CN107710038B - Method for manufacturing polarizing piece - Google Patents
Method for manufacturing polarizing piece Download PDFInfo
- Publication number
- CN107710038B CN107710038B CN201680037343.2A CN201680037343A CN107710038B CN 107710038 B CN107710038 B CN 107710038B CN 201680037343 A CN201680037343 A CN 201680037343A CN 107710038 B CN107710038 B CN 107710038B
- Authority
- CN
- China
- Prior art keywords
- polarizing
- polarizer
- adhesive layer
- exposed portion
- film
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Images
Classifications
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/80—Constructional details
- H10K59/8793—Arrangements for polarized light emission
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/02—Details
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- Physics & Mathematics (AREA)
- Nonlinear Science (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Mathematical Physics (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Polarising Elements (AREA)
- Liquid Crystal (AREA)
Abstract
The invention provides a method for manufacturing a polarizing element capable of realizing multifunction and high functionality of an electronic device such as an image display device, and capable of forming a desired non-polarizing part shape with high precision. The method for manufacturing the polarizing plate comprises the following steps: laminating a surface protection film on one surface side of the polarizer via an adhesive layer having a thickness of 10 μm or less to produce a polarizing film laminate having an exposed portion on the one surface side, the exposed portion exposing at least a part of the polarizer; a step of bringing the exposed portion of the polarizing film laminate into contact with an alkaline solution; and a step of removing the surface protection film from the polarizing film laminate.
Description
Technical Field
The present invention relates to a method for manufacturing a polarizing element. More particularly, the present invention relates to a method for manufacturing a polarizer having a non-polarizing portion.
Background
An image display device such as a mobile phone or a notebook computer (PC) may be mounted with internal electronic components such as a camera. Various studies have been made for the purpose of improving the camera performance of such an image display device (for example, patent documents 1 to 7). However, with the rapid spread of smart phones and touch panel type information processing devices, further improvements in camera performance and the like are desired. In order to cope with diversification of shapes and high functionality of image display devices, a polarizing plate having partial polarizing performance is required. In order to industrially and commercially realize these demands, it is desired to manufacture the image display device and/or its components at an acceptable cost, and there are various matters to be studied in order to obtain such a technique.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2011-81315
Patent document 2: japanese patent laid-open publication No. 2007-241314
Patent document 3: U.S. patent application publication No. 2004/0212555 specification
Patent document 4: korean laid-open patent No. 10-2012-0118205
Patent document 5: korean patent No. 10-1293210
Patent document 6: japanese laid-open patent publication No. 2012-137738
Patent document 7: japanese patent laid-open publication No. 2014-211548
Disclosure of Invention
Problems to be solved by the invention
The present invention has been made to solve the above-described conventional problems, and a main object thereof is to provide a method for manufacturing a polarizing plate capable of realizing multi-functionalization and high-functionalization of an electronic device such as an image display device, which can form a desired shape of a non-polarizing portion with high accuracy.
Means for solving the problems
The method for manufacturing the polarizing plate comprises the following steps: laminating a surface protection film on one surface side of the polarizer via an adhesive layer having a thickness of 10 μm or less to produce a polarizing film laminate having an exposed portion on the one surface side, the exposed portion exposing at least a part of the polarizer; a step of bringing the exposed portion of the polarizing film laminate into contact with an alkaline solution; and a step of removing the surface protection film from the polarizing film laminate.
In one embodiment, the step of contacting the exposed portion with an alkaline solution includes immersing the polarizing film laminate in an alkaline solution.
In one embodiment, the pressure-sensitive adhesive layer contains an acrylic resin.
In one embodiment, the method further includes a step of bringing the exposed portion of the polarizing film laminate into contact with an acidic solution.
In one embodiment, the step of contacting the exposed portion with an acidic solution includes immersing the polarizing film laminate in an acidic solution.
In one embodiment, the step of contacting the exposed portion with an alkaline solution includes immersing the polarizing film laminate in an alkaline solution, and the step of contacting the exposed portion with an acidic solution includes immersing the polarizing film laminate in an acidic solution.
In one embodiment, the polarizing film laminate is long.
In another aspect of the present invention, a polarizer is produced. The polarizer is manufactured by the manufacturing method.
In another embodiment of the present invention, a polarizing plate is produced. The polarizing plate comprises the polarizing piece.
In still another aspect of the present invention, an image display device is provided. The image display device comprises the polarizing plate.
ADVANTAGEOUS EFFECTS OF INVENTION
The polarizing film laminate used in the production method of the present invention has a surface protective film laminated on one surface of the polarizer via an adhesive layer having a thickness of 10 μm or less. By using such a polarizing film laminate, a non-polarizing portion having a desired shape can be formed with high accuracy.
Drawings
Fig. 1 is a schematic cross-sectional view of a polarizing film laminate used in one embodiment of the present invention.
Fig. 2A is a schematic plan view illustrating an example of the arrangement pattern of through-holes in the surface protection film used in one embodiment of the present invention.
Fig. 2B is a schematic plan view illustrating another example of the arrangement pattern of the through-holes of the surface protection film used in one embodiment of the present invention.
Fig. 2C is a schematic plan view illustrating another example of the arrangement pattern of the through-holes of the surface protection film used in one embodiment of the present invention.
Fig. 3A is a schematic diagram illustrating a method of measuring hole roughness. It shows a distance a between the unpolarized section and the approximate circle of the unpolarized section when the boundary (solid line) between the polarizer 1 and the unpolarized section 2 is located outside the approximate circle (broken line) of the unpolarized section.
Fig. 3B is a schematic diagram illustrating a method of measuring the roughness of the hole. It shows the distance b between the unpolarized section and the approximate circle of the unpolarized section when the boundary (solid line) between the polarizer 1 and the unpolarized section 2 is located inside the approximate circle (broken line) of the unpolarized section.
Detailed Description
Hereinafter, one embodiment of the present invention will be described, but the present invention is not limited to this embodiment.
A. Method for manufacturing polarizing piece
The manufacturing method of the present invention includes: laminating a surface protection film on one surface side of the polarizer via an adhesive layer having a thickness of 10 μm or less to produce a polarizing film laminate having an exposed portion on the one surface side, the exposed portion exposing at least a part of the polarizer; a step of bringing the exposed portion of the polarizing film laminate into contact with an alkaline solution; and a step of removing the surface protection film from the polarizing film laminate. By using the polarizing film laminate having the exposed portion, only a desired portion of the polarizer (i.e., the portion exposed from the exposed portion) can be brought into contact with the alkaline solution. By bringing the polarizing material into contact with an alkaline solution, the content of the dichroic material contained in the contact portion can be reduced, and thus a non-polarizing portion having a lower content of the dichroic material than other portions can be formed.
In the production method of the present invention, a polarizing film laminate is used in which a polarizer and a surface protection film are laminated via an adhesive layer having a thickness of 10 μm or less. By setting the thickness of the adhesive layer to 10 μm or less, bubbles can be prevented from adhering to the exposed portion by the surface tension of the adhesive. As a result, the alkaline solution sufficiently contacts the entire exposed portion, and the non-polarized light portion having a desired shape can be formed with high accuracy. The polarizer before forming the non-polarizing portion is strictly speaking an intermediate of the polarizer having the non-polarizing portion obtained by the production method of the present invention, but is simply referred to as a polarizer in the present specification. When the person skilled in the art is aware of the description of the present specification, it can be easily understood whether the "polarizer" refers to an intermediate or a polarizer having a non-polarizing portion produced by the production method of the present invention.
A-1 preparation of polarizing film laminate
A polarizing film laminate is produced by laminating a surface protective film on one surface side of a polarizer via an adhesive layer having a thickness of 10 μm or less. The polarizing film laminate used in the present invention has an exposure portion that exposes at least a part of the polarizer on the one surface side.
