CN102759760A - Method for making optical film, polarizing film, and image display apparatus - Google Patents

Method for making optical film, polarizing film, and image display apparatus Download PDF

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Publication number
CN102759760A
CN102759760A CN2012101278782A CN201210127878A CN102759760A CN 102759760 A CN102759760 A CN 102759760A CN 2012101278782 A CN2012101278782 A CN 2012101278782A CN 201210127878 A CN201210127878 A CN 201210127878A CN 102759760 A CN102759760 A CN 102759760A
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coating layer
zone
methyl
resin
base material
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神崎昌
金云基
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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Abstract

The invention provides a method for making optical film, a polarizing film, and an image display apparatus. The method for making the optical film comprises the following steps: a coating procedure used for coating the coating liquid containing active energy radial solidifying resin upon the continuously-conveying substrate film (11) to form a coating layer; and a solidifying procedure for irradiating active energy radials upon the coating layer from the substrate film (11) side under the state of pressing the surface of the coating layer against the surface of a casting mould (14). In the solidifying procedure, when the surface of the coating layer is pressed against the surface of the casting mould (14), the pressure applied to the two end areas in the width direction of the coating layer is less than that applied to the central area in the width direction between the two end areas. According to the invention, the peeling off of the solidifying resin upon the substrate film and the resin residue upon the casting module can be effectively prevented. The method allows continuous and effective manufacturing of the optical film, without causing defects.

Description

The manufacturing approach of blooming, polaroid and image display device
Technical field
The present invention relates on base material film the manufacturing approach that coating contains the coating fluid of active energy ray-curable resin and makes the blooming that its curing forms.And, the invention still further relates to the polaroid and the image display device that have used this blooming.
Background technology
Have the blooming that the resin bed of regulation optical function forms through coating on base material, for example be used for various image display devices such as liquid crystal indicator as antiglare film, optical diffusion film, hard coat film etc.
Generally, the above-mentioned resin bed that blooming possessed is to contain the coating fluid of active energy ray-curable resin and to the coating layer irradiation active energy beam that obtains it is solidified to form through coating on base material film.According to the needed optical characteristics of blooming,, also have painting layer surface is pressed against mold with regulation surface configuration and the situation that under this state, makes its curing in order to give required form to resin layer surface.
For example; Following method is disclosed in JP2007-76089-A: on base material film, be coated with uv curing resin; Make resin-coated driving fit irradiation ultraviolet radiation under the state of the concavo-convex mould roller (knurling rolls) that synchronously rotates with base material film; Make resin solidification, then, peel off the duplexer of cured resin and base material film from concavo-convex mould roller.
Shown in the method for above-mentioned JP2007-76089-A record; Making under the situation of blooming through when painting layer surface being pressed against the such mold of knurling rolls coating layer being solidified with regulation surface configuration; When peeling off the gained blooming from mold, at least a portion that the cured resin that cured resin peels off or peel off from base material film takes place at the both ends of the Width of coating layer sometimes breaks away from promptly " resin peels off ", at the residual cured resin of mould surface i.e. " resin residue ".
The part that resin peels off has taken place not only himself can become defective, and pollutes, makes the quantity-produced blooming produce further defective when the cured resin of having peeled off may cause engineering when base material film breaks away from.In addition, in the continuous production of blooming, resin produces continuous defective (cured resin is needed on the surface configuration of blooming surface, blooming or the defective of optical characteristics etc.) at the residual blooming that obtains that makes possibly of mould surface.And, when resin residue takes place, its cleaning removed to make and make efficient and reduce greatly.
In JPH05-58788-B, JP3546485-B and JP3710901-B, put down in writing and be used for giving concavo-convex roller (mold) painting layer surface; The outside (both ends of the Width of roller) through at this relief pattern is provided with even surface, can improve the fissility between coating layer and mold.
The method that the both ends at mold that JPH05-58788-B, JP3546485-B and JP3710901-B put down in writing are provided with even surface has certain effect aspect mould surface residual reducing resin, but also has room for improvement.In addition, the resin that can not say so for the resin on the base material film of this method peels off effective method.
On the other hand, as the method that prevents resin residue, though considered in the coating fluid that forms coating layer, to add release agent or, added physical strength, optical characteristics that release agent damages blooming possibly in advance at mould surface coating release agent.
The present invention In view of the foregoing accomplishes, and its purpose is to provide and can prevents effectively that resin from peeling off the generation with resin residue, and the method for unfavorable condition ground continuous high-efficient ground manufacturing blooming such as defective can not take place.
Summary of the invention
The present invention comprises following content.
[1] a kind of manufacturing approach of blooming is characterized in that, comprises following operation:
Painting process, coating contains the coating fluid of active energy ray-curable resin on the base material film of carrying continuously, forms coating layer; With
Curing process leans against in the surface pressure with coating layer under the state on surface of mold, from the base material film side coating layer is shone active energy beam,
In said curing process, when the surface pressure with coating layer leaned against said mold surperficial, the central portion zone of the Width of pressure ratio between zone, said both ends in zone, both ends of Width that is applied to coating layer was little.
[2] according to [1] described method, wherein,
In said curing process, the surface by utilizing nip roll of coating layer is pressed against the surface of mold, and said nip roll is across base material film with coating layer and said mold arranged opposite,
Said nip roll is processed to: when the surface pressure of utilizing nip roll with coating layer leaned against mold surperficial, the central portion zone of the Width of pressure ratio between zone, said both ends in zone, both ends of Width that is applied to coating layer was little.
[3] according to [2] described method, wherein,
Said nip roll is processed to: the zone corresponding with the central portion zone of coating layer is than giving prominence to laterally with corresponding zone, zone, said both ends.
[4] a kind of polaroid is characterized in that, the blooming that possesses light polarizing film and make through each described method in [1]~[3], and wherein, said blooming is layered on the said light polarizing film with base material film side and the opposed mode of said light polarizing film.
[5] a kind of image display device is characterized in that, possesses [4] described polaroid and image-displaying member, and wherein, polaroid is that the mode of said image-displaying member side is configured on the image-displaying member with its light polarizing film.
The resin that according to the method for the invention, can prevent to take place when mold is peeled off blooming cured resin effectively peels off and to the resin residue of mold.Thus, on rectangular base material film, form continuously in the continuous production of blooming of resin bed, can not produce unfavorable condition such as defective or engineering and impurely make blooming in continuous high-efficient ground.The blooming that obtains according to the present invention can be fit to be applied in the image display devices such as polaroid, liquid crystal indicator.
