WO2022009501A1 - フィルム、フィルムロールおよびフィルムの製造方法 - Google Patents
フィルム、フィルムロールおよびフィルムの製造方法 Download PDFInfo
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- WO2022009501A1 WO2022009501A1 PCT/JP2021/015821 JP2021015821W WO2022009501A1 WO 2022009501 A1 WO2022009501 A1 WO 2022009501A1 JP 2021015821 W JP2021015821 W JP 2021015821W WO 2022009501 A1 WO2022009501 A1 WO 2022009501A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D7/00—Producing flat articles, e.g. films or sheets
- B29D7/01—Films or sheets
-
- 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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
-
- 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
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
- B29C41/28—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on an endless belt
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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
- B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
- B29C55/08—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique transverse to the direction of feed
-
- 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
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H75/00—Storing webs, tapes, or filamentary material, e.g. on reels
- B65H75/02—Cores, formers, supports, or holders for coiled, wound, or folded material, e.g. reels, spindles, bobbins, cop tubes, cans, mandrels or chucks
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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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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/20—Filters
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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
Definitions
- the present invention relates to a film, a film roll, and a method for producing a film.
- winding defects are likely to occur when the film roll is formed, and the quality of the film may be impaired. For example, if the amount of air between the films is too small, winding defects such as sticking between the films occur.
- an object of the present invention is to provide a film, a film roll, and a method for producing a film, which can suppress the occurrence of winding defects.
- the first end and the second end in the width direction intersecting the longitudinal direction, the central part between the first end and the second end, and the first end and the second end. At least the thickness Te1 of the first end portion is smaller than the thickness Tc of the central portion, and the convex position is arranged at a position different from the convex position in the longitudinal direction, and the first end portion is formed.
- the film has a convex position where the thickness Te1 at the first end is smaller than the thickness Tc at the center and a concave position where the thickness Te1 at the first end is larger than the thickness Tc at the center. Since it is provided, it becomes easy to control the amount of air between the films when forming the film roll. Therefore, it is possible to suppress the occurrence of winding defects.
- FIG. 2 It is a schematic diagram which shows an example of the structure of the film roll which concerns on one Embodiment of this invention. It is a top view which shows an example of the structure of the film shown in FIG. (A) is a diagram showing the cross-sectional structure of the convex region shown in FIG. 2, and (B) is a diagram showing the cross-sectional structure of the concave region shown in FIG. 3 is a diagram showing another example of the cross-sectional structure of the end portion of the film shown in FIGS. 3A and 3B. It is a figure which shows an example of the relationship between the position in the longitudinal direction of the film shown in FIG. 2 and the difference ratio D of the thickness of the edge portion and the central portion.
- FIG. 9A is a diagram showing another example of the relationship between the position in the longitudinal direction of the film shown in FIG. 9A and the difference ratio D.
- 9A is a diagram showing another example of the relationship between the position in the longitudinal direction of the film shown in FIG. 9A and the difference ratio D.
- XY indicating a range means "X or more and Y or less”.
- the operation, physical properties, etc. are measured under the conditions of room temperature (20 to 25 ° C.) / relative humidity of 40 to 50% RH.
- FIG. 1 shows a schematic configuration of a film roll 1 according to an embodiment.
- the film roll 1 is formed by winding an optical film 11 around a winding core 12 in a roll shape.
- the optical film 11 has optical functions such as light transmission, reflection, diffusion, and absorption, and is used for, for example, a display and a touch sensor.
- the winding core 12 has, for example, a cylindrical shape and has a predetermined length (size in the X direction in FIG. 1).
- the optical film 11 is wound in the circumferential direction of the winding core 12.
- the total roll length of the film roll 1 is, for example, 500 m to 20000 m.
- FIG. 2 shows an example of the planar configuration of the optical film 11.
- the optical film 11 is wound around the core 12 along its longitudinal direction.
- the longitudinal direction of the optical film 11 may be referred to as the Y direction
- the width direction intersecting the longitudinal direction may be referred to as the X direction
- the thickness direction may be referred to as the Z direction.
- the width direction of the optical film 11 is substantially orthogonal to the longitudinal direction.
- the size of the optical film 11 in the longitudinal direction is, for example, 500 m to 20000 m
- the size of the optical film 11 in the width direction is, for example, 100 mm to 3000 mm.
- the optical film 11 has a pair of end portions e1 and e2 in the width direction and a central portion c between the pair of end portions e1 and e2.
- the pair of end portions e1, e2 and the central portion c are portions having, for example, about 10% of the total size of the optical film 11 in the width direction, and the end portions e1 are portions in the width direction of the optical film 11.
- One end and the end portion e2 include the other end in the width direction of the optical film 11, and the central portion c includes the center in the width direction of the optical film 11.
- the end portion e1 corresponds to a specific example of the first end portion of the present invention
- the end portion e2 corresponds to a specific example of the second end portion of the present invention.
- the optical film 11 has a convex region R1 and a concave region R2 arranged in the Y direction.
- the optical film 11 is provided with a plurality of convex regions R1 and concave regions R2, and the convex regions R1 and concave regions R2 are alternately arranged in the Y direction.
- FIG. 3A represents an XZ cross section of the convex region R1
- FIG. 3B represents an XZ cross section of the concave region R2.
- the thickness Te1 of the end portion e1 and the thickness Te2 of the end portion e2 are smaller than the thickness Tc of the central portion c
- Te2 is larger than the thickness Tc of the central portion c. That is, in the convex region R1, the thicknesses Te1, Te2, Tc satisfy the following mathematical formulas (1) and (2), and in the concave region R2, the thicknesses Te1, Te2, Tc are the following mathematical formulas (3) and formulas (3). It is preferable to satisfy 4).
- the thicknesses Te1, Te2, and Tc satisfy the mathematical formulas (1) and (2)
- Thickness Te1, Te2, Tc preferably satisfy the formula (3) and the formula (4).
- the convex position P1 may be any position in the convex region R1 and the concave position P2 may be any position in the concave region R2.
- the optical film 11 has such a convex position P1 and a concave position P2, more specifically, a convex region R1 and a concave region R2, the film roll When forming 1, it becomes easy to control the amount of air between the optical films 11 that overlap each other. Therefore, it is possible to suppress the occurrence of winding defects.
- the thickness Te1 of the end portion e1 may be smaller than the thickness Tc of the central portion c.
- the thickness of the end portion e1 It is sufficient that Te1 is larger than the thickness Tc of the central portion c. That is, in the convex position P1 and the convex region R1, the thickness Te1 and Tc need only satisfy at least the mathematical formula (1).
- the thickness Te1 and Tc need to be at least the mathematical formula ( It suffices if 3) is satisfied.
- the thicknesses Te1, Te2, and Tc satisfy the mathematical formulas (1) and (2) in the convex position P1 and the convex region R1, and the thicknesses Te1, Te2, and Tc are satisfied in the concave position P2 and the concave region R2. Satisfies the formula (3) and the formula (4).
- the thickness Te1 of the end portion e1 and the thickness Te2 of the end portion e2 are substantially the same.
- the average thickness of the entire optical film 11 is, for example, about 10 ⁇ m to 40 ⁇ m.
- each of the convex region R1 and the concave region R2 in the Y direction is preferably 100 m to 500 m, more preferably 250 m or more. This makes it possible to more effectively suppress the occurrence of winding defects.
- the sizes of the convex region R1 and the concave region R2 in the Y direction are, for example, substantially the same.
- the sizes of the convex region R1 and the concave region R2 in the Y direction may be different from each other.
- FIG. 4 shows another example of the cross-sectional configuration of the optical film 11 shown in FIG.
- the optical film 11 may have an embossed portion E.
- the embossed portion E is a portion that has been embossed, and has, for example, an uneven surface.
- the embossed portion E is provided at, for example, the end portions e1 and e2.
- the thicknesses Te1 and Te2 of the end portions e1 and e2 are, for example, the thickness of the convex portion of the embossed portion E.
- the difference between the thickness Te1 and Te2 of the end portions e1 and e2 and the thickness Tc of the central portion c at predetermined positions in the Y direction (for example, convex position P1 and concave position P2) is set as a difference ratio D1. It can be expressed using the difference ratio D2.
- the difference ratio D1 and the difference ratio D2 are the differences between the thickness Te1 and Te2 and the thickness Tc with respect to the average thickness Ta of the optical film 11, and can be expressed by the following mathematical formulas (5) and (6).
- the difference ratio D1 and the difference ratio D2 are positive values
- the difference ratio D1 and the difference ratio D2 are negative values.
- the absolute values of the difference ratio D1 and the difference ratio D2 are, for example, 10% or less, and more preferably 5% or less.
- the difference ratio D1 and the difference ratio D2 at a predetermined position in the Y direction are almost the same.