Fig. 1 is a schematic cross-sectional view of a polarizing film laminate used in one embodiment of the present invention. In this embodiment mode, a polarizing plate having a structure of a polarizer/protective film is used. The polarizing film laminate 100 is obtained by laminating a surface protective film 50 on the surface of a polarizer 10 of a laminate of a polarizer 10 and a protective film 20 via an adhesive layer 60 having a thickness of 10 μm or less. The surface protective film 50 has through-holes 71. The polarizing film laminate 100 has an exposure portion 51 through which the polarizer 10 is exposed from the through hole 71. The surface protective film 50 is releasably laminated on the polarizing plate (substantially, the polarizing element 10). It goes without saying that polarizers having forms other than the polarizing plate form (for example, a polarizer of a single resin film, or a laminate of a resin base material and a polarizer) may be used in the same order.
In one embodiment, the polarizing film laminate 100 may further include another surface protection film (the surface protection film 30 in fig. 1) on the surface on which the surface protection film 50 having the through-holes is not stacked. Hereinafter, the surface protection film 50 having the through-holes is also referred to as a first surface protection film, and the surface protection film 30 laminated on the side of the polarizing film laminate 100 on which the surface protection film having the through-holes is not laminated is also referred to as a second surface protection film.
The polarizing film laminate is typically in a long shape. The long polarizing film laminate can be produced, for example, by laminating a long surface protection film having through holes arranged at predetermined intervals in the longitudinal direction and/or the width direction and a long polarizer. By using a long polarizing film laminate, for example, a step of contacting with an alkaline solution and a step of contacting with another treatment liquid (for example, a step of contacting with an acidic solution) can be continuously performed by immersion. As a result, the productivity of the polarizing plate can be further improved. The long polarizing film laminate may have a plurality of exposed portions. In this case, the alkaline solution can be brought into sufficient contact with each exposed portion, and the non-polarized light portion having a desired shape can be formed with high accuracy.
Further, by using the polarizing film laminate, a polarizing material having a non-polarizing portion can be produced in a pattern corresponding to the exposed portion pattern, and therefore the non-polarizing portion can be precisely controlled and arranged over the entire long polarizing material. As a result, when a polarizing material of a predetermined size as a final product is cut from the long polarizing material, the variation in quality among the final products can be significantly controlled. In addition, since such a non-polarizing portion is selectively and easily formed at the position of the through-hole, a complicated apparatus and operation are not required. Further, according to the present embodiment, the position of the non-polarizing portion can be set in accordance with the size of the polarizing material cut out and mounted on the image display device as a final product and the position of the camera portion of the image display device, and therefore, the yield in manufacturing a polarizing material having a predetermined size is excellent.
A-1-1. polarizer
The polarizer is typically made of a resin film containing a dichroic material. The resin film is, for example, a polyvinyl alcohol resin (hereinafter referred to as "PVA resin") film. Examples of the dichroic substance include iodine and an organic dye. These dichroic substances may be used alone, or 2 or more kinds may be used in combination. Iodine is preferably used. This is because the iodine complex can be reduced to reduce the iodine content by contacting with an alkaline solution as described later, and as a result, a non-polarizing portion having characteristics suitable for use as a portion of a camera can be formed.
As the resin for forming the resin film, any appropriate resin can be used. A PVA-based resin is preferably used. Examples of the PVA-based resin include: polyvinyl alcohol, ethylene-vinyl alcohol copolymer. Polyvinyl alcohol can be produced by saponifying polyvinyl acetate. The ethylene-vinyl alcohol copolymer can be produced by saponifying an ethylene-vinyl acetate copolymer. The saponification degree of the PVA resin is usually 85 mol% or more and less than 100 mol%, preferably 95.0 mol% to 99.95 mol%, and more preferably 99.0 mol% to 99.93 mol%. The degree of saponification can be determined in accordance with JIS K6726-. By using the PVA-based resin having such a saponification degree, a polarizing plate having excellent durability can be obtained. If the saponification degree is too high, gelation may occur.
The average polymerization degree of the PVA-based resin may be appropriately selected depending on the purpose. The average polymerization degree is usually 1000 to 10000, preferably 1200 to 4500, and more preferably 1500 to 4300. The average polymerization degree can be determined in accordance with JIS K6726-.
The thickness of the polarizer (resin film) may be set to any appropriate value. The thickness is preferably 30 μm or less, more preferably 25 μm or less, still more preferably 20 μm or less, and particularly preferably less than 10 μm. On the other hand, the thickness is preferably 0.5 μm or more, and more preferably 1 μm or more. When the thickness is such a thickness, the non-polarizing portion can be formed favorably by contacting with an alkaline solution. In addition, the time for contacting the alkaline solution can be shortened. In addition, the thickness of the portion that contacts the alkaline solution may be thinner than the other portions. By using a thin resin film, the difference in thickness between the portion exposed to the alkaline solution and the portion not exposed to the alkaline solution can be reduced, and the bonding to other components such as a protective film can be performed well.
The resin film is preferably subjected to various treatments such as a swelling treatment, a stretching treatment, a dyeing treatment with the dichroic substance, a crosslinking treatment, a cleaning treatment, and a drying treatment, and is brought into a state capable of functioning as a polarizing element. When various treatments are performed, the resin film may be a resin layer formed on the substrate. The laminate of the substrate and the resin layer can be produced, for example, by a method of applying a coating solution containing the above-mentioned material for forming a resin film on the substrate, a method of laminating a resin film on the substrate, or the like.
The dyeing treatment is performed by, for example, immersing the resin film in a dyeing solution. As the staining solution, an aqueous iodine solution is preferably used. The amount of iodine blended is preferably 0.04 to 5.0 parts by weight with respect to 100 parts by weight of water. In order to increase the solubility of iodine in water, it is preferable to blend an iodide in the aqueous iodine solution. As iodide, potassium iodide is preferably used. The amount of the iodide blended is preferably 0.3 to 15 parts by weight relative to 100 parts by weight of water.
In the above stretching treatment, the resin film is typically uniaxially stretched 3 to 7 times. In addition, the stretching direction may correspond to the absorption axis direction of the manufactured polarizer.
A-1-2. surface protective film
The surface protection film 50 is provided with through-holes 71, and the through-holes 71 correspond to portions of the produced polarizing material to be brought into contact with the alkaline solution (i.e., portions corresponding to the exposed portions 51 of the polarizing film laminate).
The planar shape of the through-hole of the surface protective film may be any appropriate shape according to the purpose. Specific examples thereof include: circular, oval, square, rectangular, diamond. As described above, according to the manufacturing method of the present invention, since it is possible to prevent the polarizer exposed from the exposed portion from being insufficiently contacted with the alkaline solution due to the adhesion of the air bubbles, the non-polarized light portion having a desired shape can be formed even in the exposed portion having a more complicated shape (for example, star shape) and/or a small size.
The through-hole of the surface protective film may be formed, for example, by mechanical blanking (e.g., punching, graver blanking, plotter, water jet) or by removing a prescribed portion of the surface protective film (e.g., laser ablation or chemical dissolution).
The arrangement pattern (formation pattern) of the through holes can be set appropriately according to the purpose. Fig. 2A is a schematic plan view illustrating an example of the arrangement pattern of the through-holes of the surface protective film, fig. 2B is a schematic plan view illustrating another example of the arrangement pattern of the through-holes, and fig. 2C is a schematic plan view illustrating still another example of the arrangement pattern of the through-holes. For example, as shown in fig. 2A, the through holes 71 may be arranged at substantially equal intervals in both the longitudinal direction and the width direction of the surface protective film 50. The phrase "substantially equally spaced in both the longitudinal direction and the width direction" means that the intervals in the longitudinal direction are equally spaced, and the intervals in the width direction are equally spaced, but the intervals in the longitudinal direction and the intervals in the width direction are not necessarily equal. For example, when the longitudinal interval is L1 and the width interval is L2, L1 may be L2, or L1 may be L2. Alternatively, the through holes may be arranged at substantially equal intervals in the longitudinal direction and at different intervals in the width direction; may be disposed at different intervals in the longitudinal direction and at substantially equal intervals in the width direction (both not shown). When the through-holes are arranged at different intervals in the longitudinal direction or the width direction, the intervals between adjacent through-holes may be different entirely or only partially (the interval between specific adjacent through-holes). Further, a plurality of regions may be defined in the longitudinal direction of the surface protective film, and the interval of the through-holes in the longitudinal direction and/or the width direction may be set in each region.
