され得る。より具体的には、干渉ムラや3Dディスプレイ用液晶表示装置に用いる場合の3D像の歪みが顕著に抑制され得る。
なお、面内方向位相差Reおよび厚さ方向位相差Rthは、それぞれ、以下の式で定義される値である。
Re=(nx-ny)×d
Rth=((nx+ny)/2-nz)×d
ここで、nxはフィルムの遅相軸方向の屈折率であり、nyはフィルムの進相軸方向の屈折率であり、nzはフィルムの厚さ方向の屈折率であり、d(nm)はフィルムの厚さである。遅相軸は、フィルム面内の屈折率が最大になる方向をいい、進相軸は、面内で遅相軸に垂直な方向をいう。
接着剤層の厚さは、乾燥状態において、好ましくは0.01~10μm、さらに好ましくは0.03~5μmである。
島津製作所社製ガスクロマトグラフ GC-14Aに、カラムとしてGL Sciences Inc.社製 Inert CAP 1(df=0.4μm、0.25mmI.D.×60m)を繋ぎ、インジェクション温度を180℃に、検出器温度を180℃に、カラム温度を60℃(5分間保持)から昇温速度10℃/分で200℃まで昇温して、10分間保持する条件に設定して、測定を行い、この結果に基づいて重合転化率を算出した。
各製造例、実施例および比較例で得られたメタクリル樹脂およびメタクリル樹脂組成物のMwおよび分子量分布は、ゲルパーミエーションクロマトグラフィー(GPC)にて下記の条件でクロマトグラムを測定し、標準ポリスチレンの分子量に換算した値を算出した。ベースラインはGPCチャートの高分子量側のピークの傾きが保持時間の早い方から見てゼロからプラスに変化する点と、低分子量側のピークの傾きが保持時間の早い方から見てマイナスからゼロに変化する点を結んだ線とした。
GPC装置:東ソー社製、HLC-8320
検出器:示差屈折率検出器
カラム:東ソー社製のTSKgel SuperMultipore HZM-Mの2本とSuperhz4000を直列に繋いだものを用いた。
溶離剤: テトラヒドロフラン
溶離剤流量: 0.35mL/分
カラム温度: 40℃
検量線:標準ポリスチレン10点のデータを用いて作成
ポリカーボネート樹脂の粘度平均分子量は、ウベローデ粘度計を用いてポリカーボネート樹脂0.5gを塩化メチレン100mLに溶解した溶液の比粘度ηspを20℃で測定し、下記のSchnellの式を満足する値として、20℃の塩化メチレン溶液の極限粘度[η]から、算出した。
ηsp/c=[η]+0.45×[η]2 c
(但し[η]は極限粘度、上記条件ではc=0.5)
[η]=1.23×10- 4 Mv0 . 8 3
メタクリル樹脂の1H-NMRスペクトルを、核磁気共鳴装置(Bruker社製 ULTRA SHIELD 400 PLUS)を用いて、溶媒として重水素化クロロホルムを用い、室温、積算回数64回の条件にて、測定した。そのスペクトルからTMSを0ppmとした際の0.6~0.95ppmの領域の面積(X)と、0.6~1.35ppmの領域の面積(Y)とを計測し、次いで、三連子表示のシンジオタクティシティ(rr)を式:(X/Y)×100にて算出した。
メタクリル樹脂、ポリカーボネート樹脂およびメタクリル樹脂組成物を、JIS K7121に準拠して、示差走査熱量測定装置(島津製作所製、DSC-50(品番))を用いて、230℃まで一度昇温し、次いで室温まで冷却し、その後、室温から230℃までを10℃/分で昇温させる条件にてDSC曲線を測定した。2回目の昇温時に測定されるDSC曲線から求められる中間点ガラス転移温度を本発明におけるガラス転移温度とした。
各実施例および比較例でフィルムの製造に用いたメタクリル樹脂組成物の原料であるメタクリル樹脂を、JIS K7210に準拠して、230℃、3.8kg荷重、10分間の条件で測定した。
(メルトボリュームフローレート(MVR))
各実施例および比較例でフィルムの製造に用いたメタクリル樹脂組成物の原料であるポリカーボネート樹脂を、JIS K7210に準拠して、300℃、1.2kg荷重、10分間の条件で測定した。
各実施例および比較例で得られた二軸延伸フィルムの表面を目視により観察し以下の基準で表面平滑性を評価した。