Description of drawings
Fig. 1 is the figure that schematically shows a preference of the manufacturing installation that uses in manufacturing approach and this method of blooming of the present invention.
Fig. 2 is the concise and to the point figure of an example of the shape of the expression nip roll that can be fit to use among the present invention.
Fig. 3 is the concise and to the point figure of an other example of the shape of the expression nip roll that can be fit to use among the present invention.
Fig. 4 is the concise and to the point figure of another example of the shape of the expression nip roll that can be fit to use among the present invention.
Fig. 5 is that the fragmentary cross sectional view at the state when nip roll that the corresponding zone, zone, both ends of coating layer has an excision portion is pressed against mould surface with the painting layer surface on the base material film is used in expression.
Fig. 6 is the fragmentary cross sectional view that the state when the nip roll of convex surface processing is pressed against mould surface with the painting layer surface on the base material film is used in expression.
Symbol description
11 base material films
12 coating layers
13,16 nip roll
14 molds
15 active energy beam irradiation units
31 film reeling-up reeling-out devices
32 apparatus for coating
33 drying ovens
34 film retracting devices
Embodiment
< manufacturing approach of blooming >
The manufacturing approach of blooming of the present invention comprises following operation:
[1] painting process, coating contains the coating fluid of active energy ray-curable resin on the base material film of carrying continuously, forms coating layer; And
[2] curing process leans against in the surface pressure with coating layer under the state on surface of mold, from the base material film side coating layer is shone active energy beam, and coating layer is solidified.
Below, each operation is at length explained with reference to the accompanying drawing limit in the limit.Fig. 1 is the figure that schematically shows a preference of the manufacturing installation that uses in manufacturing approach and this method of blooming of the present invention.Arrow among the figure is represented the sense of rotation of the throughput direction or the roller of film.
[1] painting process
In this operation, coating contains the coating fluid of active energy ray-curable resin on the base material film of carrying continuously, forms coating layer.Painting process is for example as shown in Figure 1, can carry out in the following manner, that is, roll up continuously from the material volume (article that furl of rectangular base material film) that is installed to film reeling-up reeling-out device 31 and to put base material film 11, and use apparatus for coating 32 is coated with coating fluid on base material film 11.
Coating fluid is coated with method, scraper rubbing method, airblade coating method, kiss-coating method, mould Tu Fa etc. to the coating of base material film 11 intaglio plate rubbing method for example capable of using, miniature intaglio plate rubbing method, rod to carry out.
(base material film)
Base material film 11 for example can use glass, plastic foil etc. so long as the material of light transmission gets final product.As plastic foil, the transparency, physical strength with appropriateness get final product.Particularly, the polyolefin-based resins such as polyester based resin, tygon, polypropylene such as TAC acetate fibers such as (triacetyl celluloses) prime system resin, acrylic resin, polycarbonate-based resin, polyethylene terephthalate etc. of for example can giving an example.The thickness of base material film 11 for example is 10~500 μ m, considers from the film equal angles of blooming, and 10~300 μ m preferably, being more preferably is 20~300 μ m.
With the coating of improvement coating fluid or the stickability of improvement and coating layer is purpose, also can implement various surface treatments to the surface (coating layer side surface) of base material film 11.As surface treatment, can give an example is Corona discharge Treatment, glow discharge processing, acid surfaces processing, alkali surface treatment, ultraviolet treatment with irradiation etc.In addition, for example also can on base material film 11, form other layers such as undercoat, and on this other layer, be coated with coating fluid.
And, under the situation about using on the light polarizing film of after blooming is adhered to, stating,, preferably utilize various surface treatments to make surface (with the surface of the coating layer opposition side) hydrophiling of base material film in advance in order to improve the stickability of base material film and light polarizing film.This surface treatment also can be carried out after the manufacturing of blooming.
(coating fluid)
Coating fluid contains the active energy ray-curable resin, also contains Photoepolymerizationinitiater initiater (radical polymerization initiator) usually.As required, also can contain other compositions such as light transmission particulate, organic solvent equal solvent, levelling agent, spreading agent, antistatic agent, anti fouling agent, surfactant.
(1) active energy ray-curable resin
The active energy ray-curable resin can be uv curing resin, electronic beam curing property resin etc., for example, can preferably use the active energy ray-curable resin that contains multifunctional (methyl) acrylate compounds.Multifunctional (methyl) acrylate compounds is meant to have the compound of at least 2 (methyl) acryloxies in the molecule.Object lesson as multifunctional (methyl) acrylate compounds; For example, can give an example: polyvalent alcohol and (methyl) acrylic acid ester compounds, carbamate (methyl) acrylate compounds, polyester (methyl) acrylate compounds, epoxy (methyl) acrylate compounds etc. contain the multifunctional polymerization property compound of (methyl) acryloyl group more than 2 etc.
As polyvalent alcohol; For example; Can give an example: monoethylene glycol, diethylene glycol, triethylene glycol, TEG, polyglycol, propylene glycol, DPG, tripropylene glycol, four propylene glycol, polypropylene glycol, propylene glycol, butylene glycol, pentanediol, hexanediol, neopentyl glycol, 2-ethyl-1; 3-hexanediol, 2, dibasic alcohol such as 2 '-thiodiethanol, 1,4 cyclohexane dimethanol; The alcohol that ternarys such as trimethylolpropane, glycerine, pentaerythrite, two glycerine, dipentaerythritol, two (trihydroxy methyl) propane are above.
As polyvalent alcohol and (methyl) acrylic acid ester compounds; Specifically can give an example: two (methyl) acrylic acid glycol ester, diethylene glycol two (methyl) acrylic ester, two (methyl) acrylic acid 1; 6-hexanediol ester, two (methyl) acrylic acid DOPCP, trimethylolpropane tris (methyl) acrylic ester, trimethylolethane trimethacrylate (methyl) acrylic ester, tetramethylol methane three (methyl) acrylic ester, two (methyl) acrylic acid 1,6-hexanediol ester, tetramethylol methane four (methyl) acrylic ester, five polyglycereol three (methyl) acrylic ester, pentaerythrite three (methyl) acrylic ester, pentaerythrite four (methyl) acrylic ester, glycerine three (methyl) acrylic ester, dipentaerythritol three (methyl) acrylic ester, dipentaerythritol four (methyl) acrylic ester, dipentaerythritol five (methyl) acrylic ester, dipentaerythritol six (methyl) acrylic ester etc.