In one embodiment, as shown in fig. 2A, the through-holes 71 are arranged such that a straight line connecting through-holes adjacent in the longitudinal direction is substantially parallel to the longitudinal direction, and a straight line connecting through-holes adjacent in the width direction is substantially parallel to the width direction. In another embodiment, as shown in fig. 2B, the through-holes 71 are arranged such that a straight line connecting through-holes adjacent in the longitudinal direction is substantially parallel to the longitudinal direction, and a straight line connecting through-holes adjacent in the width direction has a predetermined angle θ with respect to the width directionW. In still another embodiment, as shown in fig. 2C, the through-holes 71 are arranged such that a straight line connecting through-holes adjacent in the longitudinal direction has a predetermined angle θ with respect to the longitudinal directionLAnd a straight line connecting the through-holes adjacent in the width direction has a predetermined angle theta with respect to the width directionW。θLAnd/or thetaWPreferably over 0 ° and below ± 10 °. Here, "±" means any direction including clockwise rotation and counterclockwise rotation with respect to the reference direction (the longitudinal direction or the width direction).
The embodiments shown in fig. 2B and 2C have the following advantages. Using stripsIn the case of forming a polarizing film laminate, the non-polarizing portion can be formed in a desired pattern (a pattern corresponding to the arrangement pattern of the through-holes) while roll-conveying. As a result, the arrangement pattern of the long polarizing material can be precisely controlled to form the non-polarizing portion. Here, in order to improve display characteristics of an image display device, it is sometimes necessary to dispose the absorption axis of the polarizer at a position shifted by about 10 ° at maximum with respect to the long side or the short side of the device. Since the absorption axis of the polarizer is positioned in the longitudinal direction or the width direction, by forming the non-polarizing portions in the pattern shown in fig. 2B and 2C, the positional relationship between the non-polarizing portions and the absorption axis can be uniformly controlled in the entire long polarizer, and a final product having excellent axis accuracy (and thus excellent optical characteristics) can be obtained. Therefore, the absorption axis direction of the single polarizing material cut (for example, cut or punched in the longitudinal direction and/or the width direction) can be precisely controlled to a desired angle, and variation in the absorption axis direction of each polarizing material can be remarkably suppressed. The arrangement pattern of the through-holes is not limited to the illustrated example. For example, the through-holes 71 may be arranged such that a straight line connecting through-holes adjacent in the longitudinal direction has a predetermined angle θ with respect to the longitudinal directionLAnd a straight line connecting through-holes adjacent in the width direction is substantially parallel to the width direction. Alternatively, a plurality of regions may be defined in the longitudinal direction of the surface protective film 50, and θ may be set in each regionLAnd/or thetaW。
The surface protective film is preferably a film having high hardness (e.g., elastic modulus). This is because deformation of the through-holes can be prevented, and particularly, deformation of the through-holes can be prevented during transportation and/or bonding when the polarizing film laminate in a long stripe form is used. Examples of the material for forming the surface protective film include: ester resins such as polyethylene terephthalate resins, cycloolefin resins such as norbornene resins, olefin resins such as polypropylene resins, polyamide resins, polycarbonate resins, and copolymer resins of these resins. Ester-based resins (particularly polyethylene terephthalate-based resins) are preferred. Such a material has an extremely high elastic modulus, prevents deformation of the through-hole, and has an advantage that the through-hole is less likely to be deformed even when tension is applied during transportation and/or bonding when the polarizing film laminate is used in a long-striped form.
The thickness of the surface protective film may be set to any appropriate value. For example, when used as a long polarizing film laminate, the thickness of the surface protective film is, for example, 30 μm to 150 μm, because the through-holes are less likely to be deformed even when tension is applied during transportation and/or bonding.
The elastic modulus of the surface protective film is preferably 2.2kN/mm2～4.8kN/mm2. When the elastic modulus of the surface protective film is within such a range, deformation of the through-holes can be prevented, and particularly when the surface protective film is used for producing a long-striped polarizing film laminate, there is an advantage that the through-holes are less likely to be deformed even if tension is applied during transportation and/or bonding. Further, the modulus of elasticity was measured in accordance with JIS K6781.
The tensile strength of the surface protective film is preferably 90% to 170%. When the tensile strength of the surface protective film is within such a range, there is an advantage that the surface protective film is not easily broken during transportation when used for producing a long-striped polarizing film laminate. Further, the tensile strength was measured in accordance with JIS K6781.
A-1-3 adhesive layer
The thickness of the pressure-sensitive adhesive layer 60 is 10 μm or less, preferably 5 μm or less. When the polarizing film laminate is used and contacted with the alkaline solution, air bubbles adhere to the surface protective film and the pressure-sensitive adhesive layer in the exposed portion, and the alkaline solution may not sufficiently contact the exposed portion. When the size of the exposed portion is small or the shape of the exposed portion is complicated, the influence becomes remarkable, and there is a possibility that a non-polarized portion having a desired shape cannot be formed. When the thickness of the adhesive layer is within such a range, bubbles can be prevented from adhering to the exposed portion by the surface tension of the adhesive. As a result, the exposed portion can be sufficiently contacted with the alkaline solution, and a polarizing plate having a non-polarizing portion of a desired shape can be obtained.
The adhesive layer may be formed using any suitable composition. The composition for forming an adhesive layer contains, for example, a resin component and any appropriate additive. Any suitable resin can be used as the base resin of the binder, and a resin having a glass transition temperature Tg of 0 ℃ or lower is preferable. Specific examples thereof include acrylic resins, silicone resins, rubber resins, and urethane resins. The acrylic resin is preferable because the lamination state of the surface protective film and the polarizer can be maintained well even if the thickness is 10 μm or less.
The acrylic resin is preferably an acrylic polymer containing at least 1 acrylic acid ester and/or methacrylic acid ester having an alkyl group having 1 to 14 carbon atoms (hereinafter, also referred to as a (meth) acrylate). The acrylic polymer preferably contains 50 to 100 wt% of (meth) acrylate having an alkyl group with 1 to 14 carbon atoms as a monomer component.
Examples of the (meth) acrylate having an alkyl group having 1 to 14 carbon atoms include: methyl (meth) acrylate, ethyl (meth) acrylate, n-butyl (meth) acrylate, t-butyl (meth) acrylate, isobutyl (meth) acrylate, hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, n-octyl (meth) acrylate, isooctyl (meth) acrylate, n-nonyl (meth) acrylate, isononyl (meth) acrylate, n-decyl (meth) acrylate, isodecyl (meth) acrylate, n-dodecyl (meth) acrylate, n-tridecyl (meth) acrylate, n-tetradecyl (meth) acrylate, and the like. These (meth) acrylates may be used alone in 1 kind, or in combination of 2 or more kinds.
Among them, (meth) acrylic esters having an alkyl group having 4 to 14 carbon atoms such as butyl (meth) acrylate, hexyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, n-octyl (meth) acrylate, isooctyl (meth) acrylate, n-nonyl (meth) acrylate, isononyl (meth) acrylate, n-decyl (meth) acrylate, isodecyl (meth) acrylate, n-dodecyl (meth) acrylate, n-tridecyl (meth) acrylate, and n-tetradecyl (meth) acrylate are preferably included. The adhesive force is easily controlled by the (methyl) acrylate containing the alkyl with the carbon number of 4-14, and the re-stripping property is excellent.