A:表面が平滑である。
B:表面に凹凸がある。
自動希釈型毛細管粘度計(ウベローデ型、毛細管内径=0.5mm)を用い、クロロホルムを溶媒として20℃で測定して、PMMA換算重合度で求めた。
各実施例および比較例で得られた二軸延伸フィルムから100mm×30mmの試験片を切り出し、その表面に70mmの長さの直線を記入し、110℃の温度に保たれた強制温風循環式恒温オーブン内で30分間加熱後、記入した直線の長さ(L(mm))をスケールで読取り、下記式により加熱収縮率を求めた。
加熱収縮率(%)=(70-L)/70×100
各実施例および比較例で得られた二軸延伸フィルムから50mm×50mmの試験片を切り出し、JIS K7361-1に準じて、ヘイズメータ(村上色彩研究所製、HM-150)を用いてその全光線透過率を測定した。またメタクリル樹脂組成物の評価は、1.0mm厚の成形体を熱プレスにて成形し、全光線透過率を測定した。
各実施例および比較例で得られた二軸延伸フィルムから50mm×50mmの試験片を切り出し、JIS K7136に準拠して、ヘイズメータ(村上色彩研究所製、HM-150)を用いてそのヘイズを測定した。またメタクリル樹脂組成物の評価は、1.0mm厚の成形体を熱プレスにて成形し、ヘイズを測定した。
各実施例および比較例で得られた二軸延伸フィルムから40mm×40mmの試験片を切り出した。この試験片を、自動複屈折計(王子計測社製 KOBRA-WR)を用いて、温度23±2℃、湿度50±5%において、波長590nm、40°傾斜方向の位相差値から3次元屈折率nx、ny、nzを求め、前述した式より厚さ方向位相差Rthおよび面内方向位相差Reを計算した。試験片の厚さd(nm)は、デジマティックインジケータ(ミツトヨ社製)を用いて測定し、屈折率nは、デジタル精密屈折計(カルニュー光学工業社製 KPR-20)で測定した。
各実施例および比較例で得られた未延伸フィルムを二軸延伸する際、以下の基準で延伸性を評価した。延伸は、未延伸フィルムを、100mm×100mmに切り出し、パンタグラフ式二軸延伸試験機(東洋精機社製)により、ガラス転移温度+10℃の延伸温度、一方向120%/分の延伸速度、一方向2倍の延伸倍率で逐次二軸延伸し後(面積比で4倍)、10秒保持し、次いで冷却した。
A:割れやクラックのないフィルムを10サンプル中、5サンプル以上取得できたもの。
B:割れやクラックのないフィルムを10サンプル中、4サンプル以下しか取得できなかったもの。
得られた溶液にトルエン1500gを加えて希釈した。次いで、該希釈液をメタノール100kgに注ぎ入れ、沈澱物を得た。得られた沈殿物を80℃、140Paにて24時間乾燥して、Mwが96100で、分子量分布が1.07で、シンジオタクティシティ(rr)が83%で、ガラス転移温度が133℃で、且つメタクリル酸メチルに由来する構造単位の割合が100質量%であるメタクリル樹脂〔PMMA1〕を得た。
得られた溶液にトルエン1500gを加えて希釈した。次いで、希釈液をメタノール100kgに注ぎ入れ、沈澱物を得た。得られた沈殿物を80℃、140Paにて24時間乾燥して、Mwが81400で、分子量分布が1.08で、シンジオタクティシティ(rr)が73%で、ガラス転移温度が131℃で、且つメタクリル酸メチルに由来する構造単位の含有量が100質量%であるメタクリル樹脂〔PMMA2〕を得た。
オートクレーブと配管で接続された槽型反応器に容量の2/3まで原料液を入れた。温度を140℃に維持して先ずバッチ方式で重合反応を開始させた。重合転化率が55質量%になったところで、平均滞留時間150分となる流量で、原料液をオートクレーブから槽型反応器に供給し、且つ原料液の供給流量に相当する流量で、反応液を槽型反応器から抜き出して、温度140℃に維持し、連続流通方式の重合反応に切り替えた。切り替え後、定常状態における重合転化率は55質量%であった。
PC1:出光興産社製、タフロンLC1700(品番);MVR(300℃、1.2Kg)=40cm3/10分、Mv=16200