As carbamate (methyl) acrylate compounds, can give an example isocyanates that in 1 molecule, has a plurality of NCOs and urethane reactant with (methyl) acrylic acid derivative of hydroxyl.As the organic isocyanate that in 1 molecule, has a plurality of NCOs; Can give an example: hexamethylene diisocyanate, IPDI, toluene diisocyanate, naphthalene diisocyanate, methyl diphenylene diisocyanate, XDI, dicyclohexyl methyl hydride diisocyanate etc. have the organic isocyanate of 2 NCOs in 1 molecule, and these organic isocyanates are carried out isocyanurate-modified, addition modification, biuret modified and organic isocyanate that in 1 molecule, has 3 NCOs of obtaining etc.As (methyl) acrylic acid derivative, can give an example: (methyl) acrylic acid 2-hydroxyl ethyl ester, (methyl) acrylic acid 2-hydroxypropyl acrylate, (methyl) acrylic acid 4-hydroxy butyl ester, (methyl) acrylic acid 2-hydroxy butyl ester, (methyl) acrylic acid 2-hydroxyl-3-phenoxy group propyl ester, pentaerythritol triacrylate etc. with hydroxyl.
As polyester (methyl) acrylate compounds, polyester (methyl) acrylic ester that the hydroxyl polyester is obtained with the reaction of (methyl) acrylic acid.The preferred hydroxyl polyester that uses is meant the hydroxyl polyester that the esterification through polyvalent alcohol and carboxylic acid, the compound with a plurality of carboxyls and/or its acid anhydride obtains.As polyvalent alcohol, can the illustration compound identical with aforesaid compound.And, except that polyvalent alcohol, the bisphenol-A as phenols etc. of can also giving an example.As carboxylic acid, can give an example: formic acid, acetate, butyl carboxylic acid, benzoic acid etc.As the compound with a plurality of carboxyls and/or its acid anhydride, can give an example: maleic acid, phthalic acid, fumaric acid, itaconic acid, hexane diacid, terephthalic acid (TPA), maleic anhydride, phthalic anhydride, trimellitic acid, cyclohexane dicarboxylic acid acid anhydride etc.
In above so multifunctional (methyl) acrylate compounds; Consider ester compounds such as preferred two (methyl) acrylic acid hexanediol ester, two (methyl) acrylic acid DOPCP, diethylene glycol two (methyl) acrylic ester, tripropylene glycol two (methyl) acrylic ester, trimethylolpropane tris (methyl) acrylic ester, pentaerythrite three (methyl) acrylic ester, dipentaerythritol six (methyl) acrylic ester from the intensity that improves solidfied material, the angle that obtains easy property; The addition product of hexamethylene diisocyanate and (methyl) acrylic acid 2-hydroxyl ethyl ester; The addition product of IPDI and (methyl) acrylic acid 2-hydroxyl ethyl ester; The addition product of toluene diisocyanate and (methyl) acrylic acid 2-hydroxyl ethyl ester; The addition product of addition modification IPDI and (methyl) acrylic acid 2-hydroxyl ethyl ester; And the addition product of biuret modified IPDI and (methyl) acrylic acid 2-hydroxyl ethyl ester.And these multifunctional (methyl) acrylate compounds can be distinguished independent use, also can also use with other more than one.
The active energy ray-curable resin can also contain simple function (methyl) acrylate compounds except that above-mentioned multifunctional (methyl) the acrylate compounds.As simple function (methyl) acrylate compounds; For example, can give an example: (methyl) esters of acrylic acids such as (methyl) methyl acrylate, (methyl) ethyl acrylate, (methyl) butyl acrylate, (methyl) isobutyl acrylate, (methyl) tert-butyl acrylate, (methyl) acrylic acid 2-hydroxyl ethyl ester, (methyl) acrylic acid 2-hydroxypropyl acrylate, (methyl) acrylic acid hydroxy butyl ester, (methyl) acrylic acid 2-hydroxy butyl ester, (methyl) acrylic acid 2-hydroxyl-3-phenoxy group propyl ester, (methyl) acrylic ester ethylene oxidic ester, acryloyl morpholine, N-vinyl pyrrolidone, (methyl) tetrahydrofurfuryl acrylate, (methyl) cyclohexyl acrylate, (methyl) 2-EHA, (methyl) IBOA, acetyl group (methyl) acrylic ester, (methyl) benzyl acrylate, (methyl) acrylic acid 2-ethoxy ethyl ester, (methyl) acrylic acid 3-methoxyl butyl ester, ethyl carbitol (methyl) acrylic ester, phenoxy group (methyl) acrylic ester, oxirane modification phenoxy group (methyl) acrylic ester, epoxypropane (methyl) acrylic ester, nonyl phenol (methyl) acrylic ester, oxirane modification (methyl) acrylic ester, epoxy pronane modification nonyl phenol (methyl) acrylic ester, methoxyl diethylene glycol (methyl) acrylic ester, 2-(methyl) acrylyl oxy-ethyl-2-hydroxypropyl phthalic ester, dimethylaminoethyl (methyl) acrylic ester, methoxyl triethylene glycol (methyl) acrylic ester.These compounds can be distinguished independent use, also can also use with other more than one.
In addition, the active energy ray-curable resin can also contain polyreactive oligomers.Thereby through making it contain the hardness that polyreactive oligomers can be adjusted solidfied material.Polyreactive oligomers for example can be that above-mentioned multifunctional (methyl) acrylate compounds is a polyvalent alcohol and the oligomer of the dimer of (methyl) acrylic acid ester compounds, carbamate (methyl) acrylate compounds, polyester (methyl) acrylate compounds or epoxy (methyl) acrylic ester etc., tripolymer etc.
