CN107031079B - Method for manufacturing laminated optical film - Google Patents

Method for manufacturing laminated optical film Download PDF

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Publication number
CN107031079B
CN107031079B CN201610821108.6A CN201610821108A CN107031079B CN 107031079 B CN107031079 B CN 107031079B CN 201610821108 A CN201610821108 A CN 201610821108A CN 107031079 B CN107031079 B CN 107031079B
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film
resin
substrate
active energy
coating
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CN107031079A (en
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仲俊之
川上武志
安藤卓也
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
    • 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
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/0074—Production of other optical elements not provided for in B29D11/00009- B29D11/0073
    • B29D11/00788—Producing optical films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • G02B1/045—Light guides
    • G02B1/048—Light guides characterised by the cladding material
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/14—Protective coatings, e.g. hard coatings

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Quality & Reliability (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ophthalmology & Optometry (AREA)
  • Polarising Elements (AREA)
  • Laminated Bodies (AREA)
  • Coating Of Shaped Articles Made Of Macromolecular Substances (AREA)

Abstract

The invention provides a method for manufacturing a laminated optical film, which can inhibit the damage of the surface of the optical film and the surface of a resin layer overlapped on the optical film. The method for manufacturing a laminated optical film comprises: the method for producing the optical film includes a coating step of forming a coating film 32a containing an active energy ray-curable resin on the surface of a film-like substrate 22a, a bonding step of bonding the substrate 22a to the surface of an optical film (polarizing element 38) through the coating film 32a, and a curing step of irradiating the coating film 32a with an active energy ray L from the substrate 22a side to form a resin layer 32b from the coating film 32 a. The transmittance of the active energy ray L in the base material 22a is 70% or more.

Description

Method for manufacturing laminated optical film
Technical Field
The present invention relates to a method for manufacturing a laminated optical film.
Background
A polarizing plate is one of laminated optical films, and constitutes a liquid crystal display device. The polarizing plate includes a polarizer, which is one of optical films, and a protective film laminated on one or both surfaces of the polarizer. Patent document 1 discloses that a transparent resin layer is formed by applying a resin solution to one or both surfaces of a polarizing film. When it is necessary to protect an optical film other than the polarizing element, the laminated optical film has a resin layer overlapping the optical film.
(patent document 1) Japanese patent laid-open No. 2000-199819
Disclosure of Invention
In recent years, with the thinning of mobile devices such as smartphones, it has been demanded that laminated optical films used for the mobile devices be made thinner. One method of thinning the laminated optical film is to superimpose a thinner protective layer on the optical film instead of the conventional protective film. For example, in the production of a polarizing plate, a coating film containing an active energy ray-curable resin is formed on the surface of a polarizing element using a coating device such as a gravure roll, and the coating film is cured with an active energy ray, so that a protective layer (resin layer) thinner than conventional protective films can be easily formed. However, when a coating film is applied on the surface of the polarizing element, the coating apparatus comes into contact with the polarizing element to damage the surface of the polarizing element. Such a problem may occur when a protective layer is formed on the surface of an optical film other than the polarizing element. That is, the optical properties of the optical film may be damaged by scratching the surface of the optical film by the coating apparatus. Further, the protective layer (resin layer) formed on the surface of the polarizing element is too thin, and may be scratched by contact with a roller or the like in a subsequent process or during transportation.
The present invention has been made in view of the above circumstances, and an object thereof is to provide a method for producing a laminated optical film, which can suppress damage to the surface of an optical film and the surface of a resin layer overlapping the optical film.
A method for manufacturing a laminated optical film according to an embodiment of the present invention includes: the method for producing the optical film includes a coating step of forming a coating film containing an active energy ray-curable resin on the surface of a film-like substrate, and a bonding step of bonding the substrate to the surface of the optical film via the coating film, and a curing step of irradiating the coating film with an active energy ray from the substrate side to form a resin layer from the coating film. The transmittance of the active energy ray in the substrate is 70% or more.
In one embodiment of the present invention, the active energy ray may be ultraviolet ray.
In one embodiment of the present invention, the base material may contain at least one selected from the group consisting of a cyclic polyolefin resin, a polypropylene resin, an acrylic resin, and a polyethylene resin.
In one embodiment of the present invention, the active energy ray-curable resin may be at least one selected from the group consisting of an epoxy resin, an acrylic resin, and an oxetane resin.
The method for producing a laminated optical film according to one embodiment of the present invention may further include a peeling step of peeling the substrate from the resin layer after the curing step.
In the coating step of the method for producing a laminated optical film according to one embodiment of the present invention, a coating film can be formed on the surface of a substrate that has not been subjected to surface roughening treatment.
In one embodiment of the present invention, the resin layer may be a protective layer for protecting the optical film.
According to the present invention, there is provided a method for producing a laminated optical film, which can suppress damage to the surface of an optical film and the surface of a resin layer laminated on the optical film.
Drawings
Fig. 1 is a schematic diagram showing a method for manufacturing a polarizing plate according to a first embodiment of the present invention.
Fig. 2 (a), 2 (b), and 2 (c) are schematic diagrams showing a method for manufacturing a polarizing plate according to a first embodiment of the present invention.
Fig. 3 is a schematic diagram showing a method for manufacturing a polarizing plate according to a second embodiment of the present invention.