The acrylic polymer may contain any suitable monomer component other than the (meth) acrylate having an alkyl group with 1 to 14 carbon atoms. Examples of the other monomer components include: a monomer component contributing to improvement of cohesive force and heat resistance, such as a sulfonic acid group-containing monomer, a phosphoric acid group-containing monomer, a cyano group-containing monomer, vinyl esters, an aromatic vinyl compound, and a monomer component having a functional group that improves adhesive force or functions as a crosslinking base point, such as a carboxyl group-containing monomer, an acid anhydride group-containing monomer, a hydroxyl group-containing monomer, an amide group-containing monomer, an amino group-containing monomer, an epoxy group-containing monomer, N-acryloyl morpholine, a vinyl ether, and the like. Only 1 kind of the other monomer components may be used, or 2 or more kinds may be used in combination.
Examples of the sulfonic acid group-containing monomer include: styrenesulfonic acid, allylsulfonic acid, 2- (meth) acrylamide-2-methylpropanesulfonic acid, (meth) acrylamidopropanesulfonic acid, sulfopropyl (meth) acrylate, (meth) acryloyloxynaphthalenesulfonic acid, and the like. As the monomer having a phosphoric acid group, 2-hydroxyethyl acryloyl phosphate may be mentioned. The cyano group-containing monomer may be acrylonitrile. The vinyl ester is vinyl acetate. The aromatic vinyl compound may be styrene.
Examples of the carboxylic acid group-containing monomer include: (meth) acrylic acid, carboxyethyl (meth) acrylate, carboxypentyl (meth) acrylate, itaconic acid, maleic acid, fumaric acid, crotonic acid, and the like. Examples of the acid anhydride group-containing monomer include: maleic anhydride, itaconic anhydride, and the like. Examples of the hydroxyl group-containing monomer include: 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate, 6-hydroxyhexyl (meth) acrylate, 8-hydroxyoctyl (meth) acrylate, 10-hydroxydecyl (meth) acrylate, 12-hydroxylauryl (meth) acrylate, 4-hydroxymethylcyclohexyl) -methyl acrylate, N-methylol (meth) acrylamide, vinyl alcohol, allyl alcohol, 2-hydroxyethyl vinyl ether, 4-hydroxybutyl vinyl ether, diethylene glycol monoethyl ether, and the like. Examples of the amide group-containing monomer include acrylamide and diethylacrylamide. Examples of the amino group-containing monomer include N, N-dimethylaminoethyl (meth) acrylate, N-dimethylaminopropyl (meth) acrylate, and the like. Examples of the epoxy group-containing monomer include glycidyl (meth) acrylate and allyl glycidyl ether. Examples of the vinyl ether include vinyl ethyl ether.
For example, from the viewpoint of easy adjustment of the adhesive force, other monomer components may be used so that the Tg of the polymer obtained is 0 ℃ or less. Here, the Tg of the polymer is preferably at least-100 ℃.
The weight average molecular weight of the acrylic polymer is, for example, 10 ten thousand or more.
The acrylic polymer may be prepared by any suitable polymerization method. Examples of the polymerization method include a polymerization method generally used as a method for synthesizing an acrylic polymer, such as solution polymerization, emulsion polymerization, bulk polymerization, and suspension polymerization.
The composition for forming an adhesive layer may contain, as a resin component, a resin other than the base resin. Examples of the other resin include polyether resin, modified polyether resin, and epoxy resin. When other resin is contained, the content ratio of the other resin is preferably 20% by weight or less.
The pressure-sensitive adhesive layer-forming composition may contain any appropriate additive in addition to the resin component. Examples thereof include: crosslinking agents, coupling agents, adhesion promoters, surface lubricants, leveling agents, surfactants, antistatic agents, slip modifiers, wettability modifiers, antioxidants, preservatives, light stabilizers, ultraviolet absorbers, polymerization inhibitors, crosslinking accelerators, crosslinking catalysts, inorganic or organic fillers, powders such as metal powders and pigments, and granules or foils.
As the crosslinking agent, any suitable crosslinking agent can be used. Examples thereof include isocyanate compounds, epoxy compounds, aziridine compounds and melamine compounds. The crosslinking agent may be used alone, or 2 or more kinds may be used in combination.
The content of the crosslinking agent is preferably 0.1 to 15 parts by weight, more preferably 2 to 10 parts by weight, based on 100 parts by weight of the resin component.
The adhesive layer may be formed by any suitable method. Specific examples thereof include a method of applying and drying the adhesive-forming composition to the surface-protecting film, a method of forming an adhesive layer on a separator and transferring the adhesive layer to the surface-protecting film, and the like. Examples of the coating method include: roll coating methods such as reverse coating and gravure coating, spin coating, screen coating, fountain coating, dip coating, and spray coating.
In one embodiment, the first surface protective film is an adhesive sheet having an adhesive layer with a thickness of 10 μm or less. The first surface protection film in this embodiment is a laminate having a resin film used as the surface protection film and an adhesive layer provided on one surface of the resin film, and has a through-hole penetrating through the resin film and the adhesive layer. When the first surface protection film is an adhesive sheet, the long polarizing material and the long first surface protection film can be bonded to each other roll to roll, and therefore, the manufacturing efficiency can be further improved. In this embodiment, the separator is temporarily bonded to the adhesive in a peelable manner.
The separator has a function as a protective material for protecting the adhesive layer until it is put to practical use. Examples of the separator include: a plastic film (for example, polyethylene terephthalate (PET), polyethylene, or polypropylene), a nonwoven fabric, or paper, which is surface-coated with a release agent such as a silicone release agent, a fluorine release agent, or a long-chain alkyl acrylate release agent. The thickness of the spacer may be any appropriate thickness according to the purpose. The thickness of the separator is, for example, 10 μm to 100 μm. The separator may be laminated on a laminate of the resin film and the adhesive layer used as the surface protection film, or the adhesive layer may be formed on the separator and the laminate of the separator and the adhesive layer may be laminated on the resin film used as the surface protection film.
As described above, the polarizing film laminate 100 may further include the second surface protection film 30 on the side where the first surface protection film 50 is not disposed. The second surface protective film may be the same as the first surface protective film 50 except that no through-hole is provided. As the second surface protective film, a film which is soft (e.g., has a low elastic modulus) such as a polyolefin (e.g., polyethylene) film may be used. By using the second surface protective film, the polarizing plate (polarizer/protective film) can be further appropriately protected in the step of contacting with the alkaline solution, and as a result, the step of contacting the polarizer with the alkaline solution can be further favorably performed.
A-2. Process of contacting with an alkaline solution
Next, the alkaline solution is brought into contact with the exposed portion of the polarizing film laminate. The content of the dichroic substance in the exposed portion can be reduced by contacting with an alkaline solution, and the non-polarizing portion can be formed by reducing the content of the dichroic substance. As described above, the polarizer used in the polarizing film laminate is preferably a polarizer containing iodine. When the polarizer contains iodine as a dichroic material, the iodine content in the exposed portion can be reduced by bringing the exposed portion of the polarizer into contact with an alkaline solution, and as a result, the unpolarized portion can be selectively formed only in the exposed portion. Therefore, the non-polarizing portion can be selectively formed in a predetermined portion of the polarizer with very high manufacturing efficiency without involving complicated operations. When iodine remains in the polarizer, even if the iodine complex is broken to form the non-polarizing portion, the iodine complex is formed again with the use of the polarizer, and the non-polarizing portion may not have desired characteristics. In the present invention, iodine itself is removed from a polarizer (substantially non-polarizing portion). As a result, the characteristics of the non-polarizing portion can be prevented from being changed with the use of the polarizing member.