As other polyreactive oligomers, carbamate (methyl) acrylate oligomer that can give an example and obtain through polyisocyanate that has at least 2 NCOs in the molecule and reaction with polyvalent alcohol of at least 1 (methyl) acryloxy.As polyisocyanate; The polymkeric substance of hexamethylene diisocyanate, IPDI, toluene diisocyanate, methyl diphenylene diisocyanate, XDI etc. of can giving an example as the polyvalent alcohol with at least 1 (methyl) acryloxy, is hydroxyl (methyl) acrylic ester that obtains through polyvalent alcohol and (methyl) acrylic acid esterification; As polyvalent alcohol; For example, the 1,3 butylene glycol, 1 of can giving an example; 4-butylene glycol, 1,6-hexanediol, diethylene glycol, triethylene glycol, neopentyl glycol, polyglycol, polypropylene glycol, trimethylolpropane, glycerine, pentaerythrite, dipentaerythritol etc.The part of the alcoholic extract hydroxyl group that this polyvalent alcohol with at least 1 (methyl) acryloxy is a polyvalent alcohol and (methyl) acrylic acid generation esterification and in molecule the compound of residual alcohol hydroxyl group.
And, as other the example of polyreactive oligomers, polyester (methyl) acrylate oligomer that compound and/or its acid anhydride and the reaction with polyvalent alcohol of at least 1 (methyl) acryloxy through having a plurality of carboxyls of can giving an example obtains.As the compound with a plurality of carboxyls and/or its acid anhydride, can illustration with polyester (methyl) acrylic ester of above-mentioned multifunctional (methyl) acrylate compounds in the identical compound of compound put down in writing.And, as polyvalent alcohol with at least 1 (methyl) acryloxy, can illustration with above-mentioned carbamate (methyl) acrylate oligomer in the identical polyvalent alcohol of polyvalent alcohol put down in writing.
Except that above polyreactive oligomers, as the example of carbamate (methyl) acrylate oligomer, can also give an example the hydroxyl reaction that makes isocyanates and hydroxyl polyester, hydroxyl polyethers or hydroxyl (methyl) acrylic ester and compound.The preferred hydroxyl polyester that uses is through polyvalent alcohol and carboxylic acid, has the compound of a plurality of carboxyls/or hydroxyl polyester of obtaining of the esterification of its acid anhydride.As polyvalent alcohol, have the compound of a plurality of carboxyls/or its acid anhydride, respectively can illustration with polyester (methyl) acrylate compounds of multifunctional (methyl) acrylate compounds in the identical compound of compound put down in writing.The preferred hydroxyl polyethers that uses is through to the polyvalent alcohol addition hydroxyl polyethers that alkylene oxide and/or 6-caprolactone get more than a kind or 2 kinds.Polyvalent alcohol can be with above-mentioned hydroxyl polyester in the identical polyvalent alcohol of polyvalent alcohol that can use.As hydroxyl (methyl) acrylic ester of preferred use, can illustration with carbamate (methyl) acrylate oligomer of polyreactive oligomers in the identical compound of compound put down in writing.As isocyanates, has the compound of 1 above NCO in the preferred molecule, binary isocyanate compounds such as preferred especially toluene diisocyanate, hexamethylene diisocyanate, IPDI.
These polyreactive oligomerses can be distinguished independent use, also can also use more than a kind with other.
(2) Photoepolymerizationinitiater initiater
As Photoepolymerizationinitiater initiater, for example can use acetophenone is that Photoepolymerizationinitiater initiater, benzoin are that Photoepolymerizationinitiater initiater, benzophenone series Photoepolymerizationinitiater initiater, thioxanthones are that Photoepolymerizationinitiater initiater, triazine are that Photoepolymerizationinitiater initiater,
Figure BDA0000157718500000091
diazole are Photoepolymerizationinitiater initiater etc.And, as Photoepolymerizationinitiater initiater, for example can also use 2; 4,6-trimethylbenzoyl diphenyl phosphine oxide, 2,2 '-two (Chloro-O-Phenyl)-4; 4 ', 5,5 '-tetraphenyl-1; 2 '-bisglyoxaline, 10-butyl-2-chloro-acridine ketone, 2-EAQ, benzil, 9,10-phenanthrenequione, camphorquinone, methyl benzoylformate, two cyclopentadiene titanium compounds etc.The consumption of Photoepolymerizationinitiater initiater is generally 0.5~20 weight portion with respect to active energy ray-curable resin 100 weight portions, is preferably 1~5 weight portion.
(3) light transmission particulate
As the light transmission particulate; Not special the qualification; For example can use the organic fine particles that forms by acrylic resin, melamine resin, tygon, polystyrene, organic siliconresin, acrylic acid-styrol copolymer etc., inorganic particles that forms by lime carbonate, silicon dioxide, aluminium oxide, barium carbonate, barium sulphate, titanium dioxide, glass etc. etc.And, also can use ball, the hollow pearl of organic polymer.These light transmission particulates can use a kind separately, also can mix use more than 2 kinds.The shape of light transmission particulate can be spherical, flat, tabular, needle-like, amorphous etc. any.
The not special restriction of the particle diameter of light transmission particulate, refractive index, but when blooming is optical diffusion film, antiglare film, consider that from the angle that presents internal haze effectively preferable particle size is in the scope of 0.5 μ m~20 μ m.And based on same reason, the difference of the refractive index of the active energy ray-curable resin after the curing and the refractive index of light transmission particulate is preferably in 0.04~0.15 scope.The content of light transmission particulate is generally 3~60 weight portions with respect to active energy ray-curable resin 100 weight portions, is preferably 5~50 weight portions.During with respect to active energy ray-curable resin 100 weight portion less thaies 3 weight portions, can not fully give light diffusing or anti-dazzle property at the content of light transmission particulate.On the other hand,, damage the transparency of blooming sometimes, and anti-dazzle property, light diffusing become too high if surpass 60 weight portions, when blooming being applied to image display device such as liquid crystal indicator, the trend that has the contrast of display frame to reduce.
In addition, under the situation of using the light transmission particulate, for optical characteristics and the surface configuration that makes blooming is even, the dispersion of the light transmission particulate in the preferred coating fluid is that isotropy is disperseed.