Fig. 4 (a), 4 (b), and 4 (c) are schematic diagrams showing a method for manufacturing a polarizing plate according to a second embodiment of the present invention.
Description of the symbols
38 … polarizing element (optical film), 32a, 52a, 54a … coating film, 32b, 52b, 54b … resin layer (protective layer), 22a, 42a, 44a … base material, L … active energy ray.
Detailed Description
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In the drawings, the same components are denoted by the same reference numerals. The present invention is not limited to the following embodiments.
(first embodiment)
The first embodiment relates to a method for manufacturing a polarizing plate as one of laminated optical films. The method for manufacturing a polarizing plate according to the first embodiment includes at least a coating step, a bonding step, and a curing step. In the coating step, a coating film containing an active energy ray-curable resin is formed on the surface of the film-shaped substrate. In the bonding step, the substrate is bonded to the surface of the optical film through the coating film. In the curing step, the coating film is irradiated with an active energy ray from the substrate side to form a resin layer from the coating film. The respective steps will be described in detail below.
[ coating Process ]
As shown in fig. 1 and 2 (a), in the coating step of the first embodiment, a first laminate 24 is used. The first laminate 24 has: the film-shaped polarizer 38, the adhesive layer 36 overlapping the polarizer 38, is bonded to the protective film 34 of the polarizer 38 via the adhesive layer 36.
The film-like polarizing element 38 can be produced, for example, in the following order.
First, a film-shaped polyvinyl alcohol resin is stretched in a uniaxial direction or a biaxial direction. Subsequently, the polyvinyl alcohol resin is dyed with iodine or a dichroic dye. For crosslinking, the dyed polyvinyl alcohol resin is treated in a crosslinking agent solution (for example, an aqueous boric acid solution). After the treatment with the crosslinking agent, the polyvinyl alcohol resin is washed with water and then dried. After the above sequence, the polarizing element 38 is obtained. The polyvinyl alcohol resin can be obtained by saponifying a polyvinyl acetate resin. The polyvinyl acetate-based resin may be, for example, polyvinyl acetate which is a homopolymer of vinyl acetate, or a copolymer of vinyl acetate and another monomer (for example, an ethylene-vinyl acetate copolymer). The other monomer copolymerizable with vinyl acetate may be an unsaturated carboxylic acid other than ethylene, an olefin, a vinyl ether, an unsaturated sulfonic acid, or an acrylamide having an ammonium group. The polyvinyl alcohol resin may be modified. The modified polyvinyl alcohol resin may be, for example, polyvinyl formal, polyvinyl acetal, or polyvinyl butyral modified with aldehydes.
The thickness of the polarizing element 38 may be 10 μm or less, or 8 μm or less. The thinner the polarizer 38 is, the easier it is to reduce the thickness of the polarizing plate. The thickness of the polarizing element 38 may be 2 μm or more. The thicker the polarizer 38, the easier it is to increase the mechanical strength of the polarizer 38.
The protective film 34 has a function of protecting the polarizing element 38. The protective film 34 may be an optically transparent thermoplastic resin as long as it is a light-transmitting thermoplastic resin. The resin constituting the protective film 34 may be, for example, a chain polyolefin resin, a cyclic polyolefin resin, a cellulose ester resin, a polyester resin, a polycarbonate resin, (meth) acrylic resin, a polystyrene resin, or a mixture or copolymer thereof.
The chain polyolefin resin may be, for example, a homopolymer of a chain olefin such as a polyethylene resin or a polypropylene resin. The chain polyolefin resin may be a copolymer of two or more kinds of chain olefins.
The cyclic polyolefin-based resin may be, for example, a ring-opening (co) polymer of a cyclic olefin or an addition polymer of a cyclic olefin. The cyclic polyolefin-based resin may be, for example, a copolymer (e.g., a random copolymer) of a cyclic olefin and a chain olefin. The chain olefin constituting the copolymer may be, for example, ethylene or propylene. The cyclic polyolefin resin may be a graft polymer obtained by modifying the above polymer with an unsaturated carboxylic acid or a derivative thereof, or a hydrogenated product thereof. The cyclic polyolefin resin may be, for example, a norbornene resin using a norbornene monomer such as a norbornene or polycyclic norbornene monomer.
The cellulose ester resin may be, for example, cellulose triacetate (triacetyl cellulose), cellulose diacetate, cellulose propionate, or cellulose dipropionate. Copolymers of these may be used. A cellulose ester resin in which a part of the hydroxyl groups is modified with another substituent may be used.
Polyester resins other than cellulose ester resins may be used. The polyester-based resin may be, for example, a polycondensate of a polycarboxylic acid or a derivative thereof and a polyol. The polycarboxylic acid or derivative thereof may be a dicarboxylic acid or derivative thereof. The polycarboxylic acid or derivative thereof may be, for example, terephthalic acid, isophthalic acid, dimethyl terephthalate, or dimethyl naphthalenedicarboxylate. The polyol may be, for example, a diol. Examples of the polyhydric alcohol include ethylene glycol, propylene glycol, butanediol, neopentyl glycol, and cyclohexanedimethanol.
The polyester-based resin may be, for example, polyethylene terephthalate, polybutylene terephthalate, polyphthalate, polyethylene naphthalate, polybutylene naphthalate, polypropylene terephthalate, polypropylene naphthalate, polycyclohexylenedimethylene terephthalate, or polycyclohexylenedimethylene naphthalate.