The step of bringing the polarizing film laminate into contact with the alkaline solution may be carried out by any appropriate means. Examples thereof include: dipping, dropping, coating, spraying, etc. As described above, by using the first surface protective film (and the second surface protective film used as needed), the iodine content in the polarizer is not reduced in the portion other than the exposed portion of the polarizing film laminate, and therefore, the non-polarizing portion can be formed only in a desired portion by immersion. Specifically, by immersing the polarizing film laminate in an alkaline solution, only the exposed portion of the polarizing film laminate is brought into contact with the alkaline solution.
The formation of the non-polarizing portion based on the alkaline solution is described in more detail below. After contacting the exposed portion of the polarizing film laminate, the alkaline solution permeates into the exposed portion (specifically, the polarizer). The iodine complex contained in the polarizer is reduced by the alkali contained in the alkaline solution to become iodide ions. When the iodine complex is reduced to iodide ions, the polarizing properties of the polarizer exposed from the exposed portion are substantially lost, and a non-polarizing portion is formed in the exposed portion. Further, the transmittance of the exposed portion can be improved by reducing the iodine complex. Iodine which becomes iodide ions moves from the exposed portion to the solvent of the alkaline solution. As a result, the iodide ions are also removed from the polarizer together with the alkaline solution. In this way, the unpolarized portion can be selectively formed in a predetermined portion of the polarizer, and the unpolarized portion can be further stabilized against a change with time. Further, by adjusting the material, thickness, and mechanical properties of the first surface protective film, the concentration of the alkaline solution, the immersion time of the polarizing film laminate in the alkaline solution, and the like, it is possible to prevent the alkaline solution from penetrating into an undesired portion (as a result, a non-polarizing portion is formed in the undesired portion).
As the basic compound contained in the basic solution, any appropriate basic compound can be used. Examples of the basic compound include: alkali metal hydroxides such as sodium hydroxide, potassium hydroxide, and lithium hydroxide, hydroxides of alkaline earth metals such as calcium hydroxide, inorganic alkali metal salts such as sodium carbonate, organic alkali metal salts such as sodium acetate, and ammonia water. The alkali compound contained in the alkali solution is preferably a hydroxide of an alkali metal, and more preferably sodium hydroxide, potassium hydroxide, or lithium hydroxide. By using an alkaline solution containing an alkali metal hydroxide, the iodine complex can be efficiently ionized, and the non-polarizing portion can be formed more easily. These basic compounds may be used alone in 1 kind, or in combination of 2 or more kinds.
As the solvent of the above-mentioned alkaline solution, any appropriate solvent can be used. Specifically, there may be mentioned: water, alcohols such as ethanol and methanol, ethers, benzene, chloroform, and mixed solvents thereof. The solvent is preferably water or alcohol in view of good migration of iodide ions into the solvent and easy removal of iodide ions.
The concentration of the alkaline solution is, for example, 0.01N to 5N, preferably 0.05N to 3N, and more preferably 0.1N to 2.5N. When the concentration of the alkaline solution is within such a range, the iodine content in the polarizer can be effectively reduced, and ionization of the iodine complex in the portion other than the exposed portion can be prevented.
The liquid temperature of the alkaline solution is, for example, 20 to 50 ℃. The contact time between the polarizing film laminate (substantially, the exposed portion of the polarizer) and the alkaline solution may be set according to the thickness of the polarizer, the kind of alkaline compound contained in the alkaline solution used, and the concentration of the alkaline compound, and is, for example, 5 seconds to 30 minutes.
The alkaline solution can be removed by any appropriate means as needed after contacting the exposed portion of the polarizer (after forming the non-polarizing portion). Specific examples of the method for removing the alkaline solution include: wiping with a wiper or the like, suction removal, natural drying, heat drying, air blow drying, reduced pressure drying, washing, and the like. The drying temperature when removing the alkaline solution by drying is, for example, 20 ℃ to 100 ℃.
A-3. removing Process of surface protective film
After the necessary steps are performed, the surface protective film can be removed from the polarizing film laminate. As described above, the surface protective film is releasably adhered to the surface of the polarizing member via the adhesive layer. Therefore, after the steps necessary for producing a polarizer having a non-polarizing portion are performed, the polarizer can be easily removed from the surface of the polarizer.
A-4. other procedures
The method for producing a non-polarizing portion having a non-polarizing portion of the present invention may further include any suitable step other than the steps of producing the polarizing film laminate, bringing the exposed portion of the polarizing film laminate into contact with an alkaline solution, and removing the surface protective film. Examples of the other steps include a step of contacting with an acidic solution and a cleaning step.
A-4-1. step of contacting with an acidic solution
The production method of the present invention may further include a step of bringing the polarizing film laminate into contact with an acidic solution. By further including a step of contacting with an acidic solution, the non-polarized light section having a desired size and shape can be maintained more stably (particularly in a humidified environment). The step of contacting with the acidic solution may be performed after the step of contacting with the alkaline solution.
Any suitable acidic compound can be used as the acidic compound contained in the acidic solution. Examples of the acidic compound include: inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, and hydrogen fluoride, and organic acids such as formic acid, oxalic acid, citric acid, acetic acid, and benzoic acid. The concentration of the acidic solution is, for example, 0.01N to 5N, preferably 0.05N to 3N, and more preferably 0.1N to 2.5N.
The solvent used in the acidic solution, the temperature of the acidic solution, the time of contact with the acidic solution, and the method of contact may be the same as those used in the step of contact with the basic solution described in the above item A-2.
The step of contacting with the acidic solution is preferably performed before the step of peeling the surface protective film (specifically, in a state of a polarizing film laminate). By carrying out the process in the state of the polarizing film laminate, the step of contacting the polarizing film laminate with an alkaline solution and the step of contacting the polarizing film laminate with an acidic solution can be continuously carried out.
A-4-2. cleaning Process
The manufacturing method of the present invention may further include a cleaning process. The washing step may be performed only 1 time or may be performed a plurality of times. The cleaning step may be performed at any appropriate stage in the process of manufacturing a polarizer having a non-polarizing portion. For example, the step of contacting with the acidic solution may be performed after the polarizer in contact with the alkaline solution is washed with any suitable liquid, or the step of washing with any suitable liquid may be performed after the step of contacting with the alkaline solution and the step of contacting with the acidic solution are performed.
Any suitable liquid may be used for the liquid used in the cleaning. Examples thereof include: pure water, alcohols such as methanol and ethanol, acidic aqueous solutions, and mixed solvents of these liquids. In addition, the temperature of the liquid used may be set to any appropriate temperature.
B. Polarizing element having non-polarizing portion
The polarizer produced by the method of the present invention can have a non-polarizing portion of a desired shape and size formed with high precision. Therefore, the polarizing plate of the present invention can have excellent functionality and design.
A polarizer having a non-polarizing portion is useful for an image display device having a camera, for example. This is because the camera can sufficiently exhibit an imaging function even when the non-polarized light section having a smaller size is formed, and the appearance of the image display device to be manufactured is excellent.
The planar shape of the non-polarizing portion may be any appropriate shape as long as it does not adversely affect the camera performance of the image display device. The transmittance of the non-polarizing portion (for example, the transmittance measured by light having a wavelength of 550nm at 23 ℃) is preferably 50% or more, more preferably 60% or more, still more preferably 75% or more, and particularly preferably 90% or more. Such a transmittance ensures desired transparency as a non-polarizing portion. As a result, when the polarizing member is disposed so that the non-polarizing portion corresponds to the camera portion of the image display device, adverse effects on the imaging performance of the camera can be prevented.