- the difference ratio D1 and the difference ratio D2 at a predetermined position in the Y direction are collectively referred to as a difference ratio D.
- the difference ratio D1 and the difference ratio D2 at predetermined positions in the Y direction are substantially the same, and the difference ratio D is used.
- the optical film 11 has, for example, constant portions C1 and C2 in which the difference ratio D is constant in each of the convex region R1 and the concave region R2.
- the absolute value of the difference ratio D (hereinafter referred to as
- of the convex region R1 and the concave region R2 is preferably 10% or less, and more preferably 5% or less.
- the optical film 11 preferably has an inclined portion S between the constant portion C1 and the constant portion C2 (FIGS. 5A and 5B).
- the inclined portion S is a portion where the difference ratio D (%) continuously changes along the longitudinal direction.
- at least one of the thickness Te1, Te2 of the end portions e1 and e2 and the thickness Tc of the central portion c changes continuously along the longitudinal direction. Since the optical film 11 has such an inclined portion S, it is possible to effectively suppress the occurrence of winding defects as compared with the case where there is no inclined portion S (FIG. 5C).
- By setting the size of the inclined portion S in the Y direction to 5 m or more, it is possible to more effectively suppress the occurrence of winding defects.
- per 100 m in the Y direction that is, the inclination of the inclined portion S is preferably 0.03% or more and 10.0% or less, preferably 0.05%. It is more preferably 7.5% or more, and further preferably 2.0% or more and 5.0% or less. This makes it possible to more effectively suppress the occurrence of winding defects.
- FIGS. 6A and 6B show other examples of the relationship between the position of the optical film 11 in the Y direction and the difference ratio D.
- the change of the difference ratio D in the Y direction may be non-linear.
- the difference ratio D may have a plurality of maximum values in the convex region R1 or the concave region R2 (FIG. 6B).
- An inflection point having a difference ratio D may be provided in the convex region R1 or the concave region R2.
- the relationship between the position of the optical film 11 in the Y direction and the difference ratio D is not limited to the examples shown in FIGS. 5A to 6B.
- Such an optical film 11 is made of, for example, a resin having a transparent property with respect to a desired wavelength.
- a resin include an alicyclic structure-containing polymer such as a cycloolefin resin (COP).
- the optical film 11 includes an acrylic resin, a cellulose ester resin, a polycarbonate resin, a polyether sulfone resin, a polyethylene terephthalate (PET) resin, a polyimide resin, a polymethyl methacrylate resin, a poly sulfone resin, a poly allylate resin, a polyethylene resin, and a polyvinyl chloride resin. It may be configured by such as.
- a cycloolefin resin from the viewpoint of transparency and mechanical strength.
- the cycloolefin resin include (co) polymers having structural units derived from the following structures.
- R 1 to R 4 are independently hydrogen atom, hydrocarbon group, halogen atom, hydroxy group, ester group, alkoxy group, cyano group, amide group, imide group, silyl group, or polar group (that is, the polar group). , Halogen atom, hydroxy group, ester group, alkoxy group, cyano group, amide group, imide group, or silyl group).
- R 1 to R 4 two or more thereof may be bonded to each other to form an unsaturated bond, a monocyclic ring or a polycyclic ring, and the monocyclic ring or the polycyclic ring has a double bond.
- an aromatic ring may be formed.
- R 1 and R 2 or R 3 and R 4 may form an alkylidene group.
- p and m are each independently an integer of 0 or more.
- R 1 and R 3 are preferably a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms, more preferably a hydrocarbon group having 1 to 4 carbon atoms, and particularly preferably a hydrocarbon group having 1 to 2 carbon atoms. It is a hydrogen group. It is preferable that R 2 and R 4 are hydrogen atoms or monovalent organic groups, and at least one of R 2 and R 4 is a polar group having a polarity other than the hydrogen atom and the hydrocarbon group.
- m is preferably an integer of 0 to 3
- p is preferably an integer of 0 to 3
- more preferably m + p 0 to 4
- still more preferably m + p 0 to 2
- Examples of the polar group of the specific monomer include a carboxy group, a hydroxy group, an alkoxycarbonyl group, an allyloxycarbonyl group, an amino group, an amide group, a cyano group and the like, and these polar groups are linking groups such as a methylene group. It may be bonded via. Further, a hydrocarbon group to which a polar divalent organic group such as a carbonyl group, an ether group, a silyl ether group, a thioether group and an imino group is bonded as a linking group is also mentioned as a polar group. Among these, a carboxy group, a hydroxy group, an alkoxycarbonyl group or an allyloxycarbonyl group are preferable, and an alkoxycarbonyl group or an allyloxycarbonyl group is particularly preferable.
- the obtained cycloolefin resin has a high glass transition temperature, low hygroscopicity, and various materials. It is preferable in that it has excellent adhesion to and from.
- R is preferably an alkyl group having 1 to 12 carbon atoms, more preferably an alkyl group having 1 to 4 carbon atoms, and particularly preferably an alkyl group having 1 to 2 carbon atoms.
- n is an integer of 0 or more.
- cycloolefins such as cyclobutene, cyclopentene, cycloheptene, cyclooctene, dicyclopentadiene, and norbornene.
- the carbon number of the cycloolefin as a copolymerizable monomer is not particularly limited, but is preferably 4 to 20, and more preferably 5 to 12.
- the cycloolefin resin contained in the optical film 11 may be one kind or two or more kinds.
- the cycloolefin resin contained in the optical film 11 has an intrinsic viscosity [ ⁇ inh] of preferably 0.2 to 5 dL / g, more preferably 0.3 to 3 dL / g, and further preferably 0.4 to 1.5 dL / g. Is.
- the polystyrene-equivalent number average molecular weight (Mn) measured by gel permeation chromatography (GPC) is preferably 8,000 to 100,000, more preferably 10,000 to 80,000, still more preferably 12,000 to 50,000, and the weight average molecular weight (Mw). ) Is preferably in the range of 20,000 to 300,000, more preferably 30,000 to 250,000, and even more preferably 40,000 to 200,000.
- the intrinsic viscosity [ ⁇ inh] When the intrinsic viscosity [ ⁇ inh], the number average molecular weight and the weight average molecular weight are in the above ranges, the heat resistance, water resistance, chemical resistance and mechanical properties of the cycloolefin resin and the molding processability as a cycloolefin film can be improved. It will be good.
- the value of the intrinsic viscosity [ ⁇ inh] the value obtained by measuring the viscosity of the solution in which the cycloolefin resin is dissolved in chloroform at a temperature of 30 ° C. is adopted. The viscosity is measured for three or more solutions having different concentrations of cycloolefin resins. A Ubbelohde viscometer is used for the measurement.
- the glass transition temperature (Tg) of the cycloolefin resin contained in the optical film 11 is, for example, preferably 110 ° C. or higher, more preferably 110 to 350 ° C., still more preferably 120 to 250 ° C., and particularly preferably 120 to 220 ° C. be.
- Tg is 110 ° C. or higher, deformation due to use under high temperature conditions or secondary processing such as coating and printing can be suppressed.
- Tg is 350 ° C. or lower, the molding process becomes easy and the resin can be prevented from being deteriorated by the heat during the molding process.
- Tg glass transition temperature
- the value of the intermediate point glass transition temperature obtained by performing thermal analysis of the cycloolefin resin at a heating rate of 20 ° C./min and according to JIS K7121 (1987) is adopted.
- a differential scanning calorimeter DSC220 manufactured by Seiko Instruments Inc. is used for thermal analysis.
- the optical film 11 preferably contains 50% by mass or more, more preferably 70 to 90% by mass or more of a cycloolefin-based resin.
- the optical film 11 includes known hydrocarbon resins and thermoplastic resins described in, for example, JP-A-9-221577 and JP-A-10-287732, as long as the effects of the present embodiment are not impaired.
- Thermoplastic elastomers, rubbery polymers, organic fine particles, inorganic fine particles, and the like may be blended.
- the optical film 11 may contain additives such as a specific wavelength dispersant, a sugar ester compound (also simply referred to as a sugar ester), an antioxidant, a peeling accelerator, rubber particles or a plasticizer.
- the cycloolefin resin contained in the optical film 11 may be a commercially available product or a synthetic product.
- commercial products include SANUQI (registered trademark) of Konica Minolta Corporation, Arton (registered trademark, the same shall apply hereinafter) G of JSR Corporation, Arton F, Arton R, and Arton RX, and Zeonoa of Nippon Zeon Co., Ltd. (registered).
- FIG. 7 is a flow chart showing an example of a method for manufacturing the optical film 11.
- the optical film 11 is manufactured, for example, by preparing or forming a raw film (for example, the raw film 11f of FIG. 8 described later) and then forming a convex region R1 and a concave region R2 on the raw film. Is preferable. Further, it is more preferable that the optical film 11 is manufactured, for example, by forming a raw film (step S101) and then forming a convex region R1 and a concave region R2 on the raw film (step S102).
