CN113341494B - Method for manufacturing polarizing plate having non-polarizing portion - Google Patents
Method for manufacturing polarizing plate having non-polarizing portion Download PDFInfo
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- CN113341494B CN113341494B CN202110529378.0A CN202110529378A CN113341494B CN 113341494 B CN113341494 B CN 113341494B CN 202110529378 A CN202110529378 A CN 202110529378A CN 113341494 B CN113341494 B CN 113341494B
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Classifications
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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
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8806—Specially adapted optical and illumination features
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
- G01M11/02—Testing optical properties
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
-
- 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
-
- 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
-
- 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
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Chemical & Material Sciences (AREA)
- Analytical Chemistry (AREA)
- Pathology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Health & Medical Sciences (AREA)
- Biochemistry (AREA)
- General Health & Medical Sciences (AREA)
- Immunology (AREA)
- Signal Processing (AREA)
- Computer Vision & Pattern Recognition (AREA)
- Engineering & Computer Science (AREA)
- Polarising Elements (AREA)
- Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
- Investigating, Analyzing Materials By Fluorescence Or Luminescence (AREA)
- Investigating Or Analysing Materials By Optical Means (AREA)
Abstract
The invention provides a method for inspecting a polarizing plate and a method for manufacturing the polarizing plate. The method for inspecting a polarizing plate can inspect the polarizing plate with good precision when manufacturing the polarizing plate which can realize multifunction and high-functional of an electronic device and has no quality deviation. The inspection method of the present invention includes a step of irradiating light to a range including a non-polarizing portion (2) of a polarizing plate (1) having the non-polarizing portion (2), and photographing a transmitted light image of the polarizing plate (1). Here, the contrast ratio (non-polarized portion/other portion) of the non-polarized portion (2) to other portions in the transmitted light image is 1.5 or more.
Description
The present application is a divisional application of application publication No. 2016.09.30, application publication No. 201610873657.8, and application publication entitled "inspection method of polarizer and manufacturing method of polarizer".
Technical Field
The present invention relates to a method for inspecting a polarizing plate and a method for manufacturing a polarizing plate. More specifically, the present invention relates to a method for inspecting a polarizing plate having a non-polarizing portion and a method for manufacturing a polarizing plate having a non-polarizing portion.
Background
As an image display device such as a mobile phone or a notebook Personal Computer (PC), there is an image display device mounted with internal electronic components such as a camera. Various studies have been made with a view to improving the camera performance of such an image display device (for example, patent documents 1 to 7). However, due to the rapid spread of smart phones and touch panel type information processing apparatuses, further improvement in camera performance and the like is desired. In addition, in order to cope with diversification and high functionalization of the shape of the image display device, a polarizing plate having polarizing performance locally is required. In order to realize these expectations industrially and commercially, it is desirable to manufacture an image display device and/or its components at a cost that can be tolerated, and as a result, various studies remain for specifying such techniques.
Prior art literature
Patent literature
Patent document 1: japanese patent application laid-open No. 2011-81315
Patent document 2: japanese patent laid-open No. 2007-241314
Patent document 3: U.S. patent application publication No. 2004/0212555 specification
Patent document 4: korean laid-open patent No. 10-2012-018205
Patent document 5: korean patent No. 10-1293210
Patent document 6: japanese patent application laid-open No. 2012-137738
Patent document 7: U.S. patent application publication No. 2014/018826 specification
Disclosure of Invention
Problems to be solved by the invention
The present invention has been made to solve the above-described problems, and a main object of the present invention is to provide a method for inspecting a polarizing plate with high accuracy when manufacturing the polarizing plate that can realize multifunction and high functionality of an electronic device without quality variation.
Solution for solving the problem
The method for inspecting a polarizing plate of the present invention includes a step of irradiating light to a range including a non-polarizing portion of a polarizing plate having the non-polarizing portion, and photographing a transmitted light image of the polarizing plate. The contrast ratio (unpolarized portion/other portion) between the unpolarized portion and other portions in the transmitted light image is 1.5 or more.