The non-polarizing portion is a portion having a smaller content of dichroic material than other portions of the polarizing member (portions having polarizing properties). The content of the dichroic material in the non-polarizing portion is preferably 1.0 wt% or less, more preferably 0.5 wt% or less, and still more preferably 0.2 wt% or less. The lower limit of the content of the dichroic material in the non-polarizing portion is usually equal to or lower than the detection limit. When the content of the dichroic substance in the non-polarizing portion is within such a range, not only can the desired transparency be imparted to the non-polarizing portion, but also when the non-polarizing portion is used as a portion corresponding to a camera of an image display device, extremely excellent image pickup performance can be realized from the viewpoint of both brightness and color tone. When iodine is used as the dichroic material, the iodine content in the non-polarizing portion is a value obtained from the X-ray intensity measured by fluorescent X-ray analysis using a calibration curve prepared in advance using a standard sample.
The difference between the content of the dichroic material contained in the portion other than the non-polarizing portion (portion having polarizing properties) of the polarizer and the content of the dichroic material contained in the non-polarizing portion is preferably 0.5% by weight or more, and more preferably 1% by weight or more. By setting the difference between the content of the dichroic material contained in the portion other than the non-polarizing portion and the content of the dichroic material contained in the non-polarizing portion within such a range, the non-polarizing portion has sufficient transparency, and for example, the non-polarizing portion can be suitably used as a portion corresponding to a camera for image display.
C. Polarizing plate
The polarizer may be provided in the form of a polarizing plate in practical use. The polarizing plate has a polarizer and a protective film disposed on at least one side of the polarizer. In practice, the polarizing plate has an adhesive layer as the outermost layer. The adhesive layer is typically the outermost layer on the image display device side. Temporarily bonding the separator on the adhesive layer in a peelable manner.
Examples of the material for forming the protective film include: cellulose resins such as cellulose diacetate and cellulose triacetate, (meth) acrylic resins, cycloolefin resins, olefin resins such as polypropylene, ester resins such as polyethylene terephthalate resins, polyamide resins, polycarbonate resins, and copolymer resins of these resins. The thickness of the protective film is preferably 10 μm to 100 μm. The protective film is typically laminated on the polarizer via an adhesive layer (specifically, an adhesive layer or a pressure-sensitive adhesive layer). The adhesive layer is typically formed of a PVA-based adhesive or an active energy ray-curable adhesive. The adhesive layer is typically formed of an acrylic adhesive.
The polarizing plate may further have any appropriate optical function layer according to the purpose. Typical examples of the optical functional layer include a retardation film (optical compensation film) and a surface treatment layer. The protective film may have an optical compensation function (specifically, may have a refractive index ellipsoid, an in-plane retardation, and a thickness direction retardation which are appropriately set according to the purpose).
The surface treatment layer can be arranged on the identification side of the polarizing plate. Typical examples of the surface treatment layer include a hard coat layer, an antireflection layer, and an antiglare layer.
D. Image display device
The image display device of the present invention has the above-described polarizing member. Examples of the image display device include: liquid crystal display device, organic EL device. Specifically, the liquid crystal display device includes a liquid crystal panel including a liquid crystal cell and the polarizer disposed on one side or both sides of the liquid crystal cell. The organic EL device has an organic EL panel in which the polarizing element is arranged on the viewing side. The polarizer may be disposed so that the non-polarizing portion corresponds to a camera portion of the image display device mounted thereon.
Examples
The present invention will be described in more detail with reference to the following examples, but the present invention is not limited to these examples.
Production example 1 production of surface protection film 1 having pressure-sensitive adhesive layer
An acrylic adhesive 1 was prepared by mixing 100 parts by weight of an acrylic resin (an acrylic polymer having a weight average molecular weight of 60 ten thousand and having a composition ratio of butyl acrylate/acrylic acid of 95/5) and 5 parts by weight of an epoxy-based crosslinking agent (product name: TETRAD-C, manufactured by MITSUBISH GAS CHEMICAL).
The obtained acrylic adhesive was applied to a 38 μm thick PET FILM (trade name: Diafil T100C, manufactured by MITSUBISH CHEMICALPHYESTER FILM) in a long form (width 1200mm, length 43m) so that the thickness after drying was 10 μm, thereby forming an adhesive layer. The separator was bonded to the formed adhesive layer to obtain an adhesive sheet. On the prepared adhesive sheet, 1000 circular small holes having a diameter of 2mm were formed using a sharp Knife (Pinnacle Knife). The small holes were formed at intervals of 250mm in the longitudinal direction and 400mm in the transverse direction, to obtain a surface protective film 1 having an adhesive layer.
Production example 2 production of surface protection film 2 having pressure-sensitive adhesive layer
A surface protection film 2 having an adhesive layer was produced in the same manner as in production example 1, except that the thickness of the adhesive layer was set to 5 μm.
Production example 3 production of surface protective film C1 having adhesive layer
A surface protection film C1 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 1, except that the thickness of the pressure-sensitive adhesive layer was changed to 30 μm.
Production example 4 production of surface protective film C2 having adhesive layer
A surface protection film C2 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 1, except that the thickness of the pressure-sensitive adhesive layer was 20 μm.
Production example 5 production of surface protective film C3 having adhesive layer
A surface protection film C3 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 1, except that the thickness of the pressure-sensitive adhesive layer was changed to 15 μm.
Production example 6 production of surface protective film 3 having adhesive layer
An acrylic adhesive 2 was prepared by mixing 100 parts by weight of an acrylic resin (an acrylic polymer having a weight average molecular weight of 50 ten thousand formed from a composition ratio of 2-ethylhexyl acrylate/2-hydroxyethyl acrylate: 96/4) and 4 parts by weight of an isocyanate crosslinking agent (product name: CORONATE HX, manufactured by NIPPON POLYURETHANE resin).
The obtained acrylic pressure-sensitive adhesive was applied to a 38 μm-thick PET film (trade name: E5000, manufactured by Toyo Boseki Co., Ltd.) in a long form (width 1200mm, length 43m) so that the thickness after drying was 10 μm, thereby forming a pressure-sensitive adhesive layer. The separator was bonded to the formed adhesive layer to obtain an adhesive sheet. On the prepared adhesive sheet, 1000 circular small holes having a diameter of 2mm were formed using a sharp knife. The small holes were formed at intervals of 250mm in the longitudinal direction and 400mm in the transverse direction, to obtain a surface protective film 3 having an adhesive layer.
Production example 7 production of surface protective film 4 having adhesive layer
A surface protection film 4 having an adhesive layer was produced in the same manner as in production example 6, except that the thickness of the adhesive layer was set to 5 μm.
Production example 8 production of surface protective film C4 having adhesive layer
A surface protection film C4 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 6, except that the thickness of the pressure-sensitive adhesive layer was changed to 30 μm.
Production example 9 production of surface protective film C5 having adhesive layer
A surface protection film C5 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 6, except that the thickness of the pressure-sensitive adhesive layer was 20 μm.
Production example 10 production of surface protective film C6 having adhesive layer
A surface protection film C6 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 6, except that the thickness of the pressure-sensitive adhesive layer was changed to 15 μm.
Production example 11 production of surface protection film 5 having pressure-sensitive adhesive layer
A surface protection film 5 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 1, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 12 production of surface protective film 6 having pressure-sensitive adhesive layer
A surface protection film 6 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 2, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 13 production of surface protective film C7 having pressure-sensitive adhesive layer
A surface protection film C7 having a pressure-sensitive adhesive layer was obtained in the same manner as in production example 3, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 14 production of surface protective film C8 having adhesive layer
A surface protection film C8 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 4, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 15 production of surface protective film C9 having adhesive layer
A surface protection film C9 having a pressure-sensitive adhesive layer was obtained in the same manner as in production example 5, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 16 production of surface protective film 7 having adhesive layer
A surface protection film 7 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 6, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 17 production of surface protective film 8 having adhesive layer
A surface protection film 8 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 7, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 18 production of surface protective film C10 having adhesive layer
A surface protection film C10 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 8, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 19 production of surface protective film C11 having adhesive layer
A surface protection film C11 having a pressure-sensitive adhesive layer was obtained in the same manner as in production example 9, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
Production example 20 production of surface protective film C12 having adhesive layer
A surface protection film C12 having a pressure-sensitive adhesive layer was produced in the same manner as in production example 10, except that the diameter of the pinhole formed in the pressure-sensitive adhesive sheet was set to 4 mm.