- step S101 forming a raw film
- step S102 a method for manufacturing the optical film 11 will be described.
- the raw film may be prepared in advance or newly formed.
- step S101 for example, a raw film having a width direction and a longitudinal direction is formed.
- the method for forming the raw film is not particularly limited, and a known method can be used. Among these, it is preferable to produce by the solution casting method or the melt casting method from the viewpoint of productivity, and it is more preferable to manufacture by the solution casting method from the viewpoint of transparency, transportability and flexibility.
- the solution casting method in general, a solution in which a resin, a resin, and other components that may be optionally contained are dissolved is spread on a support, dried on the support, and then a film. This is a method in which a material (web) is peeled off, and after the peeling, the web is further dried to form a film.
- the melt casting method is generally a method of melt-kneading a resin and other components which may be contained arbitrarily to produce a film, and heats a mixture thereof to a temperature at which fluidity is exhibited. It is a method of melting and casting as a fluid melt to form a film.
- the raw film according to the present invention may be a film-like material (web) or a film obtained by further drying the web after peeling.
- the amount of residual solvent when peeling the web from the support is not particularly limited as long as it has a self-supporting amount to the extent that peeling is possible.
- it is preferably in the range of 10 to 50% by mass, more preferably in the range of 15 to 40% by mass, and further preferably in the range of 20 to 30% by mass. It is within the range of%.
- Residual solvent amount (mass%) ⁇ (MN) / N ⁇ x 100
- M is the mass of the sample collected at any time during or after the production of the web or film
- N is the mass after heating M at 115 ° C. for 1 hour.
- the amount of residual solvent in the film obtained by further drying the web after peeling is preferably 1% by mass or less, more preferably 0.1% by mass or less, and particularly preferably 0 to 0.01% by mass. It is within the range.
- the raw film it is preferable to form the raw film as follows.
- a dope containing a resin and a solvent is first prepared.
- the dope is then cast on the support.
- the flow is performed while moving the support.
- the flow film formed on the support is peeled off from the support.
- the cast film is dried as needed to form a raw film containing a resin.
- the raw film may be a so-called web.
- the solvent used for the dope is not particularly limited, but for example, chlorine-based solvents such as chloroform and dichloromethane (methylene chloride); aromatic solvents such as toluene, xylene, benzene, and mixed solvents thereof; methanol, ethanol, and the like.
- Alcohol-based solvents such as isopropanol, n-butanol, 2-butanol; methyl cellosolve, ethyl cellosolve, butyl cellosolve, ethylene glycol monomethyl ether, dimethylformamide, dimethylsulfoxide, dioxane, cyclohexanone, tetrahydrofuran, acetone, methylethylketone (MEK), ethyl acetate, Diethyl ether; and the like.
- isopropanol, n-butanol, 2-butanol methyl cellosolve, ethyl cellosolve, butyl cellosolve, ethylene glycol monomethyl ether, dimethylformamide, dimethylsulfoxide, dioxane, cyclohexanone, tetrahydrofuran, acetone, methylethylketone (MEK), ethyl acetate, Diethyl
- the solid content concentration of the dope is not particularly limited, but is preferably 10 to 35% by mass, more preferably 15 to 35% by mass.
- the support is not particularly limited, but a mirror-finished surface is preferable, and a stainless steel belt (stainless steel belt) or a drum whose surface is plated with a casting is preferably used.
- a convex region R1 and a concave region R2 are formed on the raw fabric film by heating the end portion of the raw fabric film in the width direction while stretching the raw fabric film in the width direction.
- the thickness of the raw film is generally smaller than that before stretching, but it is difficult for the thickness to be smaller in the vicinity of the end portion gripped by the clip or the like than in the central portion.
- the thicknesses Te1 and Te2 of the end portions e1 and e2 of the film 11 are adjusted.
- FIG. 8 shows an example of the configuration of the clip tenter 50 used for stretching the raw fabric film (raw fabric film 11f) in the width direction.
- the raw film 11f is stretched in the width direction while being conveyed along the longitudinal direction.
- the clip tenter 50 is provided with a first relaxation area 50A before stretching, a stretching area 50B, a second relaxation area 50C after stretching, and a cooling area 50D in this order.
- the raw film 11f passes through the first relaxation area 50A, the stretching area 50B, the second relaxation area 50C, and the cooling area 50D in this order, and is conveyed.
- heating members 51 for heating both ends of the raw film 11f are arranged in each of the first relaxation area 50A, the stretching area 50B, and the second relaxation area 50C of the clip tenter 50 (for example, Japanese Patent Application Laid-Open No. 2011-115985 (Japanese Patent Publication No. 2011).
- the heating member 51 is arranged, for example, in each of the first relaxation area 50A, the stretching area 50B, and the second relaxation area 50C.
- the heating member 51 may be arranged in at least one of the first relaxation area 50A, the stretching area 50B, and the second relaxation area 50C.
- the heating member 51 may be able to adjust the temperature depending on the position in the X direction.
- a plurality of heating members 51 may be arranged side by side in the X direction, and the temperature of the heating member 51 may be changed in the X direction.
- the temperature of the heating member 51 is controlled by the control unit 52.
- the heating member 51 for example, an infrared irradiation member that irradiates infrared rays toward the end in the width direction of the raw film 11f is used.
- the heating member 51 may be a spraying member or the like that blows high-temperature air or an inert gas toward the end in the width direction of the raw film 11f, or may be a heating wire, a heating roll, or the like. good.
- the heating member 51 is arranged, for example, in front of, behind, above, or below the raw film 11f, or at a plurality of places thereof.
- the position of the heating member 51 in the X direction is preferably at a distance of 10 mm to 500 mm, more preferably at a distance of 20 mm to 400 mm from the portion where both ends of the film 11 in the width direction are formed. This makes it easier to control the sizes of the thicknesses Te1 and Te2 of the ends e1 and e2. Both ends of the film 11 in the width direction are formed, for example, by slitting a portion gripped by a clip (end portion in the width direction) from the stretched raw film 11f.
- a clip tenter 50 provided with a heating member 51 in each of the first relaxation area 50A, the stretching area 50B, and the second relaxation area 50C is used. To form.
- the transport speed of the raw film 11f is not particularly limited, but is preferably 3 m / min to 100 m / min, and more preferably 5 m / min to 50 m / min. By setting the transport speed to 3 m / min or more, more preferably 5 m / min or more, the amount of air between the films 11 can be easily adjusted, and the transport time can be shortened to reduce the cost.
- the transport speed By setting the transport speed to 100 m / min or less, more preferably 50 m / min or less, it is possible to prevent the heating member 51 for giving a sufficient amount of heat to the target range from becoming large, and it is possible to suppress the equipment cost. ..
- the temperatures at both ends of the raw film 11f in the width direction are higher than the temperature at the center by about 0 ° C to 50 ° C. preferable.
- the temperature difference between both end portions and the central portion of the portion of the raw film 11f forming the convex region R1 is set to the concave region R2. Make it larger than the temperature difference between both ends and the center of the formed part.
- the thicknesses Te1 and Te2 of the end portions e1 and e2 of the convex region R1 become smaller than the thicknesses Te1 and Te2 of the end portions e1 and e2 of the concave region R2, and the convex regions R1 and the concave shape are formed on the original film 11f.
- Region R2 is formed.
- the temperature difference between both ends of the raw film 11f and the central portion is set to 20 ° C to 30 ° C, and in the portion forming the concave region R2, both ends of the raw film 11f.
- the temperature difference between the film and the center is set to 0 ° C to 10 ° C.
- can be controlled by adjusting the temperature difference between both end portions and the center portion of the raw film 11f.
- the difference between the temperature at both ends of the raw film 11f and the temperature at the center is preferably 50 ° C. or less.
- the temperature difference between both end portions and the central portion of the raw film 11f is preferably 3 ° C. or more. This makes it possible to sufficiently reduce the thicknesses Te1 and Te2 of the ends e1 and e2 in a relatively short time without increasing the size of the equipment.
- the temperatures at both ends of the raw film 11f may be different from each other, but are preferably substantially the same.
- the temperature at both ends and the center of the raw film 11f is measured from the lower side in the gravity direction of the raw film 11f using, for example, a thermal non-contact temperature sensor (MT150 manufactured by Raytec).
- the temperature at both ends of the raw film 11f is measured, for example, at a position overlapping near the center of the heating member 51, and an average value in the range of 50 mm in the width direction is used.
- the temperature at the center of the raw film 11f is measured, for example, at an intermediate position between both ends, and an average value of 100 mm in the width direction is used.