(4) solvent
Coating fluid can contain the organic solvent equal solvent.As organic solvent, can consider selection uses from following solvent such as viscosity: aliphatic hydrocarbons such as hexane, cyclohexane, octane; Aromatic hydrocarbon such as toluene, xylene; Alcohols such as ethanol, 1-propyl alcohol, isopropyl alcohol, 1-butanols, cyclohexanol; Ketones such as MEK, methyl isobutyl ketone, cyclohexanone; Ester classes such as ethyl acetate, butyl acetate, isobutyl acetate; Glycol ethers such as glycol monoethyl ether, ethylene glycol monoethyl ether, diethylene glycol monoethyl ether, propylene glycol monomethyl ether, dihydroxypropane single-ether; Esterification such as ethylene glycol monomethyl ether acetate, propylene glycol methyl ether acetate glycol ethers; Cellosolve classes such as 2-methyl cellosolve, cellosolvo, butoxy ethanol; Carbitol classes such as 2-(2-methoxy ethoxy) ethanol, 2-(2-ethoxy ethoxy) ethanol, 2-(2-butoxy ethoxy) ethanol etc.These solvents can use separately, also can mix several uses as required.After the coating, need make above-mentioned organic solvent evaporation.Therefore, preferred boiling point is 60 ℃~160 ℃ scopes.And the saturated vapor pressure in the time of preferred 20 ℃ is 0.1kPa~20kPa scope.
Contain at coating fluid under the situation of solvent, preferably behind the above-mentioned painting process, after be provided with before the curing process stated and make solvent evaporation and carry out dry drying process.Dry example as shown in Figure 1 for example can carry out through the base material film 11 that possesses coating layer is passed in the drying oven 33.Baking temperature is suitably selected according to the kind of employed solvent, base material film.Though be generally 20 ℃~120 ℃ scope, not special restriction.And, when drying oven when being a plurality of, also can change temperature to each drying oven.
[2] curing process
This operation is to lean against under the state on surface of the mold with regulation surface configuration in the surface pressure with coating layer; From the base material film side coating layer is shone active energy beam; The coating layer that in above-mentioned painting process, forms is solidified, thereby on base material film, form the operation of the resin bed that solidifies.Through this operation, coating layer is cured, and the surface configuration of mold is transferred to painting layer surface.
Among the present invention; When the surface pressure with coating layer leaned against mold surperficial, the central portion zone of the Width of pressure ratio between this zone, both ends in zone, both ends of Width (and direction of the carrying direction quadrature of base material film) that is applied to coating layer was little.The resin that thus, can prevent to take place when mold is peeled off blooming cured resin effectively peels off and to the resin residue of mold.
The embodiment of above-mentioned effect can be thought based on following reason.That is, when the surface pressure with coating layer leaned against mold surperficial, in the zone, both ends of the Width of coating layer, coating layer was urged expansion.In the part of this pushing expansion; Coating layer contacts the time that arrives till solidifying the back with base material film short; And base material film can not receive the dipping of solvent when coating layer contains solvent; So the resin that solidifies and the adaptation of base material film are lower, therefore can think that easy generation resin peels off, resin residue.When the surface pressure with coating layer leans against mold surperficial; Pressure through the both ends that make the Width that is applied to coating layer are regional is regional less than central portion; Thereby because coating layer is not urged expansion, so thinks and to prevent effectively that resin peels off and the resin residue of mold.
When the surface pressure with coating layer leaned against mold surperficial, the pressure that is applied to the central portion zone of coating layer was more than the 0.2MPa, perhaps is preferably greater than 0.2MPa, more preferably more than the 0.25MPa, more than the further preferred 0.4MPa.If pressure less than 0.2MPa, then when being pressed against mold, is sneaked into small bubble at the interface of coating layer and mold sometimes, maybe can not the surface configuration of mold be transferred to painting layer surface well.
When the surface pressure with coating layer leaned against mold surperficial, the pressure that is applied to the zone, both ends of coating layer was below the 0.2MPa, perhaps preferably less than 0.2MPa, more preferably below the 0.15MPa, below the further preferred 0.1MPa.Through this pressure is adjusted to this scope, peel off and resin residue thereby can effectively prevent to betide the regional resin in both ends.
This curing process is for example as shown in Figure 1; Carry out through following mode: use across the nip roll 13 of the base material film with coating layer 11 with mold 14 arranged opposite of roll shape; To be pressed against the surface of mold 14 through the base material film of painting process 11 and the painting layer surface of the duplexer of coating layer; Under this state, use active energy beam irradiation unit 15,, coating layer is solidified from base material film 11 sides irradiation active energy beam.Nip roll 13 is the press fit devices that are used for the surface pressure of coating layer is leaned against the surface of mold, and utilizing nip roll 13 pressing coating layers and mold is effective preventing that bubble from sneaking into aspect the interface of coating layer and mold.Should explain that active energy beam irradiation unit 15 can use one or more.
When the surface pressure of using nip roll 13 with coating layer leaned against mold 14 surperficial, the roller that is processed into the regulation shape through use was as nip roll 13, thereby the pressure in zone, both ends that makes the Width that is applied to coating layer is less than the central portion zone.As the nip roll that is processed into the regulation shape, can be to be processed as the zone corresponding than the outstanding laterally roller in zone corresponding with the zone, both ends of coating layer with the central portion zone of coating layer, particularly, can enumerate following nip roll.
A) shown in Figure 2, have a nip roll of the short width (roller length) of width (effective width) than coating layer [with the length of the direction of the conveyance direction quadrature of base material film].If use such nip roll; Then owing to do not have nip roll with the corresponding zone, zone, both ends of coating layer; Nip roll does not contact the base material film part under the zone, both ends of coating layer, so can make the pressure that is applied to this zone, both ends less than the central portion zone.
B) shown in Figure 3, have the nip roll of the excision portion of spill with the corresponding zone (zone under the zone, both ends), zone, both ends of coating layer.Fig. 5 is that the fragmentary cross sectional view that 12 surface pressure of the coating layer on the base material film 11 is leaned against mold 14 state when surperficial in the nip roll 13 that has an excision portion with the corresponding zone, zone, both ends of coating layer 12 is used in expression.Have the nip roll of excision portion if use, then with above-mentioned a) likewise because nip roll does not contact the base material film part under the zone, both ends of coating layer, so can make the pressure that is applied to this zone, both ends less than the central portion zone.