< example 1>
As the substrate, a long film (thickness: 100 μm) of amorphous polyethylene terephthalate isophthalate copolymer (IPA-copolymerized PET) having a water absorption of 0.75% and a Tg of 75 ℃ was used. On one side of the substrate, a corona treatment was carried out and on this corona-treated side, a coating was applied at 25 ℃ with a 9: a laminate was prepared by drying an aqueous solution containing polyvinyl alcohol (polymerization degree 4200, saponification degree 99.2 mol%) and acetoacetyl-modified PVA (polymerization degree 1200, acetoacetyl-modified degree 4.6%, saponification degree 99.0 mol% or more, product name "GOHSEFIMER Z200" manufactured by Nippon synthetic chemical industries Co., Ltd.) at a ratio of 1 to form a PVA-based resin layer having a thickness of 11 μm.
The obtained laminate was subjected to free-end uniaxial stretching in the longitudinal direction (longitudinal direction) between rolls having different peripheral speeds in an oven at 120 ℃ (air-assisted stretching).
Next, the laminate was immersed in an insolubilization bath (an aqueous boric acid solution prepared by adding 4 parts by weight of boric acid to 100 parts by weight of water) at a liquid temperature of 30 ℃ for 30 seconds (insolubilization treatment).
Then, the polarizing plate was immersed in a dyeing bath at a liquid temperature of 30 ℃ for a predetermined period of time while adjusting the iodine concentration, so that the polarizing plate had a predetermined transmittance. In this example, the resultant was immersed in an aqueous iodine solution prepared by compounding 0.2 parts by weight of iodine and 1.5 parts by weight of potassium iodide with respect to 100 parts by weight of water for 60 seconds (dyeing treatment).
Subsequently, the substrate was immersed for 30 seconds in a crosslinking bath (an aqueous boric acid solution prepared by adding 3 parts by weight of potassium iodide and 3 parts by weight of boric acid to 100 parts by weight of water) at a liquid temperature of 30 ℃ (crosslinking treatment).
Then, the laminate was uniaxially stretched in the longitudinal direction (longitudinal direction) between rolls having different peripheral speeds so that the total stretching ratio was 5.5 times (underwater stretching) while being immersed in an aqueous boric acid solution (aqueous solution prepared by blending 4 parts by weight of boric acid and 5 parts by weight of potassium iodide with respect to 100 parts by weight of water) having a liquid temperature of 70 ℃.
Then, the laminate was immersed in a cleaning bath (aqueous solution prepared by adding 4 parts by weight of potassium iodide to 100 parts by weight of water) at a liquid temperature of 30 ℃ (cleaning treatment).
Then, an aqueous PVA resin solution (product name "GOHSEFIMER (registered trademark) Z-200", manufactured by Nippon synthetic chemical industries, Ltd., resin concentration: 3% by weight) was applied onto the surface of the PVA resin layer of the laminate, and a protective film (thickness: 25 μm) was laminated thereon, followed by heating in an oven maintained at 60 ℃ for 5 minutes. Then, the substrate was peeled from the PVA resin layer to obtain a polarizing plate (width: 1200mm, length: 43m) having a polarizer with a transmittance of 42.3% and a thickness of 5 μm.
Next, the surface protective film 1 having the pressure-sensitive adhesive layer from which the separator was peeled was bonded to the polarizer-side surface of the obtained polarizing plate via a pressure-sensitive adhesive layer, thereby obtaining a laminate. The obtained laminate was immersed in an alkaline solution (aqueous sodium hydroxide solution, 1mol/L (1N)) at room temperature for 8 seconds and 0.1mol/L (0.1N) hydrochloric acid for 30 seconds, respectively. Then, the film was dried at 60 ℃ and the PET film was peeled off to obtain a polarizing plate comprising a polarizing element having a transparent portion.
[ examples 2 to 8]
A polarizing plate including a polarizer having a transparent portion was produced in the same manner as in example 1, except that the surface protection films having the pressure-sensitive adhesive layers described in table 1 were used.
Comparative examples 1 to 12
A polarizing plate including a polarizer having a transparent portion was produced in the same manner as in example 1, except that the surface protection films having the pressure-sensitive adhesive layers described in table 1 were used.
The transmittance and iodine content of the transparent portions of the polarizers formed in the examples and comparative examples were measured by the following methods.
1. Transmittance (Ts)
Measured using a spectrophotometer (DOT-3, product name, manufactured by village color technology research). The transmittance (T) is a Y value after visibility correction by a 2-degree field of view (C light source) of JIS Z8701-1982.
2. Iodine content
The iodine content of the transparent portion of the polarizer was determined by fluorescent X-ray analysis. Specifically, the iodine content of the polarizer was determined from the X-ray intensity measured under the following conditions using a calibration curve prepared in advance using a standard sample.
An analysis device: fluorescent X-ray analysis device (XRF) manufactured by scientific and electric industry, product name "ZSX 100 e"
And (3) for a cathode: rhodium
Spectroscopic crystal: lithium fluoride
Excitation light energy: 40kV-90mA
Iodine measurement line: I-LA
The quantitative method comprises the following steps: FP method
2 θ angular peak: 103.078deg (iodine)
Measuring time: 40 seconds
The transparent portions of the polarizers obtained in the examples and comparative examples each had a transmittance of 90% or more, and the iodine content was less than 1 wt%. These transparent portions may function as non-polarizing portions.
[ evaluation method ]
The degree of shape integration of each transparent portion formed on the polarizing plate was measured by the following method. In 1000 transparent portions of the polarizer, a case where the ratio of the shape integration degree exceeding 0.05 was 40% or less was "excellent", a case where the ratio of the shape integration degree exceeding 0.05 was 50% or less was "good", and a case where the ratio of the shape integration degree exceeding 0.05 was "x". The results are shown in table 1.
[ conformity of shape ]
The edge of the unpolarized portion of the polarizers prepared in examples 1 to 8 and comparative examples 1 to 12 was detected by using an ultrahigh-speed flexible image display system (product name: XG7700, manufactured by KEYENCE corporation) to determine the circle approximation of the unpolarized portion. The distance between the circumference of the approximate circle of the non-polarizing portion (the dotted line portion in fig. 3A and 3B) and the boundary between the polarizer 1 and the non-polarizing portion 2 (the solid line portion in fig. 3A and 3B) was measured at 2 ° intervals, and the total distance at 180 ° was determined. In the measurement point, when the boundary between the polarizer 1 and the non-polarizing portion 2 is located outside the non-polarizing portion approximate circle (i.e., in the case of fig. 3A), the distance a between the non-polarizing portion 2 and the non-polarizing portion approximate circle is measured, and when the boundary between the polarizer 1 and the non-polarizing portion 2 is located inside the non-polarizing portion approximate circle (i.e., in the case of fig. 3B), the distance B between the non-polarizing portion 2 and the non-polarizing portion approximate circle is measured. The sum of the maximum value of the distance a and the maximum value of the distance b is calculated as the hole roughness. The calculated value of the hole roughness was divided by the diameter of the small hole formed in the PET film (examples 1 to 4 and comparative examples 1 to 3 and 7 to 9: 2mm, examples 5 to 8 and comparative examples 4 to 6 and 10 to 12: 4mm) to obtain a value of the degree of shape integration.