- the draw ratio in the width direction is not particularly limited, but is preferably 5% or more, more preferably 10% or more, and further preferably 15% or more. Thereby, the thicknesses Te1 and Te2 of the ends e1 and e2 can be effectively adjusted by heating the ends e1 and e2. Further, the draw ratio in the width direction is preferably 1000% or less. As a result, the stretching equipment can be stretched without increasing the size, and the equipment cost can be suppressed.
- the stretching ratio in the width direction can be adjusted by the distance between the clips of the clip tenter 50.
- the stretch ratio in the width direction can be evaluated by comparing the widths of the films before and after stretching.
- the above-mentioned draw ratio and temperature are examples, and are appropriately adjusted in order to obtain the desired orientation, physical properties and surface condition of the film 11.
- the stretching in the width direction is not limited to the clip tenter 50, and any method can be used, but for example, a pin tenter or the like may be used.
- the draw ratio in the transport direction is not particularly limited. Any method can be used for stretching in the transport direction, and for example, a pantograph method, an inter-roll draw method, a float method, or the like can be used.
- the convex region R1 and the concave region R2 may be formed by using another method.
- the convex region R1 and the concave region R2 may be formed by controlling the spreading amount when casting the dope.
- a choke bar also referred to as a die bolt
- the like can be used to adjust the flow spread amount of the dove (see, for example, Japanese Patent Application Laid-Open No. 2016-190344) to form the convex region R1 and the concave region R2.
- the spread amount of the dope is adjusted (see, for example, Japanese Patent Application Laid-Open No.
- the convex region R1 And the concave region R2 may be formed.
- increasing the thicknesses Te1 and Te2 of the ends e1 and e2 increasing the flow rate of the dope for forming the ends e1 and e2, and decreasing the thicknesses Te1 and Te2 of the ends e1 and e2, the end.
- the flow rate of the dope for forming the portions e1 and e2 may be reduced.
- the convex region R1 and the concave region R2 may be formed by controlling the presence / absence and size of the embossed portion (for example, the embossed portion E in FIG. 4) (for example, Japanese Patent Application Laid-Open No. 2009-73154). See Gazette). By combining a plurality of these methods, the convex region R1 and the concave region R2 may be formed.
- the optical film 11 having the convex region R1 and the concave region R2 can be manufactured in this way.
- the film roll 1 is formed by winding the optical film 11 around the core 12 using, for example, a winder.
- the optical film 11 of the present embodiment has a convex region R1 (or a convex position P1) in which the thicknesses Te1 and Te2 of the end portions e1 and e2 are smaller than the thickness Tc of the central portion c, and the thicknesses of the end portions e1 and e2. Since Te1 and Te2 are provided with a concave region R2 (or concave position P2) in which Te1 and Te2 are larger than the thickness Tc of the central portion c, it is easy to control the amount of air between the optical films 11 when forming the film roll 1. It becomes. Therefore, it is possible to suppress the occurrence of winding defects. Hereinafter, this action and effect will be described in detail.
- FIG. 9A, 9B, and 9C each show the relationship between the position of the optical film in the Y direction (longitudinal direction) and the difference ratio D according to the comparative example.
- Each of the optical films according to these comparative examples has only one of the convex region R1 and the concave region R2.
- the optical film shown in FIG. 9A and the optical film shown in FIG. 9C have only the convex region R1, and the thickness of the end portion is smaller than the thickness of the central portion at all positions in the longitudinal direction. (Difference ratio D> 0).
- the optical film shown in FIG. 9B has only the concave region R2, and the thickness of the end portion is larger than the thickness of the central portion at all positions in the longitudinal direction (difference ratio D ⁇ 0).
- difference ratio D difference ratio
- the amount of air between the optical films overlapping each other is relatively small, and strong sticking is likely to occur in the thicker central portion.
- Black bands may occur on the film roll due to the sticking between the optical films.
- expansion and contraction occurs between the central portion where the sticking is strong and the end portion where the sticking is weak, and the optical film is deformed.
- minute air trapped between the films may grow with winding and form dents (dents).
- Deterioration of the optical film caused by the occurrence of such winding defects also affects devices such as displays or touch sensors using this optical film. For example, in a display, the visibility of an image is reduced, and in a touch sensor, the resistance value fluctuates and the sensor function is deteriorated.
- the optical film 11 of the present embodiment has both the convex region R1 and the concave region R2 with respect to the optical film according to these comparative examples, it is possible to control the amount of air between the optical films 11 overlapping with each other. can.
- FIG. 10 shows an example of the configuration of the end face of the film roll 1.
- the convex regions R1 and the concave regions R2 are alternately overlapped with each other, so that sticking between the optical films 11 is suppressed and the shape is maintained. That is, it is possible to suppress the generation of black bands and dents and to suppress the deformation of the optical film 11 over time.
- the optical film 11 has a convex position P1 in which the thicknesses Te1 and Te2 of the end portions e1 and e2 are smaller than the thickness Tc of the central portion c, and the edges. Since the concave positions P2 in which the thicknesses Te1 and Te2 of the portions e1 and e2 are larger than the thickness Tc of the central portion c are provided, it is easy to control the amount of air between the optical films 11 when forming the film roll 1. It becomes. Therefore, it is possible to suppress the occurrence of winding defects.
- this optical film 11 since the occurrence of winding defects is suppressed, it is possible to make a thin film. Further, a low elasticity material can also be preferably used for the optical film 11. In addition, when manufacturing a long optical film 11, it is possible to suppress a decrease in productivity. When the total winding length of the film roll 1 is 1000 m or more, preferably 4000 m or more, the occurrence of winding defects can be suppressed more effectively.
- the film roll 1 may be formed by winding a laminate of a plurality of films.
- This laminate may have, for example, an optical film 11 and a protective film (protective film 21 in FIG. 11 described later).
- the optical film 11 corresponds to a specific example of the functional film of the present invention.
- FIG. 11 shows an example of the cross-sectional structure of the laminated body of the optical film 11 and the protective film 21.
- the protective film 21 is for protecting the optical film 11, and is configured to be removable from the optical film 11.
- the protective film 21 is, for example, a polyester resin such as polyethylene terephthalate or polyethylene naphthalate, a polyether sulphon resin, a polysulphon resin, a polycarbonate resin, a polyamide resin, a polyimide resin, a polyolefin resin, a (meth) acrylic resin such as polymethylmethacrylate, and the like. It contains a polyarylate resin, a polystyrene resin, a polyvinyl alcohol resin, an epoxy resin, and a mixture thereof.
- the film roll 1 is formed by winding the laminated body.
- a transparent conductive film may be laminated on the optical film 11.
- the material for forming the transparent conductive film for example, metals such as Sn, In, Ti, Pb, Au, Pt and Ag, or oxides thereof and the like are used.
- the oxides are, for example, indium tin oxide (ITO), aluminum oxide, silicon oxide, titanium oxide, zinc oxide and tungsten oxide.
- the transparent conductive film may be formed by using aluminum nitride, silicon nitride, titanium nitride, cadmium sulfide, zinc sulfide, zinc selenide, or the like.
- An adhesive layer and an anchor coat layer may be provided between the optical film 11 and the transparent conductive film.
- the adhesive layer can be formed by using, for example, a heat-resistant resin such as an epoxy resin, polyimide, polybutadiene, phenol resin and polyetheretherketone.
- the anchor coat layer is formed by curing by a known curing method, for example, UV curing or heat curing, using an anchor coating agent containing, for example, an acrylic prepolymer such as epoxy diacrylate, urethane diacrylate and polyester diacrylate. be able to.
- An adhesive layer may be provided between the optical film 11 and the transparent conductive film for the purpose of improving the smoothness of the film and the adhesion to the transparent conductive film.
- This adhesive layer can be obtained, for example, by applying a resin varnish and drying to remove the solvent.
- the laminate containing the optical film 11 and the transparent conductive film may have a gas barrier layer on the opposite side to the transparent conductive film.
- the gas barrier layer may be formed of an inorganic material or an organic material. Examples of usable inorganic materials include silicon oxide, aluminum oxide, indium oxide and the like, and examples of organic materials include polyvinyl alcohol, ethylene-vinyl alcohol copolymer and polyamide. Further, a protective coat layer for protecting the gas barrier layer may be laminated on the gas barrier layer.
- the optical film 11 includes, for example, a color filter substrate, a light guide plate, a protective film, a polarizing film, a retardation film, a touch panel, a transparent electrode substrate, a CD (Compact Disc), an MD (Mini Disc), and a DVD (Digital Versaille).
- a color filter substrate such as Disc
- a protective film such as a protective film
- a polarizing film such as a polarizing film
- a retardation film a touch panel
- a transparent electrode substrate a CD (Compact Disc), an MD (Mini Disc), and a DVD (Digital Versaille).
- TFT Thin Film Transistor
- a liquid crystal display substrate and an organic EL
- display element members specifically, color filter substrates, light guide plates, protective films, polarizing films, retardation films, touch sensors, transparent electrode substrates, TFT substrates, liquid crystal display substrates, organic EL display substrates, etc. Can be suitably used for.