C) nip roll shown in Figure 4, that two ends are processed by convex surface.So-called convex surface processing is the processing that roller diameter is slowly diminished to the end.Fig. 6 is the fragmentary cross sectional view of the state of expression when using the nip roll 13 of convex surface processing that 12 surface pressure of the coating layer on the base material film 11 are leaned against mold 14 surfaces.Through the nip roll of using such two ends to be processed, thereby also can make the pressure in the zone, both ends that is applied to coating layer regional less than central portion by convex surface.Especially; Two ends are by the use of the nip roll of convex surface processing; Owing to do not produce the pressure that is applied to coating layer position jumpy, slowly diminish to both ends from the central portion zone; So can effectively prevent the producible resin residue in position of so rapid Thickness Variation of generation, see on the one hand and preferred from this at above-mentioned pressure position jumpy.
After coating layer in this operation solidifies,, be fulcrum is peeled off the resin bed of base material film and curing from mold 14 duplexer with the nip roll 16 of outlet side with reference to Fig. 1.The blooming that the resin bed by base material film and curing that obtains constitutes is furled by film retracting device 34 usually.At this moment,, also can be situated between by adhesive phase with releasable in order to protect resin bed, at resin layer surface the fit diaphragm by polyethylene terephthalate, tygon etc. form on one side furl on one side.
After peeling off from mold 14, the active energy beam irradiation that can append.
As active energy beam; Can be according to type suitably selection from ultraviolet ray, electron beam, near ultraviolet ray, visible light, near infrared ray, infrared ray, X ray etc. of the active energy ray-curable resin that contains in the coating fluid; But wherein preferred ultraviolet ray and electron beam; Consider preferred especially ultraviolet ray from handling easy and obtaining high-octane angle.
As ultraviolet light source, for example can use low pressure mercury lamp, medium pressure mercury lamp, high-pressure sodium lamp, ultrahigh pressure mercury lamp, carbon arc lamp, metal halide lamp, xenon lamp etc.And, also can use ArF excimer laser, KrF excimer laser, Excimer lamp or synchrotron radiation light etc.Wherein, preferably use ultrahigh pressure mercury lamp, high-pressure sodium lamp, low pressure mercury lamp, xenon arc lamp, metal halide lamp.
And; As electron beam, the electron beam that can give an example and emit with 50~1000keV, preferred 100~300keV energy by various electron-beam accelerators such as Cockcroft, John Douglas Te Waerdun type, model De Graff type, resonance transformer type, insulating core transformer type, linear pattern, high-frequency and high-voltage type, high-frequency type.
When active energy beam was ultraviolet ray, the accumulation light quantity of ultraviolet UVA was preferably 40mJ/cm 2~2000mJ/cm 2, be more preferably 70mJ/cm 2~1800mJ/cm 2At accumulation deficiency in light quantity 40mJ/cm 2The time, the curing of coating layer is insufficient, and the hardness step-down of the resin bed that obtains sometimes or uncured resin are attached to guide roller etc. and become the operation pollution cause.And, surpass 2000mJ/cm in the accumulation light quantity 2The time, become the reason of base material film constricted fold sometimes because of the heat that radiates from ultraviolet lamp.
The mold that uses in this operation is the mold that is used for the resin layer surface that on base material film, forms is given required form, has the surface configuration that the transfer print structure by this required form constitutes.Through the limit painting layer surface is pressed against this surface configuration limit and makes coating layer solidify (or coating layer is solidified), thereby can the surface configuration of mold be transferred to resin layer surface.As mold, can give an example, have the mold (for example mirror roller) on the surface that constitutes by minute surface and have the mold (for example knurling rolls) of convex-concave surface.
Have at mold under the situation of convex-concave surface; The pattern of concaveconvex shape can be the pattern of rule; Also can be random pattern or the quasi-random pattern that has been paved with more than one random patterns of specific dimensions; But when the blooming that obtains being adapted to image display device such as liquid crystal indicator, from preventing that causing reflected image to be colored as irised angle by the catoptrical interference that surface configuration causes considers, preferably random pattern or quasi-random pattern.
The not special restriction of the outer shape of mold can be a tabular, also can be roller cylindric or cylindraceous shown in Figure 1, but consider from the production continuity, preferably mold cylindric or cylindraceous such as mirror roller, knurling rolls.At this moment, form the surface configuration of regulation in the side of cylindric or mold cylindraceous.
The not special restriction of the material of the base material of mold can suitably be selected from metal, glass, carbon, resin or their complex, but consider preferable alloy from the processability equal angles.As the metal material that be fit to use, consider from the viewpoint of cost, can enumerate aluminium, iron, or the alloy that is the main body with aluminium or iron etc.
As the method that obtains mold, for example, the following method of can giving an example: grind base material, implement sandblast processing, implement the method (spy opens the 2006-53371 communique) of chemical nickel plating then; After base material is carried out copper facing or nickel plating, grind, implement sandblast processing, implement the method (spy opens the 2007-187952 communique) of chromium plating then; After having implemented copper facing or nickel plating, grind, implement sandblast processing, implement etching work procedure or copper facing operation then, then implement the method (spy opens the 2007-237541 communique) of chromium plating; After copper facing or nickel plating are carried out in the surface of base material, to grind, the face coating after grinding forms photosensitive resin film; Behind exposing patterns on this photosensitive resin film, develop, the photosensitive resin film after developing is used as mask; Carry out etch processes, peel off photosensitive resin film, carry out etch processes then; After making the male and fomale(M&F) rust, the male and fomale(M&F) that forms is implemented the method for chromium plating; And use work mechanism such as rotating disk, utilize the cutting tool cutting as the method (No. 2007/077892 pamphlet of International Publication) of the base material of mold etc.
The concave-convex surface shape of the mold of being made up of random pattern or quasi-random pattern can form through following mode: will be through for example FM silk screening, DLDS (Dynamic Low-Discrepancy Sequence; Dynamically low diversity sequence) random pattern of generations such as method, the microphase-separated method of patterning of utilizing segmented copolymer or BPF. method makes public to photosensitive resin film; Develop; Photosensitive resin film after developing as mask, is implemented etch processes, thereby form.