The polycarbonate-based resin is a polymer in which polymerized units (monomers) are bonded to each other via carbonate groups. The polycarbonate-based resin may be a modified polycarbonate having a modified polymer skeleton, or may be a copolymerized polycarbonate.
The (meth) acrylic resin may be, for example, a poly (meth) acrylate (e.g., polymethyl methacrylate); methyl methacrylate- (meth) acrylic acid copolymer; methyl methacrylate- (meth) acrylate copolymers; methyl methacrylate-acrylate- (meth) acrylic acid copolymer; methyl (meth) acrylate-styrene copolymers (e.g., MS resins); copolymers of methyl methacrylate and a compound having an alicyclic hydrocarbon group (e.g., methyl methacrylate-cyclohexyl methacrylate copolymer, methyl methacrylate- (meth) acrylic acid norbornyl copolymer, etc.).
The protective film 34 may contain at least one additive selected from the group consisting of a lubricant, a plasticizer, a dispersant, a heat stabilizer, an ultraviolet absorber, an infrared absorber, an antistatic agent, and an antioxidant.
The thickness of the protective film 34 may be 90 μm or less, 50 μm or less, or 30 μm or less. The thinner the protective film 34 is, the easier the polarizing plate can be made thinner. The thickness of the protective film 34 may be 5 μm or more. The thicker the protective film 34 is, the more easily the mechanical strength and the workability of the protective film 34 are improved.
The protective film 34 may be a film having an optical function such as a retardation film or a brightness enhancement film. For example, a retardation film to which an arbitrary retardation value is given can be obtained by stretching a film formed of the above thermoplastic resin, or forming a liquid crystal layer on the film.
The pressure-sensitive adhesive layer 36 may contain an aqueous pressure-sensitive adhesive such as polyvinyl alcohol, and may contain an active energy ray-curable resin described later. The thickness of the cured adhesive layer 36 may be, for example, 0.05 μm or more and 10 μm or less. The thicker the pressure-sensitive adhesive layer 36, the more difficult it is to form air bubbles between the polarizer 38 and the protective film 34, and the more firmly the polarizer 38 and the protective film 34 are adhered to each other. The thinner the adhesive layer 36 is, the easier the polarizing plate can be made thinner.
As shown in fig. 1 and fig. 2 (a), in the coating step of the first embodiment, a coating film 32a containing an active energy ray-curable resin is formed on the surface of a film-like substrate 22a using a coating apparatus 1. That is, in the coating step, the second laminate 22b having the base material 22a and the coating film 32a formed on the surface of the base material 22a is produced. The coating apparatus 1 may be, for example, a gravure coater such as an MCD type ultra-precision coater. The coating film 32a may be formed of only an active energy ray-curable resin. As described above, since the coating film 32a is formed on the surface of the base material 22a instead of the surface of the polarizing element 38, the coating apparatus 1 is not directly in contact with the surface of the polarizing element 38. So that no damage of the surface of the polarizing element 38 due to contact with the coating device 1 occurs.
The transmittance of the active energy ray in the substrate 22a is 70% or more. The active energy ray may be, for example, ultraviolet ray, visible light, electron beam, or X-ray. The transmittance of the active energy ray in the base material 22a may be 75% or more, 76.7% or more, 80% or more, or 89% or more. The transmittance of the active energy ray in the base material 22a is 95% or less, 99% or less, or less than 100%. Further, the transmittance T of the active energy ray in the substrate 22a can be defined as, for example, (I/I)0)×100。I0Is the radiant emittance of the active energy ray incident in the base material 22 a. I is the degree of emission of the active energy ray transmitted through the base material 22 a.
The transmittance of the active energy ray in the substrate 22a can be measured using, for example, an ultraviolet-visible-near infrared spectrophotometer "V-7100" manufactured by japan spectrographic corporation.
The activation energy ray may be ultraviolet ray. The base material 22a having an ultraviolet transmittance of 70% or more may contain at least one selected from the group consisting of cyclic polyolefin resins, polypropylene resins, acrylic resins, and polyethylene resins, for example.
The cyclic polyolefin-based resin may be, for example, a ring-opening (co) polymer of a cyclic olefin or an addition polymer of a cyclic olefin. The cyclic polyolefin-based resin may be, for example, a copolymer (e.g., a random copolymer) of a cyclic olefin and a chain olefin. The chain olefin constituting the copolymer may be, for example, ethylene or propylene. The cyclic polyolefin resin may be a graft polymer obtained by modifying the above polymer with an unsaturated carboxylic acid or a derivative thereof, or a hydrogenated product thereof. The cyclic polyolefin resin may be, for example, a norbornene resin using a norbornene monomer such as a norbornene or polycyclic norbornene monomer.
The acrylic resin ((meth) acrylic resin) may be, for example, poly (meth) acrylate (e.g., polymethyl methacrylate); methyl methacrylate- (meth) acrylic acid copolymer; methyl methacrylate- (meth) acrylate copolymers; methyl methacrylate-acrylate- (meth) acrylic acid copolymer; methyl (meth) acrylate-styrene copolymers (e.g., MS resins); copolymers of methyl methacrylate and a compound having an alicyclic hydrocarbon group (e.g., methyl methacrylate-cyclohexyl methacrylate copolymer, methyl methacrylate- (meth) acrylic acid norbornyl copolymer, etc.).