- a color filter can be obtained by laminating a color filter layer on a color filter substrate containing an optical film 11.
- laminating method a known pigment dispersion method, dyeing method, electrodeposition method, printing method, transfer method or the like can be used.
- This color filter can be used as a color filter of a liquid crystal display device, and can also be used as a part of parts such as a color display and a liquid crystal display device.
- the optical film 11 can be used not only for optical parts but also for electrically insulating parts, electric / electronic parts, electronic parts encapsulants, medical equipment, and packaging materials.
- the optical film 11 containing a cycloolefin resin is excellent in heat resistance and electrical characteristics, and its dimensional change is small even after high temperature treatment or chemical treatment, so that it is most suitable as an electrically insulating component.
- the electrically insulating component include a covering material for electric wires and cables, an insulating material for OA equipment such as computers, printers and copiers, and an insulating component for flexible printed boards, and are particularly suitable as flexible printed boards. Used for.
- the optical film 11 can also be suitably used for, for example, a touch sensor (claim 12).
- a touch sensor is, for example, a device mounted on the surface of a display device to convert physical contact of a user's finger, touch pen, or the like into an electrical signal and output it.
- This display device is, for example, a liquid crystal display device, a plasma display device, an EL display device, or the like.
- the touch sensor including the optical film 11 is, for example, a transparent electrode type touch sensor.
- the transparent electrode type touch sensor for example, the optical film 11 is coated with a metal oxide to form a transparent electrode, and the position is sensed by the contact point with the transparent electrode.
- the metal oxide for example, indium tin oxide (ITO) is used.
- the optical film 11 is coated with a metal oxide by vacuum vapor deposition or sputtering.
- the optical film 11 used for such a touch sensor preferably has high heat resistance.
- the heat resistance can be evaluated, for example, by the glass transition temperature, and it is preferable that the optical film 11 has, for example, a high glass transition temperature equal to or higher than the sputtering temperature and a high mechanical strength.
- the optical film 11 used for the touch sensor preferably has transparency in the visible light region, and for example, it preferably has a light transmittance of 90% or more with respect to visible light.
- the optical film 11 containing a cycloolefin resin has a high glass transition temperature and high heat resistance, and also has high light transmission to visible light, so that it can be suitably used for a touch sensor.
- a raw film was prepared as follows.
- PET resin Toyobo ester film E7002 manufactured by Toyobo Co., Ltd. 100 parts by mass dichloromethane 200 parts by mass ethanol 10 parts by mass
- the above components were put into a closed container, and the PET resin was dissolved while stirring to prepare a dope.
- this dope was uniformly cast on a stainless steel belt support at a temperature of 31 ° C. and a width of 1800 mm using an endless belt casting device to form a casting film.
- the temperature of the stainless steel belt was controlled to 28 ° C.
- the solvent was evaporated on the stainless belt support until the amount of residual solvent in the cast film reached 30%.
- the cast film was peeled from the stainless belt support at a peeling tension of 128 N / m, and then the cast film was stretched 1.15 times in the width direction under the condition of 160 ° C.
- the residual solvent at the start of stretching was 5% by mass.
- the cast film was dried while being conveyed by a large number of rollers.
- the raw film was stretched in the width direction using a clip tenter while gripping both ends of the raw film in the width direction with clips.
- the convex region R1 and the concave region R2 were formed by heating both ends of the raw film in the width direction in the stretched area (stretched area 50B in FIG. 8).
- An infrared irradiation member was used as the heating member.
- the heating member was arranged at a distance within 150 mm from the position where both ends in the width direction of the film roll were formed.
- a convex region was formed by setting the central portion of the raw film at 130 ° C.
- the average thickness of the film produced above the difference ratio D of each of the convex region R1 and the concave region R2 where
- the size in the longitudinal direction was measured. Further, using an in-line film thickness meter and an encoder (length measuring meter), the amount of change in the difference ratio D of the inclined portion per 100 m in the longitudinal direction was measured (see FIGS. 5A and 5B).
- the average thickness of the produced film was 25 ⁇ m, and the difference ratio D of each of the convex region and the concave region where
- the longitudinal size of the convex region R1 and the longitudinal size of the concave region R2 were the same, 250 m.
- the amount of change in the difference ratio D per 100 m in the inclined portion was 7.5%.
- the glass transition temperature of this film was 80 ° C. After that, a film roll was produced by winding the produced film around a winding core.
- the total volume length was 4000 m.
- a raw film was prepared as follows.
- silica particle dispersion 20 parts by mass of silica particles (Aerosil® R812, manufactured by Nippon Aerosil Co., Ltd., hydrophobic fumed silica, average primary particle diameter Rs 1: 7 nm, specific surface area: 260 ⁇ 30 m 2 / g) and 80 parts by mass.
- a mixture with ME50 a mixed solvent having a mass ratio of methylene chloride and ethanol of 50:50
- ME50 a mixed solvent having a mass ratio of methylene chloride and ethanol of 50:50
- a dope having the following composition was prepared. First, 90 parts by mass of methylene chloride and 10 parts by mass of ethanol were added to the pressurized dissolution tank. Next, 80 parts by mass of acrylic resin (MR1000, manufactured by Nippon Shokubai Co., Ltd., lactone acrylic resin) was put into this pressurized dissolution tank with stirring. Next, the rubber particle dispersion liquid prepared above was put into a pressurized dissolution tank, and then stirred to dissolve the acrylic resin. This acrylic resin solution was filtered using SHP150 (manufactured by Roki Techno Co., Ltd.) to obtain a dope.
- MR1000 manufactured by Nippon Shokubai Co., Ltd., lactone acrylic resin
- a film was formed using the above-mentioned dope. Specifically, using an endless belt casting device, the dope was uniformly spread on the stainless belt support at a temperature of 30 ° C. and a width of 1800 mm to form a casting film. The temperature of the stainless steel belt was controlled to 28 ° C.
- the solvent was evaporated until the amount of residual solvent in the casting film was 30% by mass. Then, the cast film was peeled from the stainless belt support at a peeling tension of 128 N / m. The amount of residual solvent in the cast film after peeling was 30% by mass.
- the raw film was stretched in the width direction using a clip tenter.
- a film roll was produced in the same manner as in the stretching of the raw fabric film described in Example 1 above, except that the temperatures of the central portion and both ends of the raw fabric film at this time were changed.
- the central portion of the raw fabric film was set to 140 ° C. and both ends were set to 170 ° C. to form a convex region, and the central portion and both end portions of the raw fabric film were both set to 140 ° C. to form a concave region.
- the draw ratio in the width direction was 30%.
- a raw film was prepared as follows.
- a dope having the following composition was prepared. First, 200 parts by mass of dichloromethane and 10 parts by mass of ethanol were added to the pressurized dissolution tank. Next, 100 parts by mass of cycloolefin resin (ARTON (registered trademark) F4520, manufactured by JSR Corporation) and 5 parts by mass of ultraviolet absorption are absorbed in a pressurized dissolution tank containing a mixed solution of dichloromethane and ethanol while stirring. The agent (Tinuvin (registered trademark) 477, manufactured by BASF Japan Co., Ltd.) and 3 parts by mass of the above-mentioned fine particle additive solution were added.
- ARTON (registered trademark) F4520 is a polymer having a structural unit having the following structure.
- the dope was uniformly spread on the stainless belt support at a temperature of 31 ° C. and a width of 1800 mm to form a casting film.
- the temperature of the stainless steel belt was controlled to 28 ° C.
- the solvent was evaporated on the stainless belt support until the amount of the residual solvent in the cast film reached 30% by mass.
- the cast film was peeled from the stainless belt support at a peeling tension of 128 N / m.
- the exfoliated flow film was stretched 1.15 times in the width direction under the condition of 160 ° C.
- the residual solvent in the cast film at the start of stretching was 5% by mass.
- the cast film was dried while being conveyed by a large number of rollers.
- the portions (both ends) sandwiched between the tenter clips were slit with a laser cutter, and then the cast film was wound.
- a raw film having a thickness of 33 ⁇ m was obtained.
- the raw film was stretched in the width direction using a clip tenter.
- a film roll was produced in the same manner as in the stretching of the raw fabric film described in Example 1 above, except that the temperatures of the central portion and both ends of the raw fabric film at this time were changed. Specifically, the central portion of the raw fabric film was set to 180 ° C. and both ends were set to 210 ° C. to form a convex region, and the central portion and both end portions of the raw fabric film were both set to 180 ° C. to form a concave region. In both the convex region R1 and the concave region R2, the draw ratio in the width direction was 30%.