The blooming of the present invention that obtains as described above is the blooming that is applicable to image display devices such as liquid crystal indicator; For example, can be: the resin bed on the base material film be that the hard coat of the scar that is used to prevent that various external force from causing is hard coat film (containing the light transmission particulate sometimes); Resin bed is to be used to make the light diffusion of penetrating from liquid crystal cells and the light diffusion layer (containing the light transmission particulate as light diffusing agent) that improves the visual angle is promptly looked and recognized the sidelight diffusion barrier; Resin bed is to be used to prevent that the antiglare layer with concave-convex surface (containing the light transmission particulate sometimes) that extraneous light is mirrored, dazzled from being antiglare film; Resin bed is to be used to make the light diffusion of inciding liquid crystal cells and to prevent that the light diffusion layer (containing the light transmission particulate as light diffusing agent) of interference line that back light unit causes etc. from being rear side optical diffusion film (diffuser plate) etc.Hard coat film, look and recognize sidelight diffusion barrier and antiglare film and can be used as usually to look and recognize looking of side polaroid and recognize the side diaphragm and fit in light polarizing film and use (surface that promptly, is configured in image display device).The rear side optical diffusion film is usually as the backlight side diaphragm of backlight side polaroid and fit in light polarizing film.
Blooming of the present invention can also possess the anti-reflection layer that is layered in (with the face of base material film opposition side) on the resin bed.Anti-reflection layer is provided with for unlimited reduction reflectivity, can prevent mirroring to display device through forming anti-reflection layer.As anti-reflection layer, can enumerate: the low-index layer that constitutes by the low material of refractive index ratio resin bed; And by the stepped construction of the material of refractive index ratio resin floor height high refractive index layer that constitutes and the low-index layer that constitutes by the low material of this high refractive index layer of refractive index ratio etc.The not special restriction of the laminating method of anti-reflection layer can directly be laminated on the resin bed, also can prepare in addition in advance with anti-reflection layer be laminated on the base material film and duplexer, and use bonding agent etc. that it is fitted on the resin bed.
< polaroid >
Polaroid of the present invention possesses: light polarizing film and the blooming that obtains through above-mentioned manufacturing approach, said blooming is layered on this light polarizing film with base material film side and the opposed mode of this light polarizing film.Light polarizing film has the function of from incident light, taking out linear polarization, and its kind is not special to be limited.As the example of suitable light polarizing film, can give an example and on polyvinyl alcohol resin, adsorb the light polarizing film of dichromatism pigment and this dichromatism pigment generation orientation.As polyvinyl alcohol resin, except the saponified of vinyl acetate is the polyvinyl alcohol (PVA), the part of can also giving an example formaldehyde condensed polyvinyl alcohol, ethylene saponified etc.As the dichromatism pigment, can use iodine or dichromatic organic dyestuff.And the polyene alignment films of the desalination acid treatment thing of the processed thing of polyvinyl alcohol (PVA), PVC also can become light polarizing film.The thickness of light polarizing film is generally about 5~80 μ m.
Polaroid of the present invention can be in above-mentioned light polarizing film the range upon range of blooming of the present invention of single or double (normally single face) and polaroid, also can be at the range upon range of transparent protective film of the one side of above-mentioned light polarizing film, the range upon range of blooming of the present invention of another side and polaroid.
At this moment, blooming also has the function of the protective clear layer (diaphragm) as light polarizing film.Protective clear layer can form on light polarizing film through the method for using applying transparent resin films such as bonding agent, the method that is coated with the coating fluid that contains transparent resin etc.Likewise, blooming of the present invention can use bonding agent etc. to fit on the light polarizing film.
The transparent resin film preferably clear property, physical strength, thermal stability, moisture shielding etc. that become transparent protective film are good; As such transparent resin film; For example, can illustration by the cellulose-based resin of cellulose acetates such as triacetyl cellulose, diacetyl cellulose, cellulose-acetate propionate etc.; Polycarbonate-based resin; Polyacrylate, polymethylmethacrylate etc. (methyl) acrylic resin; Polyester based resin such as polyethylene terephthalate, PEN; Chain such as tygon, polypropylene polyolefin-based resins; Cyclic polyolefin hydrocarbon system resin; Phenylethylene resin series; Polysulfones; Polyethersulfone; The film that polyvinyl chloride resin etc. form.These transparent resin films can be optically isotropic resin moldings, also can be that the visual angle when being assembled into image display device with compensation is that purpose has optically anisotropic resin molding.
< image display device >
Image display device of the present invention is the polaroid and the device that various information projections are obtained to the image-displaying member of picture of combination the invention described above.The kind of image display device of the present invention is not special to be limited; Except that the LCD that has used liquid crystal panel (LCD), can also give an example: Brown tube (cathode-ray tube (CRT): CRT) screen of display, plasma scope (PDP), field-emitter display (FED), surface conductive type electron emission display device (SED), OLED display, laser writer, projection TV etc.
For example, polaroid of the present invention is being configured in when making liquid crystal panel on the liquid crystal cells, polaroid is that the mode (its resin bed is the outside) of liquid crystal cell side is configured on the liquid crystal cells with its light polarizing film.For other image display device too.Blooming can be configured in looking of image-displaying member and recognize side, also can be configured in backlight side, perhaps also can be configured in both sides.Looking when recognizing side configuration blooming, blooming can play a role as hard coat film, optical diffusion film, antiglare film or antireflection film etc.On the other hand, when backlight side configuration blooming, blooming can prevent to disturb the optical diffusion film (diffuser plate) of line etc. etc. as making the light diffusion of injecting liquid crystal cells and play a role.
Embodiment
Below, enumerate embodiment, the present invention will be described in more detail, but the present invention is not limited to these embodiment.
< embodiment 1 >
Mix following composition, prepare ultra-violet solidified coating fluid.
Uv curing resin: pentaerythritol triacrylate 60 weight portions and polyfunctional carbamate acrylic ester (reaction product of hexamethylene diisocyanate and pentaerythritol triacrylate) 40 weight portions,
Photoepolymerizationinitiater initiater: " Lucirin TOP " (BASF AG's system, chemical name: 2,4,6-trimethylbenzoyl diphenyl phosphine oxide) 5 weight portions,
Diluting solvent: ethyl acetate 100 weight portions.