The active energy ray-curable resin is a resin that is cured by irradiation with an active energy ray. The active energy ray-curable resin may be one kind of resin, or may contain a plurality of kinds of resins.
When the active energy ray is ultraviolet light, the active energy ray-curable resin is an ultraviolet-curable resin. The ultraviolet curable resin may be formulated as a solventless adhesive. Therefore, when the active energy ray-curable resin is an ultraviolet-curable resin, a drying step of removing the solvent may be performed after the coating step, the bonding step, or the curing step. In addition, ultraviolet curable resins are more easily used in combination with protective films having a lower moisture permeability than aqueous adhesives.
The ultraviolet curable resin may contain a cationically polymerizable curable compound or a radically polymerizable curable compound. The ultraviolet curable resin may contain a cationic polymerization initiator or a radical polymerization initiator for initiating a curing reaction of the curable compound.
The cationically polymerizable curable compound may be, for example, an epoxy resin (a compound having at least one epoxy group in the molecule) or an oxetane resin (a compound having at least one oxetane ring in the molecule). The radical polymerizable curable compound may be, for example, a (meth) acrylic resin (a compound having at least one (meth) acryloyloxy group in a molecule). The radical polymerizable curable compound may be a vinyl resin having a radical polymerizable double bond.
The active energy ray-curable resin may contain a cationic polymerization accelerator, an ion scavenger, an antioxidant, a chain transfer agent, an adhesion imparting agent, a thermoplastic resin, a filler, a flow control agent, a plasticizer, an antifoaming agent, an antistatic agent, a leveling agent, a solvent, or the like, as required.
The active energy ray may be ultraviolet a wave (UVA). The ultraviolet A wave is ultraviolet with a wavelength of 400-315 nm. The resin constituting the base material 22a having a transmittance of ultraviolet a wave of 70% or more may be, for example, a cyclic polyolefin resin, a polypropylene resin, or an acrylic resin. The active energy ray-curable resin (ultraviolet-curable resin) that is cured by irradiation with ultraviolet a waves may be, for example, an epoxy resin, an acrylic resin, or an oxetane resin. The active energy ray may be ultraviolet B wave (UVB). The ultraviolet B wave is ultraviolet with a wavelength of 315-280 nm. The resin constituting the base material 22a having a transmittance of ultraviolet B-wave of 70% or more may be, for example, a cyclic polyolefin resin, a polypropylene resin, or an acrylic resin. The active energy ray-curable resin (ultraviolet-curable resin) that is cured by irradiation with ultraviolet B-wave may be, for example, an epoxy resin, an acrylic resin, or an oxetane resin. The active energy ray may be ultraviolet C wave (UVC). The ultraviolet C wave is ultraviolet with wavelength less than 280 nm. The base material 22a may be a resin having an ultraviolet C-wave transmittance of 70% or more.
The active energy ray may be visible light. The base material 22a may be a resin having a visible light transmittance of 70% or more.
For example, when the active energy ray is ultraviolet ray using a high-pressure mercury lamp as a light source, the wavelength of the ultraviolet ray is 300nm, and the base material 22a is formed of a cyclic polyolefin resin film or a polypropylene resin film, the transmittance of the active energy ray in the base material 22a is 89%. The active energy ray-curable resin to be cured by irradiation with active energy rays at this time is, for example, an epoxy resin. For example, when the active energy ray is ultraviolet ray having a wavelength of 300nm using a high-pressure mercury lamp as a light source and the base 22a is formed of an acrylic resin film, the transmittance of the active energy ray in the base 22a is 76.7%. The active energy ray-curable resin to be cured by irradiation with active energy rays at this time is, for example, an epoxy resin.
The thickness of the base material 22a may be, for example, 5 μm or more and 100 μm or less. The thinner the substrate 22a is, the higher the transmittance of the active energy ray in the substrate 22a tends to be. The thicker the base material 22a is, the lower the transmittance of the active energy rays in the base material 22a tends to be.
[ bonding Process ]
As shown in fig. 1 and 2 (a), the first laminate 24 is transferred in the direction d24 and supplied between a pair of bonding rollers (rollers 7a and 7 b). The guide roller 5a is in contact with the surface of the protective film 34 provided on the first laminate 24. The second laminate 22b is transferred in the direction d22 and supplied between the pair of rollers 7a and 7 b. The guide roller 5b is in contact with the surface of the base material 22a of the second laminate 22 b.
As shown in fig. 1 and fig. 2 (a) and (b), in the bonding step, the first laminate 24 and the second laminate are stacked with the coating film 32a of the second laminate 22b facing the polarizing element 38 of the first laminate 24. The overlapped first laminate 24 and second laminate 22b are sandwiched between a pair of rollers 7a and 7 b. In other words, the surface of the polarizing element 38 is bonded to the substrate 22a via the coating film 32a by using a pair of bonding rollers. As a result, a third laminate 26a having a base 22a, a coating film 32a overlapping the base 22a, a polarizing element 38 overlapping the coating film 32a, an adhesive layer 36 overlapping the polarizing element 38, and a protective film 34 overlapping the adhesive layer 36 was obtained.
[ curing step and peeling step ]
As shown in fig. 1, the third laminate 26a is transferred between the pair of rollers 7a and 7b along the direction d 26. Then, in the curing step, the irradiation device 3 irradiates the coating film 32a with the activation energy ray L from the base material 22a side. That is, the active energy ray L is indirectly irradiated to the coating film 32a through the substrate 22 a. That is, the active energy ray L passes through the substrate 22a to reach the coating film 32 a. The coating film 32a is cured into the resin layer 32b by irradiation of the active energy ray L.