- Example 4 In the production of the film roll of Example 3, the film roll was produced in the same manner except that the temperatures of the central portion and both ends of the raw fabric film when the raw fabric film was stretched in the width direction were changed. Specifically, the central portion of the raw film is set to 180 ° C. and both ends are set to 200 ° C to form a convex region, and the central portion of the raw fabric film is set to 180 ° C and both ends are set to 190 ° C to form a concave region. did. As a result, the maximum value of
- Example 5 In the production of the film roll of Example 3, the film roll was produced in the same manner except that the temperature rise rate and the temperature decrease rate of the temperatures at both ends of the raw film were changed. Specifically, the temperature raising rate and the temperature lowering rate of both ends of the raw film were slowed down by 2.1 times as compared with Example 3. As a result, the amount of change in the difference ratio D per 100 m at the inclined portion was changed from the film roll of Example 3 above.
- Example 6 In the production of the film roll of Example 4, the film roll was produced in the same manner except that the temperature rise rate and the temperature decrease rate of the temperatures at both ends of the raw film were changed. Specifically, as compared with Example 4, the rate of temperature increase and decrease of the temperature at both ends of the raw film are set to 2. It was one times slower. As a result, the amount of change in the difference ratio D per 100 m at the inclined portion was changed from the film roll of Example 4 above.
- Example 7 In the production of the film roll of Example 6, the film roll was produced in the same manner except that the length of the entire winding length was changed.
- Example 8 In the production of the film roll of Example 4, the film roll was produced in the same manner except that the cycle of temperature change at both ends of the raw film was changed. Specifically, the cycle of temperature change of the heating member was shortened as compared with the case of producing the film roll of Example 4. As a result, the sizes of the convex region R1 and the concave region R2 in the longitudinal direction were changed from the film roll of Example 4.
- Example 9 In the production of the film roll of Example 6, the film roll was produced in the same manner except that the method of forming the convex region R1 and the concave region R2 was changed. Specifically, a plurality of heat bolts were arranged in the width direction of the casting die, and the value of the voltage applied to the heat bolt was changed according to the position in the width direction. As a result, the amount of dope spreading at both ends of the casting die and the amount of doping spreading at the center of the casting die were adjusted, respectively, to form the convex region R1 and the concave region R2. Specifically, the flow gaps at both ends in the width direction were changed between ⁇ 2.5% and 2.5% with respect to the flow gap at the center in the width direction.
- Example 10 In the production of the film roll of Example 6, the film roll was produced in the same manner except that the method of forming the convex region R1 and the concave region R2 was changed. Specifically, the temperature of the embossed ring was changed from 180 ° C. to 200 ° C. under constant pressure. As a result, the height of the embossing formed was adjusted, and the convex region R1 and the concave region R2 were formed.
- Example 11 In the production of the film roll of Example 1, the temperature of the center and both ends of the raw film when the raw film is stretched in the width direction, and the rate of temperature increase and decrease of the temperature of both ends of the raw film are lowered. Changed with speed. Other than this, a film roll was produced in the same manner as in Example 1 above. As a result, the maximum value of
- Example 12 In the production of the film roll of Example 6, the film roll was produced in the same manner except that the temperatures at both ends of the raw film were changed non-linearly. As a result, the difference ratio D changed in a sine curve shape along the longitudinal direction.
- Example 13 In the production of the film roll of Example 6, the film roll was produced in the same manner except that the length of the entire winding length was changed.
- Example 14 In the production of the film roll of Example 6, the film roll was produced in the same manner except that the length of the entire winding length was changed.
- Example 15 In the production of the film roll of Example 4, the film roll was produced in the same manner except that the cycle of temperature change at both ends of the raw film was changed. Specifically, the period of temperature change of the heating member was made longer than that at the time of producing the film roll of Example 4. As a result, the sizes of the convex region R1 and the concave region R2 in the longitudinal direction were changed from the film roll of Example 4.
- Example 2 In the production of the film roll of Example 3, the film roll was produced in the same manner except that the temperatures of the central portion and both ends of the raw fabric film when the raw fabric film was stretched in the width direction were changed. Specifically, the raw fabric film was stretched in the width direction while maintaining the central portion of the raw fabric film at 180 ° C. and both ends at 190 ° C. As a result, only a concave region was formed on the film roll.
- the film was placed on a table provided substantially horizontally with respect to the black Rasha paper, and the presence or absence of deformation of the film was confirmed by the reflected light of the light applied to the film.