[ Table 1]
Examples 1 to 8 using polarizing film laminates having an adhesive layer thickness of 10 μm or less produced polarizers having non-polarizing portions corresponding to the shape of the pinholes formed in the PET film at a high yield. In the case of a polarizer having such a non-polarizing portion, for example, when the non-polarizing portion is used in a manner such that it corresponds to a camera portion of an image display device, alignment workability is improved, and the camera can be aligned satisfactorily. Even in examples 1 to 4 in which the size of the pinhole formed in the surface protective film was as small as 2mm, a polarizer having a non-polarizing portion in the shape close to the shape of the pinhole formed in the PET film was obtained.
Industrial applicability
The polarizer produced by the method of the present invention is suitable for use in image display devices (liquid crystal display devices, organic EL devices) having cameras, such as mobile phones including smart phones, notebook PCs, and tablet PCs.
Description of the reference numerals
10 … polarizer
20 … protective film
30 … surface protective film
50 … surface protective film
60 … adhesive layer
51 … exposed part
71 … through the hole
100 … polarizing film laminate
Claims (10)
1. A method of manufacturing a polarizer having a non-polarizing portion, comprising:
a step of laminating a surface protection film having a through-hole on one surface side of a polarizer via an adhesive layer having a thickness of 10 μm or less to produce a polarizing film laminate having an exposed portion on the one surface side, the exposed portion exposing at least a part of the polarizer;
a step of bringing the exposed portion of the polarizing film laminate into contact with an alkaline solution; and
a step of removing the surface protective film from the polarizing film laminate,
the through hole corresponds to the exposed portion, and the through hole penetrates through the adhesive layer.
2. The method of manufacturing a polarizer according to claim 1, wherein the step of contacting the exposed portion with an alkaline solution includes immersing the polarizing film laminate in an alkaline solution.
3. The method of manufacturing a polarizing plate according to claim 1 or 2, wherein the adhesive layer contains an acrylic resin.
4. The method for producing a polarizer according to claim 1 or 2, further comprising a step of bringing an exposed portion of the polarizing film laminate into contact with an acidic solution.
5. The method of manufacturing a polarizer according to claim 4, wherein the step of contacting the exposed portion with an acidic solution includes immersing the polarizing film laminate in an acidic solution.
6. The method of manufacturing a polarizer according to claim 5, wherein the step of contacting the exposed portion with an alkaline solution includes immersing the polarizing film laminate in an alkaline solution, and the step of contacting the exposed portion with an acidic solution includes immersing the polarizing film laminate in an acidic solution.
7. The method of manufacturing a polarizing plate according to claim 1 or 2, wherein the polarizing film laminate is in a long shape.
8. A polarizer produced by the method according to any one of claims 1 to 7.
9. A polarizing plate having the polarizing element according to claim 8.
10. An image display device comprising the polarizing plate according to claim 9.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2015-127716 | 2015-06-25 | ||
| JP2015127716A JP6152138B2 (en) | 2015-06-25 | 2015-06-25 | Manufacturing method of polarizer |
| PCT/JP2016/068133 WO2016208510A1 (en) | 2015-06-25 | 2016-06-17 | Method for manufacturing polarizer |
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| CN107710038A CN107710038A (en) | 2018-02-16 |
| CN107710038B true CN107710038B (en) | 2020-11-03 |
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| JP (1) | JP6152138B2 (en) |
| KR (1) | KR102003632B1 (en) |
| CN (1) | CN107710038B (en) |
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| WO (1) | WO2016208510A1 (en) |
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| CN111239883B (en) * | 2020-02-19 | 2022-08-23 | 京东方科技集团股份有限公司 | Polarizer, LCD screen and OLED screen |
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| US4181756A (en) * | 1977-10-05 | 1980-01-01 | Fergason James L | Process for increasing display brightness of liquid crystal displays by bleaching polarizers using screen-printing techniques |
| US4396646A (en) * | 1981-07-20 | 1983-08-02 | Polaroid Corporation | Method of making patterned polarizers |
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| JPS4864941A (en) * | 1971-12-09 | 1973-09-07 | ||
| US4466704A (en) * | 1981-07-20 | 1984-08-21 | Polaroid Corporation | Patterned polarizer having differently dyed areas |
| JP4208187B2 (en) * | 2002-10-28 | 2009-01-14 | 日東電工株式会社 | Adhesive optical film, method for producing adhesive optical film, and image display device |
| US20040212555A1 (en) | 2003-04-23 | 2004-10-28 | Falco Mark A. | Portable electronic device with integrated display and camera and method therefore |
| JP4646951B2 (en) | 2007-06-06 | 2011-03-09 | 株式会社半導体エネルギー研究所 | Display device with sensor |
| KR20100125537A (en) * | 2009-05-21 | 2010-12-01 | 동우 화인켐 주식회사 | Method for preparing polarization grating screen, polarization grating screen and 3d display device comprising the same |
| JP5434457B2 (en) | 2009-10-09 | 2014-03-05 | ソニー株式会社 | Optical unit and imaging device |
| US8467177B2 (en) * | 2010-10-29 | 2013-06-18 | Apple Inc. | Displays with polarizer windows and opaque masking layers for electronic devices |
| KR101293210B1 (en) | 2010-12-15 | 2013-08-05 | 주식회사 엘지화학 | Method and apparatus for forming hole of polarizing plate for display device |
| KR101495759B1 (en) | 2011-04-18 | 2015-02-26 | 주식회사 엘지화학 | Polarizer having hole for cammera, LCD panel and display apparatus utilizing the same |
| JP2012247574A (en) * | 2011-05-26 | 2012-12-13 | Nitto Denko Corp | Adhesion type polarizing plate and image display device |
| JP2014081482A (en) * | 2012-10-16 | 2014-05-08 | Nitto Denko Corp | Polarizer and image display device |
| JP6370029B2 (en) * | 2013-03-13 | 2018-08-08 | 日東電工株式会社 | Polarizing film with adhesive layer and image display device |
| JP2014211548A (en) | 2013-04-19 | 2014-11-13 | 住友化学株式会社 | Production method of polarizing laminate film having region showing no polarizance, and polarizing plate |
| TWI611221B (en) * | 2014-03-26 | 2018-01-11 | Ｌｇ化學股份有限公司 | Methods for manufacturing for polarizing element, polarizing element roll and single sheet type polarizing element having locally bleaching areas |
| JP6214594B2 (en) * | 2014-04-25 | 2017-10-18 | 日東電工株式会社 | Polarizer, polarizing plate and image display device |
| KR101766015B1 (en) * | 2014-06-30 | 2017-08-08 | 주식회사 엘지화학 | Method for manufacturing polarizing plate |
| JP6604714B2 (en) * | 2014-09-03 | 2019-11-13 | 日東電工株式会社 | Manufacturing method of polarizer |
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- 2015-06-25 JP JP2015127716A patent/JP6152138B2/en active Active
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- 2016-06-17 CN CN201680037343.2A patent/CN107710038B/en active Active
- 2016-06-17 WO PCT/JP2016/068133 patent/WO2016208510A1/en active Application Filing
- 2016-06-17 KR KR1020177036950A patent/KR102003632B1/en active IP Right Grant
- 2016-06-24 TW TW105119989A patent/TWI709479B/en active
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| US4181756A (en) * | 1977-10-05 | 1980-01-01 | Fergason James L | Process for increasing display brightness of liquid crystal displays by bleaching polarizers using screen-printing techniques |
| US4396646A (en) * | 1981-07-20 | 1983-08-02 | Polaroid Corporation | Method of making patterned polarizers |
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| Publication number | Publication date |
|---|---|
| JP2017009906A (en) | 2017-01-12 |
| WO2016208510A1 (en) | 2016-12-29 |
| JP6152138B2 (en) | 2017-06-21 |
| KR20180011244A (en) | 2018-01-31 |
| TWI709479B (en) | 2020-11-11 |
| CN107710038A (en) | 2018-02-16 |
| KR102003632B1 (en) | 2019-07-24 |
| TW201707941A (en) | 2017-03-01 |
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