In 1 aspect, the shape and/or characteristics of the non-polarizing portion are checked.
In 1 embodiment, the photographing is performed through a surface protective film for protecting the polarizing plate.
In the 1 aspect, the imaging is performed such that the other optical member is not interposed between the surface protective film and the imaging unit.
According to another aspect of the present invention, a method of manufacturing a polarizing plate can be provided. The manufacturing method includes a step of forming a non-polarized portion in the polarizing plate, and a step of inspecting the polarizing plate by the inspection method.
In 1 aspect, the inspection is continuously performed after the non-polarized portion is formed.
In 1 embodiment, the non-polarizing portion is formed by bringing an alkaline solution into contact with a polarizing plate.
In 1 aspect, the polarizing plate is contacted with the alkaline solution in a state where at least a part of the polarizing plate is covered with a surface protective film so as to be exposed.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, a polarizing plate having a non-polarizing portion can be inspected with high accuracy.
Drawings
Fig. 1 is a plan view showing 1 specific example of a polarizing plate to be inspected according to the present invention.
Fig. 2 is a schematic diagram showing 1 embodiment of the inspection method of the present invention.
Fig. 3 is a schematic plan view showing a specific example of a surface protective film in a longitudinal shape.
Fig. 4 is a schematic perspective view showing a specific example of lamination between a polarizing plate and a protective material.
Fig. 5 is a partial cross-sectional view of a polarizing film laminate in 1 embodiment of the present invention.
Fig. 6 is a schematic perspective view of a polarizing plate according to 1 embodiment of the present invention.
Description of the reference numerals
1. A polarizing plate; 2. a non-polarizing portion; 10. a polarizing film laminate; 11. an exposure portion; 20. a surface protective film; 21. a through hole; 30. a protective film; 40. a surface protective film; 100. an inspection device; 110. a light source section; 120. and an imaging unit.
Detailed Description
Hereinafter, embodiments of the present invention will be described, but the present invention is not limited to these embodiments.
A. Polarizing plate
Fig. 1 is a plan view showing 1 specific example of a polarizing plate to be inspected according to the present invention. The polarizing plate 1 is composed of a resin film containing a dichroic substance. In the polarizing plate 1, a small circular non-polarizing portion 2 is formed in the center of the upper end portion of the polarizing plate 1.
The unpolarized portion can be of any suitable form. For example, the unpolarized portion is a decolored portion locally decolored. The decoloring section is formed by, for example, laser irradiation or chemical treatment. As another specific example, the unpolarized portion is a through hole. The through-hole is formed by, for example, mechanical blanking (e.g., punch, thomson knife blanking, plotter (japanese), water knife cutting) or removal of a predetermined portion (e.g., laser ablation or chemical dissolution).
In the illustrated example, the small circular non-polarizing portion 2 is formed in the center portion of the upper end portion of the polarizing plate 1, but the number, arrangement, shape, size, and the like of the non-polarizing portions may be appropriately designed. For example, the camera unit of the image display device to be mounted may be designed according to the position, shape, size, and the like of the camera unit. Specifically, the non-polarizing portion is designed not to correspond to a portion other than the camera (for example, an image display portion) of the image display apparatus.
The transmittance of the unpolarized portion (for example, the transmittance measured at 23 ℃ C. With light having a wavelength of 550 nm) is preferably 50% or more, more preferably 60% or more, still more preferably 75% or more, and particularly preferably 90% or more. If the polarizer is disposed such that the non-polarizing portion corresponds to the camera portion of the image display device, for example, it is possible to prevent adverse effects on the photographing performance of the camera.