- the film was irradiated with light using a fluorescent lamp of 2500 lux or more, and the fluorescent lamp was arranged within 2 m from the film.
- the black band of the film roll was evaluated according to the following evaluation criteria. The results are shown in Table 1 below; ⁇ Evaluation criteria ⁇ A: There is no part of the film roll that looks different in color, B: There is a part of the film roll that looks different in color, but no deformation of the film is confirmed. C: Deformation of the film was confirmed.
- the film and film roll according to the present invention have a convex position (or a convex region) in which the thickness of the end portion in the width direction is smaller than the thickness of the central portion, and a concave shape in which the thickness of the end portion is larger than the thickness of the central portion.
- a position or concave area
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Abstract
Description
っていてもよい。
、エーテル基、シリルエーテル基、チオエーテル基、イミノ基など、極性を有する2価の有機基が連結基となって結合している炭化水素基なども、極性基として挙げられる。これらの中では、カルボキシ基、ヒドロキシ基、アルコキシカルボニル基またはアリロキシカルボニル基が好ましく、特にアルコキシカルボニル基またはアリロキシカルボニル基が好ましい。
上のシクロオレフィン系樹脂を含んでいる。
図7は、光学フィルム11の製造方法の一例を表す流れ図である。光学フィルム11は、たとえば、原反フィルム(たとえば、後述の図8の原反フィルム11f)を準備または形成した後、この原反フィルムに凸状領域R1および凹状領域R2を形成することにより製造することが好ましい。また、光学フィルム11は、たとえば、原反フィルムを形成した後(ステップS101)、この原反フィルムに凸状領域R1および凹状領域R2を形成する(ステップS102)ことにより製造することがより好ましい。以下、この光学フィルム11の製造方法について説明する。
残留溶剤量(質量%)={(M-N)/N}×100
なお、Mはウェブまたはフィルムを製造中または製造後の任意の時点で採取した試料の質量で、NはMを115℃で1時間の加熱後の質量である。
51が配置されている(たとえば、特開2011-115985号公報参照)。加熱部材51は、たとえば、第1緩和エリア50A、延伸エリア50Bおよび第2緩和エリア50C各々に配置されている。加熱部材51は、第1緩和エリア50A、延伸エリア50Bおよび第2緩和エリア50Cのうち、少なくともいずれか1つに配置されていればよい。加熱部材51により、X方向の位置による温度調整が可能であってもよい。たとえば、複数の加熱部材51をX方向に並べて配置し、X方向で加熱部材51の温度を変化させるようにしてもよい。加熱部材51の温度は、制御部52により制御される。
部と中央部との温度差が小さくなるほど|D|が大きくなる。
本実施形態の光学フィルム11には、端部e1、e2の厚みTe1、Te2が中央部cの厚みTcよりも小さい凸状領域R1(または凸状位置P1)と、端部e1、e2の厚みTe1、Te2が中央部cの厚みTcよりも大きい凹状領域R2(または凹状位置P2)とが設けられているので、フィルムロール1を形成する際に、光学フィルム11間のエアー量の制御が容易となる。よって、巻取り不良の発生を抑えることが可能となる。以下、この作用効果について詳細に説明する。
フィルムロール1は、複数のフィルムの積層体を巻き取ることにより形成されていてもよい。この積層体は、たとえば、光学フィルム11および保護フィルム(後述の図11の保護フィルム21)を有していてもよい。ここでは、光学フィルム11が、本発明の機能フィルムの一具体例に対応する。
光学フィルム11には、透明導電膜が積層されていてもよい。透明導電膜を形成するための材料としては、たとえば、Sn、In、Ti、Pb、Au、PtおよびAg等の金属、又はこれらの酸化物等が使用される。この酸化物は、たとえば、酸化インジウム・スズ(ITO)、酸化アルミニウム、酸化ケイ素、酸化チタン、酸化亜鉛および酸化タングステンである。透明導電膜は、窒化アルミニウム、窒化ケイ素、窒化チタン、硫化カドミウム、硫化亜鉛またはセレン化亜鉛等を用いて形成されていてもよい。
ノール樹脂およびポリエーテルエーテルケトン等の耐熱樹脂を用いて形成することができる。アンカーコート層は、たとえば、エポキシジアクリレート、ウレタンジアクリレートおよびポリエステルジアクリレート等のアクリルプレポリマー等を含むアンカーコート剤を用いて、公知の硬化手法、たとえばUV硬化や加熱硬化により硬化させて形成することができる。
光学フィルム11は、たとえば、カラーフィルター用基板、導光板、保護フィルム、偏光フィルム、位相差フィルム、タッチパネル、透明電極基板、CD(Compact Disc)、MD(Mini Disc)、DVD(Digital Versatile
Disc)等の光学記録基板、TFT(Thin Film Transistor)用基板、液晶表示基板および有機EL(Electroluminescence)表示基板、あるいは、光伝送用導波路および光学素子封止材等の光学部品として、好適に使用することができる。中でも、表示素子用部材、具体的には、カラーフィルター用基板、導光板、保護フィルム、偏光フィルム、位相差フィルム、タッチセンサー、透明電極基板、TFT用基板、液晶表示基板、有機EL表示基板等に好適に用いることができる。
覆することにより透明電極を形成し、この透明電極への接点により位置が感知される。金属酸化物には、たとえば、インジウムスズ酸化物(Indium Tin Oxide:ITO)が用いられる。たとえば、真空蒸着またはスパッタリングにより、光学フィルム11に金属酸化物が被覆される。
まず、以下のようにして原反フィルムを作製した。
PET樹脂(東洋紡株式会社製 東洋紡エステルフィルムE7002) 100質量部
ジクロロメタン 200質量部
エタノール 10質量部
まず、上記の成分を密閉容器に投入し、攪拌しながらPET樹脂を溶解させ、ドープを調製した。
次いで、このドープを、無端ベルト流延装置を用いて、温度31℃、1800mm幅でステンレスベルト支持体上に均一に流延(キャスト)させ、流延膜を形成した。ステンレスベルトの温度は28℃に制御した。次に、ステンレスベルト支持体上で、流延膜中の残留溶剤量が30%になるまで溶剤を蒸発させた。続いて、剥離張力128N/mで、流延膜をステンレスベルト支持体上から剥離した後、この流延膜を、160℃の条件下で幅方向に1.15倍延伸した。延伸開始時の残留溶剤は5質量%であった。次に、流延膜を多数のローラーで搬送させながら乾燥させた。続いて、流延膜のうち、テンタークリップで挟んだ部分(両端部分)をレーザーカッターでスリットした後、流延膜の巻き取りを行った。これにより、膜厚33μmの原反フィルムが作製された。
ルムの中央部および両端部をともに130℃にして凹状領域を形成した。凸状領域R1および凹状領域R2ともに、幅手方向の延伸倍率は30%であった。
まず、以下のようにして原反フィルムを作製した。
10質量部のゴム粒子(カネカ株式会社製カネエース(登録商標)M210、平均一次粒子径R:200nm)と、90質量部のME16(メチレンクロライドとエタノールが84:16の質量比である混合溶媒)とを含む溶液を、ディゾルバーで50分間撹拌混合した。この後、この溶液を、1500rpm条件下でマイルダー分散機(大平洋機工株式会社製)を用いて分散させ、ゴム粒子分散液を得た。
20質量部のシリカ粒子(アエロジル(登録商標)R812、日本アエロジル株式会社製、疎水性ヒュームドシリカ、平均一次粒子径Rs1:7nm、比表面積:260±30m2/g)と、80質量部のME50(メチレンクロライドとエタノールが50:50の質量比である混合溶媒)との混合物を、ディゾルバーで50分間撹拌混合した。この後、この混合物をマントンゴーリンで分散させ、添加液を得た。
次いで、下記組成のドープを調製した。まず、加圧溶解タンクに90質量部のメチレンクロライドおよび10質量部のエタノールを添加した。次いで、この加圧溶解タンクに、80質量部のアクリル樹脂(MR1000、日本触媒株式会社製、ラクトンアクリル樹脂)を撹拌しながら投入した。次いで、上記調製したゴム粒子分散液を加圧溶解タンクに投入した後、撹拌を行い、アクリル樹脂を溶解させた。このアクリル樹脂溶液を、SHP150(株式会社ロキテクノ製)を使用して濾過し、ドープを得た。
次いで、上記のドープを用いて製膜を行った。具体的には、無端ベルト流延装置を用い、ドープを温度30℃、1800mm幅でステンレスベルト支持体上に均一に流延させ、流延膜を形成した。ステンレスベルトの温度は28℃に制御した。
発させた。次いで、剥離張力128N/mで、流延膜をステンレスベルト支持体から剥離した。剥離後の流延膜の残留溶媒量は30質量%であった。
まず、以下のようにして原反フィルムを作製した。
11.3質量部の微粒子(アエロジル(登録商標)R812、日本アエロジル株式会社製)と、84質量部のエタノールとを、ディゾルバーで50分間撹拌混合した後、この混合液をマントンゴーリンで分散させた。これにより、微粒子分散液を得た。
下記組成のドープを調製した。まず加圧溶解タンクに200質量部のジクロロメタンおよび10質量部のエタノールを添加した。次に、ジクロロメタンおよびエタノールの混合溶液の入った加圧溶解タンクに、攪拌しながら、100質量部のシクロオレフィン樹脂(ARTON(登録商標) F4520、JSR株式会社製)と、5質量部の紫外線吸収剤(Tinuvin(登録商標) 477、BASFジャパン株式会社製)と、3質量部の上記微粒子添加液とを投入した。続いて、この混合物を加熱し、攪拌しながらシクロオレフィン樹脂を溶解させた。次いで、このシクロオレフィン樹脂溶液を安積濾紙株式会社製の安積濾紙No.244を使用してろ過し、ドープを調製した。
次いで、無端ベルト流延装置を用い、ドープを温度31℃、1800mm幅でステンレスベルト支持体上に均一に流延させ、流延膜を形成した。ステンレスベルトの温度は28℃に制御した。次に、ステンレスベルト支持体上で、流延膜中の残留溶剤量が30質量%になるまで溶剤を蒸発させた。次いで、剥離張力128N/mで、ステンレスベルト支持体上から流延膜を剥離した。続いて、剥離した流延膜を、160℃の条件下で幅方向に1.15倍延伸した。延伸開始時の流延膜の残留溶剤は5質量%であった。続いて、この流延膜を多数のローラーで搬送させながら乾燥させた。次に、この流延膜のうち、テンタークリップで挟んだ部分(両端部分)をレーザーカッターでスリットした後、この流延膜の巻き取りを行った。これにより、厚み33μmの原反フィルムを得た。
上記実施例3のフィルムロールの作製において、原反フィルムを幅手方向に延伸する際の原反フィルムの中央部および両端部の温度を変更した以外は、同様にしてフィルムロールを作製した。具体的には、原反フィルムの中央部を180℃、両端部を200℃にして凸状領域を形成し、原反フィルムの中央部を180℃、両端部を190℃にして凹状領域を形成した。これにより、上記実施例3のフィルムロールから凸状領域R1および凹状領域R2各々の|D|の最大値が変更された。
上記実施例3のフィルムロールの作製において、原反フィルムの両端部の温度の昇温速度および降温速度を変更した以外は、同様にしてフィルムロールを作製した。具体的には、実施例3と比較して、原反フィルムの両端部の温度の昇温速度および降温速度を、2.1倍遅くした。これにより、上記実施例3のフィルムロールから、傾斜部分での100m当たりの差分比率Dの変化量が変更された。
上記実施例4のフィルムロールの作製において、原反フィルムの両端部の温度の昇温速度および降温速度を変更した以外は、同様にしてフィルムロールを作製した。具体的には、実施例4と比較して、原反フィルムの両端部の温度の昇温速度および降温速度を、2.