The irradiation device 3 may be, for example, a low-pressure mercury lamp, a medium-pressure mercury lamp, a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, a chemical lamp, a black light lamp, a microwave excitation light lamp, or a metal halide lamp.
The peeling step may be performed after the curing step. As shown in fig. 1 and (b) and (c) of fig. 2, in the peeling step, the base material 22a is peeled from the resin layer 32b of the third laminate 26 a. In the peeling step, the guide roller 5c is brought into contact with the base material 22a of the third laminate 26 a. The fourth laminate 26b from which the base material 22a has been peeled is transferred in the direction d 26.
When the peeling step is performed, the polarizing plate does not include the substrate 22 a. The polarizing plate (fourth laminate 26b) completed through the peeling step has, as shown in fig. 2 (c): the resin layer 32b, the polarizer 38 directly overlapping the resin layer 32b, and the protective film 34 bonded to the polarizer 38 via the adhesive layer 36. In addition, the substrate 22a may not be peeled off as long as the substrate 22a is not necessarily unnecessary in the subsequent process. By protecting the resin layer 32b, the substrate 22a can suppress the occurrence of scratches or irregularities on the surface of the resin layer 32 b.
The resin layer 32b may be a protective layer that protects the polarizing element 38. The resin layer 32b may be an optical compensation layer (OC layer). The polarizing plate (fourth laminate 26b) may include another optical layer laminated on the protective film 34 or the resin layer 32 b. The other optical layer may be, for example, a reflective polarizing film, a film having an antiglare function, a film having a surface antireflection function, a reflective film, a transflective film, a viewing angle compensation film, a hard coat layer, an adhesive layer, a touch sensor layer, an antistatic layer, or an antifouling layer.
In the curing step, since the transmittance of the active energy ray L in the substrate 22a is 70% or more, the coating film 32a is easily cured uniformly and sufficiently, as compared with the case where the transmittance of the active energy ray L in the substrate is less than the lower limit value. As a result, the resin layer 32b having high hardness and not easily scratched is formed. Therefore, even when the substrate 22a is peeled from the resin layer 32b, a part of the resin layer 32b or uncured resin is less likely to adhere to the surface of the peeled substrate 22 a. That is, the surface of the resin layer 32b bonded to the substrate 22a can be suppressed from being damaged accompanying the peeling of the substrate 22 a. For the above reasons, damage of the resin layer 32b overlapping with the film-shaped polarizing element 38 (optical film) is suppressed.
In the peeling step, the coating film 32a may be formed on the surface of the substrate 22a that has not been subjected to the surface roughening treatment in the coating step. When the surface roughening treatment is performed on the substrate 22a, the coating film 32a is likely to adhere closely to the surface of the substrate 22a, and it becomes difficult to peel off the substrate 22a from the cured coating film 32a (resin layer 32 b). When the surface roughening treatment is performed on the substrate 22a, the substrate 22a is peeled off from the surface of the resin layer 32b contacting the substrate 22a, and thus the substrate is damaged. Therefore, by forming the coating film 32a on the surface of the substrate 22a that has not been subjected to the surface roughening treatment, the substrate 22a can be easily peeled from the resin layer 32b in the peeling step, and damage to the surface of the resin layer 32b can be suppressed. The surface roughening treatment may be, for example, plasma treatment, corona treatment, ultraviolet irradiation treatment, flame treatment (flame treatment).
The peeling step may not be performed. When the peeling step is not performed, the surface of the substrate 22a may be roughened before the coating step. In the subsequent coating step, a coating film 32a may be formed on the surface of the substrate 22a having a roughened surface. As a result, it becomes difficult to peel the substrate 22a from the resin layer 32 b. When the peeling process is not performed, the completed polarizing plate comprises: the substrate 22a, the resin layer 32b overlapping the substrate, and the polarizer 38 overlapping the resin layer 32b are bonded to the protective film 34 on the polarizer 38 via the adhesive layer 36. Substrate 22a may function as a film to protect polarizing element 38. The polarizing plate may have other optical layers laminated on the substrate 22 a.
(second embodiment)
The method for manufacturing a polarizing plate according to a second embodiment of the present invention is the same as the first embodiment except for the following points. In the second embodiment, as in the first embodiment, damage to the resin layer 32b overlapping the polarizing element 38 (optical film) can be suppressed. The description of the common matters between the first and second embodiments will be omitted below.
The method for manufacturing a polarizing plate according to the second embodiment includes at least a coating step, a bonding step, and a curing step, as in the first embodiment. In the coating step of the second embodiment, only the coating film is formed on the surfaces of the pair of substrates. In the bonding step of the second embodiment, a film-shaped polarizing element is disposed between a pair of substrates. Then, a pair of substrates were bonded to both surfaces of the polarizing element via a coating film. In the curing step of the second embodiment, the coating film is irradiated with an active energy ray from each side of the pair of substrates, thereby forming a pair of resin layers sandwiching the polarizing element. The respective steps will be described in detail below.