Then, use the intaglio plate spreader that above-mentioned coating fluid is applied on the triacetyl cellulose that thickness is 80 μ m (TAC) film (base material film), make that the thickness after solidifying is 10 μ m, obtain the duplexer (painting process) of base material film and coating layer.Then, the duplexer that utilizes drying oven to make to obtain is dry.Then; Use being situated between, configured in parallel and two ends are pressed against milled processed has been carried out on the surface for minute surface ground upward also driving fit of chrome-plated roller (mold) by the nip roll shown in Figure 4 of convex surface processing (the configuration roller diameter is to convex surface processing part that roll end slowly diminishes under the Width both ends of coating layer) with painting layer surface opposed to each other by duplexer and chrome-plated roller.At this moment, the kneading in central portion zone is pressed and is set at 0.4Mpa, and the kneading in zone, both ends is pressed and is set at 0Mpa, is not promptly exerted pressure in the zone, both ends.Under this state, be 700mW/cm with the maximal illumination of UVA from the base material film side 2, UVA the accumulation light quantity be 300mJ/cm 2The mode irradiation ultraviolet radiation, make coating layer solidify (curing process).Then, peel off duplexer, thereby the average film thickness that obtains the resin bed that the solidfied material by uv curing resin forms is the blooming of 10 μ m from chrome-plated roller.
< embodiment 2 >
Use shown in Figure 4, through the nip roll of convex surface processing, make the kneading in central portion zone press, the kneading in zone, both ends pressed be 0.2Mpa, in addition, make blooming identically with embodiment 1 to 0.4Mpa.
< embodiment 3 >
Use shown in Figure 4, through the nip roll of convex surface processing, make the kneading in central portion zone press, the kneading in zone, both ends pressed be 0.1Mpa, in addition, make blooming identically with embodiment 1 to 0.2Mpa.
< embodiment 4 >
Use shown in Figure 3, have the nip roll of the excision portion of spill with the corresponding zone (zone under the zone, both ends), zone, both ends of the effective width of coating layer; The kneading pressure that makes the central portion zone is that 0.4Mpa is (owing to have excision portion; So pressing, the kneading of end regions is 0Mpa); In addition, make blooming with embodiment 1 identically.
< embodiment 5 >
Use shown in Figure 2, have a nip roll of the width (roller length) shorter than the effective width of coating layer; The kneading pressure that makes the central portion zone is that 0.4Mpa is (because the width of nip roll is narrower than the effective width of coating layer; So pressing, the kneading of end regions is 0Mpa); In addition, make blooming with embodiment 1 identically.
< comparative example 1 >
Use has the cylindric nip roll (processing is not implemented by there not being concavo-convex even surface to constitute in the roller surface) of the width (roller length) longer than the effective width of coating layer, in addition, makes blooming with embodiment 1 identically.
(evaluation of resin residue)
The surface of the chrome-plated roller after the blooming has been made in observation; Affirmation is applied to the position B that the pressure of coating layer changes in the position A at the both ends of the resin bed that has been equivalent to solidify and embodiment 1~5 (embodiment 1~3: the middle section of the not convex surface processing in the chrome-plated roller and through the boundary position in the zone, both ends of convex surface processing; The height plane difference position of the inclined to one side middle section in 4: two excision portions of embodiment, embodiment 5: the Width both ends of chrome-plated roller) have or not resin residue.When resin residue is not all seen in any position, be zero; The part of seeing resin residue in a certain position but resin residue taking place is △ less than 1/3 o'clock of roller whole peripheral surface, the part that all see resin residue in any position, resin residue takes place be 1/3 of roller whole peripheral surface when above be *.The result is shown in table 1.
(evaluation that resin peels off)
The zone, both ends of the Width in the curing resin layer of the blooming that obtains attaches adhesive tape (Nichiban Co., Ltd. system " Cellotape (registered trademark) "; 24mm is wide); Repeat 3 times with after the angle operation of peeling off that becomes 45 degree with respect to resin layer surface; Observe zone, above-mentioned both ends with magnifier, confirm to have or not resin to peel off (resin bed is peeled off or resin bed breaks away from from base material film from base material film).Do not see when resin peels off being zero, when seeing be *.
Should explain, use the processing ease of above-mentioned adhesive tape to confirm not to break away from but be in the existence of the resin bed part (such part is comprised in the category that resin peels off) of the state of peeling off, breaking away from easily from base material film from base material film.The result is shown in table 1.
Table 1
As shown in table 1; Be processed into the little nip roll in pressure ratio central portion zone in the zone, both ends of the Width that is applied to said coating layer through use; Compare with the situation (comparative example 1) of using the nip roll do not implement any processing, can suppress effectively that resin peels off and resin residue.Especially; When using two ends to be pressed less than 0.2Mpa by the kneading in the nip roll of convex surface processing and zone, both ends; The pressure that is applied to coating layer slowly diminishes to both ends from the central portion zone; And the kneading pressure that the zone, both ends is applied is enough low, so even also can prevent resin residue effectively at the position B that the pressure that is applied to coating layer changes, and can prevent effectively that resin from peeling off.In embodiment 2,4 and 5, A does not see resin residue in the position, but B sees few resin residue in the position.

Claims (5)

1. the manufacturing approach of a blooming is characterized in that, comprises following operation:
Painting process, coating contains the coating fluid of active energy ray-curable resin on the base material film of carrying continuously, forms coating layer; With
Curing process leans against in the surface pressure with said coating layer under the state on surface of mold, from said base material film side coating layer is shone active energy beam,
In said curing process, when the surface pressure with said coating layer leaned against said mold surperficial, the central portion zone of the Width of pressure ratio between zone, said both ends in zone, both ends of Width that is applied to said coating layer was little.
2. method according to claim 1, wherein,
In said curing process, the surface by utilizing nip roll of said coating layer is pressed against the surface of said mold, and said nip roll is across base material film with said coating layer and said mold arranged opposite,
Said nip roll is processed to: when the surface pressure of utilizing nip roll with said coating layer leaned against said mold surperficial, the central portion zone of the Width of pressure ratio between zone, said both ends in zone, both ends of Width that is applied to said coating layer was little.
3. method according to claim 2, wherein,
Said nip roll is processed to: the zone corresponding with the central portion zone of said coating layer is than giving prominence to laterally with corresponding zone, zone, said both ends.
4. a polaroid is characterized in that possessing
Light polarizing film and the blooming of making through each described method in the claim 1~3,
Wherein, said blooming is layered on the said light polarizing film with said base material film side and the opposed mode of said light polarizing film.
5. an image display device is characterized in that, possesses described polaroid of claim 4 and image-displaying member,
Wherein, said polaroid is that the mode of said image-displaying member side is configured on the said image-displaying member with its light polarizing film.
CN2012101278782A 2011-04-28 2012-04-26 Method for making optical film, polarizing film, and image display apparatus Pending CN102759760A (en)

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Application publication date: 20121031