1倍遅くした。これにより、上記実施例4のフィルムロールから、傾斜部分での100m当たりの差分比率Dの変化量が変更された。
上記実施例6のフィルムロールの作製において、全巻長の長さを変更した以外は同様にして、フィルムロールを作製した。
上記実施例4のフィルムロールの作製において、原反フィルムの両端部の温度変化の周期を変更した以外は、同様にしてフィルムロールを作製した。具体的には、実施例4のフィルムロールの作製時よりも、加熱部材の温度変化の周期を短くした。これにより、上記実施例4のフィルムロールから凸状領域R1および凹状領域R2の長手方向の大きさが変更された。
上記実施例6のフィルムロールの作製において、凸状領域R1および凹状領域R2の形成方法を変更した以外は同様にして、フィルムロールを作製した。具体的には、流延ダイスの幅手方向にヒートボルトを複数配置し、幅手方向の位置に応じてヒートボルトに印加する電圧の値を変化させた。これにより、流延ダイス両端部のドープ流延量と流延ダイス中央部のドープ流延量とが各々調整され、凸状領域R1および凹状領域R2が形成された。具体的には、幅手方向両端部の流延ギャップを、幅手方向中央部の流延ギャップに対して-2.5%~2.5%の間で変化させた。
上記実施例6のフィルムロールの作製において、凸状領域R1および凹状領域R2の形成方法を変更した以外は同様にして、フィルムロールを作製した。具体的には、一定押圧のもと、エンボスリングの温度を180℃~200℃まで変化させた。これにより、形成されるエンボスの高さが調整され、凸状領域R1および凹状領域R2が形成された。
上記実施例1のフィルムロールの作製において、原反フィルムを幅手方向に延伸する際の原反フィルムの中央部および両端部の温度と、原反フィルムの両端部の温度の昇温速度および降温速度とを変更した。これ以外は、上記実施例1同様にしてフィルムロールを作製した。これにより、上記実施例1のフィルムロールから凸状領域R1および凹状領域R2各々の|D|の最大値と、傾斜部分での100m当たりの差分比率Dの変化量とが変更された。
上記実施例6のフィルムロールの作製において、原反フィルムの両端部の温度を非線形に変化させた以外は同様にして、フィルムロールを作製した。これにより、長手方向に沿って、差分比率Dが正弦曲線(サインカーブ)状に変化した。
上記実施例6のフィルムロールの作製において、全巻長の長さを変更した以外は同様にして、フィルムロールを作製した。
上記実施例6のフィルムロールの作製において、全巻長の長さを変更した以外は同様にして、フィルムロールを作製した。
上記実施例4のフィルムロールの作製において、原反フィルムの両端部の温度変化の周期を変更した以外は、同様にしてフィルムロールを作製した。具体的には、実施例4のフィルムロールの作製時よりも、加熱部材の温度変化の周期を長くした。これにより、上記実施例4のフィルムロールから凸状領域R1および凹状領域R2の長手方向の大きさが変更された。
上記実施例3のフィルムロールの作製において、原反フィルムを幅手方向に延伸する際の原反フィルムの中央部および両端部の温度を変更した以外は、同様にしてフィルムロールを作製した。具体的には、原反フィルムの中央部を180℃、両端部を210℃に維持したまま原反フィルムを幅手方向に延伸させた。これにより、フィルムロールに凸状領域のみが形成された。
上記実施例3のフィルムロールの作製において、原反フィルムを幅手方向に延伸する際の原反フィルムの中央部および両端部の温度を変更した以外は、同様にしてフィルムロールを作製した。具体的には、原反フィルムの中央部を180℃、両端部を190℃に維持したまま原反フィルムを幅手方向に延伸させた。これにより、フィルムロールに凹状領域のみが形成された。
上記比較例1のフィルムロールの作製において、原反フィルムを幅手方向に延伸する際の原反フィルムの中央部および両端部の温度を変更した以外は、同様にしてフィルムロールを作製した。具体的には、原反フィルムの中央部を180℃、両端部を210℃にして第1凸状領域を形成し、原反フィルムの中央部を180℃、両端部を200℃にして第2凸状領域を形成した。これにより、互いに異なる差分比率Dの値を有する2つの凸状領域(第1凸状領域および第2凸状領域)が形成された。
(ブラックバンドの評価)
フィルムロール作製直後に、白色蛍光灯のもと、フィルムロール表面から巻芯方向を目視し、フィルム表面の色を観察した。観察は、フィルムロール全幅にわたり、フィルムロール1周分について行った。このとき、巻芯の色が透けて見え、周囲と色が異なって見える部分の有無を確認した。この色の確認には、所定の限度見本を用いた。色が異なって見える部分が存在した場合には、この部分についてフィルムの変形の有無を確認した。具体的には、黒色のラシャ紙に対して略水平に設けた台にフィルムを載せ、フィルムに照射した光の反射光によりフィルムの変形の有無を確認した。フィルムへの光の照射は、2500ルクス以上の蛍光灯を用いて行い、蛍光灯はフィルムから2m以内に配置した。このようにして、フィルムロールのブラックバンドを下記評価基準に従って評価した。この結果を下記表1に表す;
≪評価基準≫
A:フィルムロールに色が異なって見える部分が存在しない、
B:フィルムロールに色が異なって見える部分が存在するが、フィルムの変形は確認されない、
C:フィルムの変形が確認された。
フィルムロール作製直後に、黒色の巻芯の表面を外観から目視で観察し、色が異なって見える部分の有無を確認した。次に、フィルムロールを23℃、90%RH条件下で500時間置き、再び、黒色の巻芯の表面を外観から目視で観察し、色が異なって見える部分の有無を確認した。フィルムロール作製直後および500時間経過後それぞれで、色が異なって見える部分が存在した場合には、この部分についてフィルムの変形の有無を確認した。このようにして、フィルムロールの経時変化を下記評価基準に従って評価した。この結果を下記表1に表す;
≪評価基準≫
A:500時間経過後であっても、フィルムロールに色が異なって見える部分が増えていない、
B:500時間経過後に、フィルムロールに色が異なって見える部分が増えているが、この部分でフィルムの変形は確認されない、
C:500時間経過後に、新たに、フィルムの変形が確認された。
Claims (16)
- 長手方向に交差する幅手方向の第1端部および第2端部と、
前記第1端部および前記第2端部の間の中央部と、
前記第1端部および前記第2端部のうちの少なくとも前記第1端部の厚みTe1が前記中央部の厚みTcよりも小さい、凸状位置と、
前記長手方向において前記凸状位置とは異なる位置に配置されるとともに、前記第1端部の厚みTe1が前記中央部の厚みTcよりも大きい、凹状位置と
を備える、フィルム。 - 前記凸状位置では、前記第2端部の厚みTe2が前記中央部の厚みTcより小さく、
前記凹状位置では、前記第2端部の厚みTe2が前記中央部の厚みTcより大きい、請求項1に記載のフィルム。 - 前記凸状位置が設けられるとともに、前記第1端部および前記第2端部のうちの少なくとも前記第1端部の厚みTe1が前記中央部の厚みTcよりも小さい凸状領域と、
前記凹状位置が設けられるとともに、前記第1端部の厚みTe1が前記中央部の厚みTcよりも大きい凹状領域とを更に有する、請求項1または2に記載のフィルム。 - 前記長手方向に沿って、交互に配置された複数の前記凸状領域および前記凹状領域を有する、請求項3に記載のフィルム。
- 前記凸状領域および前記凹状領域の前記長手方向の大きさが、100m以上500m以下である、請求項3または4に記載のフィルム。
- 前記凸状位置での前記第1端部の厚みTe1と前記中央部の厚みTcとの差は、前記凸状位置での前記フィルムの平均の厚みに対して10%以下であり、
前記凹状位置での前記第1端部の厚みTe1と前記中央部の厚みTcとの差は、前記凹状位置での前記フィルムの平均の厚みに対して10%以下である、請求項1~5のいずれかに記載のフィルム。 - 前記凸状位置での前記第1端部の厚みTe1と前記中央部の厚みTcとの差は、前記凸状位置での前記フィルムの平均の厚みに対して5%以下であり、
前記凹状位置での前記第1端部の厚みTe1と前記中央部の厚みTcとの差は、前記凹状位置での前記フィルムの平均の厚みに対して5%以下である、請求項1~6のいずれかに記載のフィルム。 - 前記凸状位置と前記凹状位置との間に、前記第1端部の厚みTe1および前記中央部の厚みTcの少なくとも一方が連続的に変化する傾斜部分を更に有する、請求項1~7のいずれかに記載のフィルム。
- 前記傾斜部分の前記長手方向の大きさは5m以上である、請求項8に記載のフィルム。
- 脂環式構造含有重合体を含む、請求項1~9のいずれかに記載のフィルム。
- 光学機能を有する、請求項1~10のいずれかに記載のフィルム。
- タッチセンサーに用いられる、請求項1~11のいずれかに記載のフィルム。
- 請求項1~12のいずれかに記載のフィルムと、
前記フィルムに積層された保護フィルムとを有する、積層体。 - 巻芯と、
前記巻芯に巻かれた請求項1~12のいずれかに記載のフィルムまたは請求項13に記載の積層体と、
を備える、フィルムロール。 - 原反フィルムを準備または形成することと、
前記原反フィルムの長手方向の互いに異なる位置に凸状位置および凹状位置を形成することと、
を含み、
前記凸状位置は、前記原反フィルムの前記長手方向に交差する幅手方向の第1端部および第2端部のうちの少なくとも前記第1端部の厚みTe1を、前記第1端部および前記第2端部の間の中央部の厚みTcよりも小さくして形成し、
前記凹状位置は、前記第1端部の厚みTe1を前記中央部の厚みTcよりも大きくして形成する、フィルムの製造方法。 - 前記凸状位置および前記凹状位置を形成することでは、前記原反フィルムを前記幅手方向に延伸させながら、前記第1端部および前記第2端部のうちの少なくとも前記第1端部の加熱を行い、
前記凸状位置を形成するときの前記第1端部と前記中央部との温度差を、前記凹状位置を形成するときの前記第1端部と前記中央部との温度差よりも大きくする、請求項15に記載のフィルムの製造方法。
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