As shown in fig. 3 and 4 (a), in the coating step of the second embodiment, a coating film 54a containing an active energy ray-curable resin is formed on the surface of a film-like substrate 44a using a coating apparatus 1a, thereby producing a laminate 44 b. The laminate 44b of the second embodiment may be the same as the second laminate 22b of the first embodiment. In the coating step, a coating film 52a containing an active energy ray-curable resin is formed on the surface of the film-like substrate 42a using the coating apparatus 1b, thereby producing a laminate 42 b. The laminate 42b of the second embodiment may be the same as the second laminate 22b of the first embodiment. The composition of the coating film 54a of the laminate 44b may be the same as that of the coating film 52a of the laminate 42 b. The composition of the coating film 54a of the laminate 44b may be different from the coating film 52a of the laminate 42 b. The composition of the substrate 44a of the laminate 44b may be the same as that of the substrate 42a of the laminate 42 b. The composition of the substrate 44a of the laminate 44b may be different from that of the substrate 42a of the laminate 42 b. As described above, since the coating film 52a is formed on the surface of the base material 42a instead of the surface of the polarizing element 38, the coating apparatus 1b does not directly contact the surface of the polarizing element 38. Further, the coating film 54a is formed on the surface of the base material 44a instead of the surface of the polarizing element 38, so the coating apparatus 1a does not directly contact the surface of the polarizing element 38. Therefore, damage to both surfaces of the polarizing element 38 due to contact with the coating apparatuses 1a and 1b does not occur.
As shown in fig. 3, in the second embodiment, the stacked body 44b is transferred in the direction d44 and supplied to a pair of bonding rollers (rollers 7c and 7 d). The guide roller 5d is in contact with the surface of the base material 44a included in the stacked body 44 b. The laminate 42b is transported in the direction d42 and supplied between the rollers 7c and 7 d. The guide roller 5e is in contact with the surface of the base material 42a of the laminate 42 b. Further, a film-like polarizing element 38 is supplied between the rollers 7c and 7 d.
As shown in fig. 3 and (a) and (b) of fig. 4, in the bonding step of the second embodiment, the polarizing element 38 is sandwiched between the pair of laminates 44b and 42 b. The coating film 54a of the laminate 44b faces one surface of the polarizing element 38. The coating film 52a of the laminate 42b faces the other surface of the polarizing element 38. The laminate 44b, the polarizing element 38, and the laminate 42b are sandwiched between the pair of rollers 7c and 7d in an overlapping manner. As a result, as shown in fig. 4 (b), the substrate 44a is bonded to one surface of the polarizer 38 via the coating film 54a, and the substrate 42a is bonded to the other surface of the polarizer 38 via the coating film 52 a. That is, in the bonding step, the laminate 46a is obtained, which has: a substrate 42a, a coating film 52a overlapping the substrate 42a, a polarizing element 38 overlapping the coating film 52a, a coating film 54a overlapping the polarizing element 38, and a substrate 44a overlapping the coating film 54 a.
As shown in fig. 4, in the second embodiment, the stacked body 46a is transferred between the pair of rollers 7c and 7d along the direction d 46. In the curing step, the irradiation device 3a is used to indirectly irradiate the coating film 54a with the active energy ray L from the substrate 44a side, thereby curing the coating film 54 a. That is, the active energy ray L passes through the base material 44a to reach the coating film 54 a. At the same time, the irradiation device 3b is used to indirectly irradiate the active energy ray L from the substrate 42a side to the coating film 52a, thereby curing the coating film 52 a. That is, the active energy ray L passes through the base material 42a to reach the coating film 52 a. In the above curing step, the resin layer 52b is formed from the coating film 52a, and the resin layer 54b is formed from the coating film 54 a.
As shown in fig. 3 and 4 (b) and (c), in the second embodiment, the peeling step may be performed after the curing step. In the peeling step, the substrate 44a is peeled from the resin layer 54b of the laminate 46 a. In the peeling step, the guide roller 5f is in contact with the base 44a of the laminate 46 a. In the peeling step, the substrate 42a is peeled from the resin layer 52b of the laminate 46 a. In the peeling step, the guide roller 5g is in contact with the substrate 42a of the laminate 46 a. The laminate 46b peeled off from the substrates 42a and 44a is transferred in the direction d 46.
When the peeling step is performed, the polarizing plate does not include the substrate 42a or 44 a. For example, a polarizing plate completed through a peeling process includes at least: the resin layer 52b, the polarizing element 38 directly overlapping the resin layer 52b, and the other resin layer 54b directly overlapping the polarizing element 38. The polarizing plate may include another optical layer laminated on the resin layer 52b or 54 b. In addition, the substrate 42a or 44a may not be peeled off as long as the substrate 42a or 44a is not necessarily required in the subsequent process. By protecting the resin layer 52b with the substrate 42a, the occurrence of scratches or irregularities on the surface of the resin layer 52b can be suppressed. By protecting the resin layer 54b with the substrate 44a, the occurrence of scratches or irregularities on the surface of the resin layer 54b can be suppressed.
In the case of performing the peeling step, the substrates 42a and 44a, which are not subjected to the surface roughening treatment, may be used in the coating step.
In the second embodiment, only one of the substrates 42a and 44a may be peeled in the peeling step. When only one of the substrates 42a and 44a is peeled off, a substrate without surface roughening treatment may be used as the substrate on the side not peeled off in the coating step. In the second embodiment, the peeling step may not be performed. When the peeling step is not performed, a substrate subjected to surface roughening treatment may be used in the coating step. Substrates 42a and 44a are disposed on the outer surface of the completed polarizing plate without performing a peeling step. The polarizing plate may have another optical layer laminated on the substrate 42a or 44 a.