The polarizing plate (other portion than the unpolarized portion) preferably exhibits absorption dichroism at any one of wavelengths 380nm to 780 nm. The single body transmittance of the polarizing plate (other than the unpolarized portion) is preferably 39% or more, more preferably 39.5% or more, still more preferably 40% or more, and particularly preferably 40.5% or more. The theoretical upper limit of the transmittance of the monomer is 50% and the practical upper limit is 46%. The monomer transmittance is a Y value obtained by performing visibility correction by measurement with a 2-degree field of view (C light source) of JIS Z8701, and can be measured by using, for example, a microscopic spectroscopic system (Lambda Vision inc. Manufactured by LVmicro). The degree of polarization of the polarizing plate (excluding the unpolarized portion) is preferably 99.9% or more, more preferably 99.93% or more, and still more preferably 99.95% or more.
The thickness of the polarizer may be set to any appropriate value. The thickness is preferably 30 μm or less, more preferably 25 μm or less, further preferably 20 μm or less, particularly preferably 10 μm or less. On the other hand, the thickness is preferably 0.5 μm or more, and more preferably 1 μm or more.
Examples of the dichroic material include iodine and organic dyes. These may be used singly or in combination of two or more. Iodine is preferably used.
Any suitable resin may be used as the resin for forming the resin film. Preferably, a polyvinyl alcohol resin is used. Examples of the polyvinyl alcohol resin include polyvinyl alcohol and ethylene-vinyl alcohol copolymer. Polyvinyl alcohol is obtained by saponifying polyvinyl acetate. The ethylene-vinyl alcohol copolymer is obtained by saponifying an ethylene-vinyl acetate copolymer.
B. Inspection method
The inspection method of the present invention includes a step of irradiating light to a range including a non-polarizing portion of a polarizing plate having the non-polarizing portion, and photographing a transmitted light image of the polarizing plate. In the photographing step, light is typically irradiated from one side of the polarizing plate having the non-polarizing portion, and light transmitted through the polarizing plate is photographed from the other side.
The contrast ratio (non-polarized portion/other portion) between the non-polarized portion and other portion in the transmitted light image is 1.5 or more, preferably 1.8 or more, and more preferably 2.0 or more. By performing imaging at such a contrast ratio, the unpolarized portion (for example, the shape and/or characteristics of the unpolarized portion) can be inspected with high accuracy.
Fig. 2 is a schematic diagram showing 1 embodiment of the inspection method of the present invention. As shown in the drawing, the inspection apparatus 100 includes a light source unit 110, an imaging unit 120, and an image processing unit, not shown, for processing an image captured by the imaging unit 120. The light source 110 is arranged to irradiate light to a range including the unpolarized section 2 of the polarizing plate 1 (in terms of practical use, a polarizing plate). The imaging unit 120 is disposed on the opposite side of the polarizer 1 to the side on which the light source unit 110 is disposed, and images the transmitted light image of the polarizer 1. Although not shown, a polarizing filter may be disposed between the light source 110 and the imaging unit 120 according to the structure of the polarizing plate.
The light source unit may be configured using any appropriate light source. The light source may be either a white light source or a monochromatic light source. The light source may be of any appropriate shape, and may be, for example, a surface light source, a line light source, a point light source, or a ring light source. Specific examples of the light source include a fluorescent lamp, a halogen tungsten lamp, a metal halide lamp, and an LED.
The irradiation angle of the light to the polarizer (irradiation angle of the light to the main surface of the polarizer) is preferably 89 ° to 91 °, and more preferably 89.5 ° to 90.5 °. With such an irradiation angle, the roughness of the profile in the thickness direction of the polarizing plate can be inspected with high accuracy.
Typically, the imaging unit is a camera configured by using a lens and an image sensor. As the image sensor, either a CCD type image sensor or a CMOS type image sensor may be used.
The number of pixels of the image sensor is preferably 2000dpi or more, more preferably 4000dpi to 6000dpi. By using an image sensor having such a number of pixels, a high-quality image can be captured, and thus inspection can be performed with higher accuracy.