PC2:三菱エンジニアリングプラスチックス社製、ユーピロンHL-4000(品番);MVR(300℃、1.2Kg)=60cm3/10分、Mv=15100
PC3:住化スタイロンポリカーボネート社製、SD POLYCA SD-2201
W(品番);MVR(300℃、1.2Kg)=115cm3/10分、Mv=13000
PC4:住化スタイロンポリカーボネート社製、SD POLYCA TR-2001
(品番);MVR(300℃、1.2Kg)=200cm3/10分、Mv=11400
PC5:三菱エンジニアリングプラスチックス社製、AL071;MVR(300℃、1.2Kg)=1000cm3/10分以上(流動性が高く正確な測定が困難であった)、
Mv=5500
PC6:PC4の50質量部とPC5の50質量部を混合したもの;MVR(300℃、1.2kg)=1000cm3/10分以上(流動性が高く正確な測定が困難であった)、Mv=8500
B1:三菱レイヨン社製メタブレンP570A(平均重合度:2384、MMA53質量%/BA47質量%)
B2:三菱レイヨン社製メタブレンP550A(平均重合度:7734、MMA88質量%/BA12質量%)
B3:クレハ社製パラロイドK125P(平均重合度:19874、MMA79質量%/BA21質量%)
B4:三菱レイヨン社製メタブレンP530A(平均重合度:24455、MMA80質量%/BA20質量%)
B5:三菱レイヨン社製メタブレンP531A(平均重合度:37162、MMA80質量%/BA20質量%)
メタクリル樹脂〔PMMA1〕100質量部、ポリカーボネート樹脂〔PC1〕2.5質量部および加工助剤〔B2〕2質量部を混ぜ合わせ、二軸押出機(テクノベル社製、商品名:KZW20TW-45MG-NH-600)で250℃にて混練押出してメタクリル樹脂組成物〔1〕を製造した。得られたメタクリル樹脂組成物〔1〕を熱プレス成形して50mm×50mm×1.0mmの板状成形体を成形し、全光線透過率、ヘイズおよびガラス転移温度を測定した。メタクリル樹脂組成物〔1〕の物性を表3に示す。
表3および表4に示す配合とする以外は実施例1と同じ方法でメタクリル樹脂組成物〔2〕~〔18〕を製造した。得られたメタクリル樹脂組成物〔2〕~〔18〕を熱プレス成形して50mm×50mm×1.0mmの板状成形体を成形し、全光線透過率、ヘイズおよびガラス転移温度を測定した。メタクリル樹脂組成物〔2〕~〔18〕の物性を表3および表4に示す。
平均重合度2400、ケン化度99.9モル%、厚さ75μmのポリビニルアルコールフィルムを、30℃の温水中に60秒間浸漬して膨潤させた。次いで、0.3質量%(重量比:ヨウ素/ヨウ化カリウム=0.5/8)の30℃のヨウ素溶液中で1分間染色しながら、3.5倍まで延伸した。その後、65℃の4質量%のホウ酸水溶液中に0.5分間浸漬しながら総合延伸倍率が6倍になるよう延伸した。延伸後、70℃のオーブンで3分間乾燥を行い、厚さ22μmの偏光子を得た。
実施例8の二軸延伸フィルムを偏光子保護フィルムAとして用いた。ポリエステルウレタン(第一工業製薬社製、商品名:スーパーフレックス210、固形分:33%)16.8g、架橋剤(オキサゾリン含有ポリマー、日本触媒社製、商品名:エポクロスWS-700、固形分:25%)4.2g、1質量%のアンモニア水2.0g、コロイダルシリカ(扶桑化学工業社製、クォートロンPL-3、固形分:20質量%)0.42gおよび純水76.6gを混合し、易接着剤組成物を得た。
得られた易接着剤組成物を、コロナ放電処理を施した実施例8の二軸延伸フィルムのコロナ放電処理面に、乾燥後の厚さが100nmとなるように、バーコーターで塗布した。その後、フィルムを熱風乾燥機(110℃)に投入し、易接着剤組成物を約5分乾燥させて、実施例8の二軸延伸フィルム上に易接着層を形成した。
厚さ40μmのトリアセチルセルロースフィルムを、10%の水酸化ナトリウム水溶液(60℃)に30秒間浸漬してケン化した後、60秒間水洗し、偏光子保護フィルムBを得た。