The first and second embodiments of the present invention have been described above, but the present invention is not limited to the above embodiments.
For example, the optical film on which the resin layer is formed may be another optical layer, not a polarizing element. For example, a resin layer can be formed on the surface of an optical layer such as a protective film, a reflective polarizing film, a film having an antiglare function, a film having a surface antireflection function, a reflective film, a transflective film, a viewing angle compensation film, a touch sensor layer, or a liquid crystal layer by the same method as when the resin layer is formed on the surface of the polarizing element.
(examples)
The present invention will be described in detail below by using examples and comparative examples, but the present invention is not limited to the following examples.
[ example 1]
(1) Primer layer Forming Process
Polyvinyl alcohol powder was dissolved in hot water at 95 ℃ to prepare a polyvinyl alcohol aqueous solution having a concentration of 3% by weight. As the polyvinyl alcohol powder, "Z-200" (average degree of polymerization 1100, degree of saponification 99.5 mol%) manufactured by Nippon synthetic chemical industry Co., Ltd was used. A crosslinking agent is mixed in a polyvinyl alcohol aqueous solution. The amount of the crosslinking agent added was adjusted to 5 parts by weight relative to 6 parts by weight of polyvinyl alcohol powder. As the crosslinking agent, "SUMIREZ resin 650" manufactured by TIAOKANG CHEMICAL INDUSTRY Co., Ltd. Through the above steps, a coating liquid (coating liquid 1) for forming a primer layer was obtained.
As a base film, an unstretched polypropylene film having a thickness of 90 μm (melting point: 163 ℃ C.) was prepared. One surface of the substrate film is subjected to corona treatment. The surface of the base material film subjected to the corona treatment was coated with the coating liquid 1 using a small-diameter gravure coater. The coating liquid applied to the substrate film was dried at 80 ℃ for 10 minutes, whereby a primer layer was formed. The thickness of the primer layer was 0.2 μm.
(2) Production of multilayer film (resin layer Forming step)
Polyvinyl alcohol powder was dissolved in hot water at 95 ℃ to prepare an aqueous polyvinyl alcohol solution having a concentration of 8% by weight. As the polyvinyl alcohol powder, "PVA 124" (average polymerization degree 2400 and saponification degree 98.0 to 99.0 mol%) manufactured by Korea, Ltd was used. The polyvinyl alcohol aqueous solution was used as a coating liquid (coating liquid 2) for forming a polyvinyl alcohol resin layer.
On the surface of the primer layer formed on the substrate film, the coating liquid 2 was applied using a lip coater. The coating liquid 2 applied to the surface of the primer layer was dried at 80 ℃ for 20 minutes, and thereby a polyvinyl alcohol resin layer was formed on the primer layer. Through the above steps, a laminated film formed of the base film, the primer layer overlapping with the base film, and the polyvinyl alcohol resin layer overlapping with the primer layer was obtained.
(3) Production of stretched film (stretching Process)
The free end of the laminated film was uniaxially stretched 5.3 times at 160 ℃ to obtain a stretched film. For stretching the laminated film, a floating type vertical uniaxial stretching apparatus was used. The thickness of the stretched polyvinyl alcohol resin layer was 5.0. mu.m.
(4) Production of polarizing multilayer film (dyeing step)
The stretched film was immersed in an aqueous solution of iodine and potassium iodide (dyeing solution) for about 180 seconds to dye the polyvinyl alcohol resin layer. The temperature of the staining solution was adjusted to 30 ℃. The weight of iodine in the dyeing liquid was adjusted to 0.6 parts by weight per 100 parts by weight of water. The weight of potassium iodide in the dyeing liquid was adjusted to 10 parts by weight per 100 parts by weight of water. After the dyeing treatment, the remaining dyeing liquid on the polyvinyl alcohol resin layer was washed with pure water at 10 ℃.
Next, in the first crosslinking treatment, the stretched film was immersed in an aqueous solution containing boric acid (first crosslinking liquid) for 120 seconds. The temperature of the first crosslinking liquid was adjusted to 78 ℃. The weight of boric acid in the first crosslinking liquid was adjusted to 9.5 parts by weight per 100 parts by weight of water.
Next, in the second crosslinking treatment, the stretched film was immersed in an aqueous solution (second crosslinking solution) containing boric acid and potassium iodide for 60 seconds. The temperature of the second crosslinking liquid was adjusted to 70 ℃. The weight of boric acid in the second crosslinking liquid was adjusted to 9.5 parts by weight per 100 parts by weight of water. The weight of potassium iodide in the second crosslinking liquid was adjusted to 4 parts by weight per 100 parts by weight of water.
After the second crosslinking treatment, the stretched film was washed in pure water at 10 ℃ for 10 seconds. The stretched film after cleaning was dried at 40 ℃.
Through the above steps, a polarizing laminated film comprising a base film and a film-like polarizing element superposed on the base film is obtained.
(5) Production of polarizing element with protective film
As the first protective film, a film made of a cellulose triacetate resin is prepared. The thickness of the first protective film was 25 μm. When the polarizing plate is disposed on the display unit, the first protective film is disposed on the outer side (the side opposite to the display unit).
The surface of the first protective film is subjected to corona treatment. An ultraviolet-curable adhesive is applied to the surface of the corona-treated first protective film to form a first adhesive layer. "KR-70T" manufactured by ADEKA (Inc.) was used as the ultraviolet-curable adhesive. The ultraviolet-curable adhesive was applied using a small-diameter gravure coater.
The first protective film is bonded to the surface of the polarizing element having the polarizing laminated film via the first adhesive layer. For the bonding of the first protective film, a pair of bonding rollers is used.
Next, the first adhesive layer was cured by irradiating ultraviolet rays from the polarizing laminated film side to the first adhesive layer using a high-pressure mercury lamp. The thickness of the cured first adhesive layer was 1.2 μm. The cumulative quantity of ultraviolet light was adjusted to 200mJ/cm2。
Through the above steps, a laminate is obtained, which is formed of a base film, a polarizing element stacked on the base film, a first adhesive layer stacked on the polarizing element, and a first protective film bonded to the polarizing element via the first adhesive layer. The polarizing element with the protective film is obtained by peeling the base material film from the laminate, the first pressure-sensitive adhesive layer overlapping the polarizing element, and the first protective film bonded to the polarizing element via the first pressure-sensitive adhesive layer.
(6) Manufacture of polarizing plate
(coating Process)
An epoxy resin, which is one of active energy ray-curable resins (ultraviolet-curable resins), is prepared for forming the protective layer. When the polarizing plate is arranged on the display unit, the protective layer is arranged on the side of the display unit. "KR-25T" manufactured by ADEKA, Inc. was used as the epoxy resin. As a transfer substrate, a film formed of a cyclic polyolefin resin film was prepared. The thickness of the transfer substrate was 20 μm. An epoxy resin is applied to the surface of a substrate using a small-diameter gravure coater, and a coating film of the epoxy resin is formed on the surface of the substrate.
(bonding step)
The transfer substrate is bonded to the surface of a polarizing element constituting the polarizing element with the protective film via a coating film. A laminating roller was used for lamination.
(curing step)
The coating film was irradiated with ultraviolet rays (active energy rays) from the transfer substrate side using a high-pressure mercury lamp. The coating film is cured by irradiation with ultraviolet rays to form a resin layer. The cumulative quantity of ultraviolet light irradiated onto the transfer substrate was adjusted to 200mJ/cm2. The wavelength of the ultraviolet light is 300 nm. The transmittance of ultraviolet rays in the transfer substrate is shown in table 1 below. The thickness of the resin layer was 3.5. mu.m.
(peeling step)
After the curing step, the transfer substrate is peeled from the resin layer.
Through the above steps, the polarizing plate of example 1 was produced, which had: the polarizing film includes a resin layer, a polarizing element overlapping with the resin layer, a first adhesive layer, and a first protective film bonded to the polarizing element with the first adhesive layer interposed therebetween.
Examples 1 to 3 and comparative example 1
Polarizing plates of other examples and comparative example 1 were produced in the same manner as in example 1, except that the transfer base material shown in table 1 below was used. The transmittance of ultraviolet rays in the transfer substrates used in the other examples and comparative example 1 is shown in table 1 below.
Comparative example 2
In the coating step of comparative example 2, an epoxy resin was directly applied to the surface of the polarizer constituting the polarizer with a protective film by using a small-diameter gravure coater to form a coating film.
In the curing step of comparative example 2, the coating film formed on the surface of the polarizer was directly irradiated with ultraviolet rays, and a resin layer was formed on the surface of the polarizer.
As described above, the polarizing plate of comparative example 2 was produced in the same manner as in example 1, except that the resin layer was formed without using the transfer substrate.
< observation of the surface of the resin layer >
The polarizing plate of example 1 was cut to prepare a sample. The sample size was 500mm by 500 mm. The sample was placed under a fluorescent lamp, and the surface of the resin layer of the sample was aligned with light. The reflected image of the light on the surface of the resin layer was observed. The observation results are shown in table 1 below.
The surfaces of the resin layers of the other examples and comparative examples were observed by the same method as in example 1. The observation results are shown in table 1 below. A in Table 1 below means that no scratches or irregularities were observed on the surface of the resin layer. B means that irregularities are found on the surface of the resin layer. C means that a flaw was found on the surface of the resin layer.
[ TABLE 1]
Figure BDA0001113930360000201
(availability in industry)
According to the present invention, a laminated optical film can be produced which can suppress damage to the surface of an optical film and the surface of a resin layer superposed on the optical film.

Claims (3)

1. A method of manufacturing a laminated optical film,
which comprises a coating step, a bonding step, a curing step, and a peeling step,
in the coating step, a coating film containing an active energy ray-curable resin is formed on the surface of the film-like substrate that has not been subjected to the corona treatment,
in the bonding step, the substrate is bonded to the surface of the optical film via the coating film,
in the curing step, the coating film is irradiated with an active energy ray from the substrate side to form a resin layer from the coating film,
in the peeling step, the substrate is peeled from the resin layer,
the substrate has a transmittance of the active energy ray of 70% or more, the substrate is a cyclic polyolefin resin or an acrylic resin, and the resin layer is a protective layer for protecting the optical film.
2. The method for manufacturing a laminated optical film according to claim 1, wherein the active energy ray is ultraviolet ray.
3. The method for producing a laminated optical film according to claim 1 or 2, wherein the active energy ray-curable resin is at least one selected from the group consisting of epoxy resins, acrylic resins, and oxetane resins.
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