本発明のフィルムは透明性、耐熱性が高いため、光学用途以外の用途として、IRカットフィルムや、防犯フィルム、飛散防止フィルム、加飾フィルム、金属加飾フィルム、太陽電池のバックシート、フレキシブル太陽電池用フロントシート、シュリンクフィルム、インモールドラベル用フィルムに使用することができる。
12 接着剤層
13 易接着層
14 偏光子保護フィルム
15 接着剤層
16 光学フィルム
Claims (14)
- メタクリル樹脂、ポリカーボネート樹脂および高分子加工助剤を含むメタクリル樹脂組成物であって、
前記メタクリル樹脂は、メタクリル酸メチル由来の構造単位の含有量が80質量%以上であって、重量平均分子量が200000以下であり、
前記ポリカーボネート樹脂は、1000以上、32000以下の粘度平均分子量を有しており、前記メタクリル樹脂100質量部に対する前記ポリカーボネート樹脂の含有量が1質量部以上、4質量部以下であり、
前記高分子加工助剤は、3,000以上、40,000以下の平均重合度を有しており、
前記メタクリル樹脂100質量部に対する前記高分子加工助剤の含有量が0.3質量部以上、6質量部以下であり、
メタクリル樹脂組成物中に含有される前記メタクリル樹脂と前記ポリカーボネート樹脂との合計量が、80質量%以上であるメタクリル樹脂組成物。 - 前記メタクリル樹脂が、三連子表示のシンジオタクティシティ(rr)が50%以上であり、且つメタクリル酸メチルに由来する構造単位の含有量が92質量%以上、100質量%以下である請求項1に記載のメタクリル樹脂組成物。
- 前記メタクリル樹脂のシンジオタクティシティ(rr)が、58%以上、85%以下である請求項1または2に記載のメタクリル樹脂組成物。
- 前記メタクリル樹脂が、メタクリル酸メチル由来の構造単位の含有量が99質量%以上である請求項1~3のいずれかひとつに記載のメタクリル樹脂組成物。
- 前記ポリカーボネート樹脂が、5000以上、18000以下の粘度平均分子量を有する請求項1~4のいずれかひとつに記載のメタクリル樹脂組成物。
- 前記メタクリル樹脂組成物の重量平均分子量が70000~200000である請求項1~5のいずれかひとつに記載のメタクリル樹脂組成物。
- 前記メタクリル樹脂組成物の分子量分布が1.2~2.5である請求項1~6のいずれかひとつに記載のメタクリル樹脂組成物。
- 請求項1~7のいずれかひとつに記載のメタクリル樹脂組成物からなる成形体。
- 請求項1~7のいずれかひとつに記載のメタクリル樹脂組成物からなるフィルム。
- 厚さが10~50μmである、請求項9に記載のフィルム。
- 面積比で1.5~8倍に二軸延伸された請求項9または10に記載のフィルム。
- 偏光子保護フィルムとして用いられる請求項9~11のいずれかひとつに記載のフィルム。
- 請求項12に記載のフィルムが少なくとも1枚積層された偏光板。
- メタクリル酸メチル由来の構造単位の含有量が80質量%以上であって、重量平均分子量が200000以下であるメタクリル樹脂100質量部と、
1000以上、32000以下の粘度平均分子量を有するポリカーボネート樹脂1質量部以上、4質量部以下と、
3,000以上、40,000以下の平均重合度を有する高分子加工助剤0.3質量部以上、6質量部以下と、
の少なくとも3成分を混合してなるメタクリル樹脂組成物の製造方法。
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JP6559656B2 (ja) | 2019-08-14 |
KR20160147856A (ko) | 2016-12-23 |
JPWO2015162926A1 (ja) | 2017-04-13 |
TW201544536A (zh) | 2015-12-01 |
KR102275215B1 (ko) | 2021-07-08 |
TWI651355B (zh) | 2019-02-21 |
CN106471055A (zh) | 2017-03-01 |
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