As described above, when the polarizing filter is used in photographing, the polarizing filter is disposed such that the absorption axis thereof is orthogonal to the absorption axis of the polarizing plate to be inspected. Here, "orthogonal" also includes a case of being substantially orthogonal. Here, "substantially orthogonal" includes a case of 90 ° ± 3.0 °, preferably 90 ° ± 1.0 °, and more preferably 90 ° ± 0.5 °. In the illustrated example, when the polarization filter is disposed between the polarizing plate 1 and the imaging unit 120, light (linearly polarized light) that has passed through a portion of the polarizing plate 1 other than the non-polarizing unit 2 is absorbed by the polarization filter, and a portion of light that has passed through the non-polarizing unit 2 is allowed to pass through the polarization filter, so that the light that has passed through the polarization filter can be imaged substantially as an image of the non-polarizing unit. The polarizing filter may be disposed between the light source unit and the polarizing plate to be inspected. The details are discussed later, but whether or not to use the polarizing filter may be determined according to the form of the polarizing plate (polarizing plate) as the inspection object.
The quality (e.g., shape and/or characteristics of the unpolarized section) of the polarizing plate is checked based on the image obtained in the photographing step. Specifically, the image processing unit analyzes the image data transmitted as an electrical signal from the imaging unit, and checks the quality of the polarizing plate. Specific examples of the inspection item include shape accuracy (roundness, etc. in the case of a circle) of the unpolarized portion, roughness of the contour, steepness of the contour, transmittance, and the like. The image processing unit preferably detects a non-polarized portion that does not satisfy a predetermined criterion as a defective formation.
The analysis of the image data described above may be performed based on, for example, luminance information. Specifically, the luminance of the unpolarized portion becomes relatively high and the luminance of the other portion becomes low for the obtained image data (transmitted light image data), and therefore, the unpolarized portion can be specified based on the contrast ratio in the obtained image data. Further, the distance from the center to each contour portion is obtained by equally dividing the contour of the specific unpolarized portion by 180, and the value obtained by subtracting the minimum value from the maximum value of the obtained 180 distance data can be used as the evaluation criterion of the roundness. For example, if the obtained value is equal to or less than a predetermined value, the roundness of the unpolarized portion can be evaluated as good. Further, the rough surface roughness evaluation method can be used to evaluate the rough surface roughness of the rough surface by equally dividing the rough surface of the unpolarized portion by 180 to obtain an approximate ellipse as a reference, and setting the maximum value of the distance from the approximate ellipse to the actual rough surface in each region equally divided by 180. For example, when the obtained maximum value is equal to or less than a predetermined value, the roughness of the contour of the unpolarized section can be evaluated as good. Further, the average luminance of the unpolarized portion and other portions (peripheral portions of the unpolarized portion) was obtained, the average luminance of the unpolarized portion was set to 100%, the average luminance of the other portions was set to 0%, and the maximum value of the distances from the center of the unpolarized portion to 180 in the case of binarizing the luminance of 10% and 20% into black and white was set as the evaluation criterion for the steepness of the contour. For example, when the obtained maximum value is equal to or less than a predetermined value, the steepness of the contour of the unpolarized section can be evaluated as good.
For example, the transmittance of the unpolarized portion may be evaluated by obtaining an average luminance value, a maximum luminance value, and a minimum luminance value of the unpolarized portion, and dividing the maximum luminance value by the average luminance value, or dividing the minimum luminance value by the average luminance value. Specifically, when the polarization function and the transmittance are low in the unpolarized portion, the obtained value is also low.
C. Method for manufacturing polarizing plate having non-polarizing portion
The method for manufacturing a polarizing plate having a non-polarizing portion according to the present invention includes forming a non-polarizing portion in a polarizing plate and inspecting the non-polarizing portion by the inspection method.
C-1. Formation of unpolarized portions
As a representative example, a polarizing plate can be obtained by subjecting the resin film to various treatments such as swelling treatment, stretching treatment, dyeing treatment of the dichroic material, crosslinking treatment, washing treatment, and drying treatment. The resin film may be a resin layer formed on a substrate when various treatments are performed. The formation of the non-polarizing portion may be performed during the process of manufacturing the polarizing plate.
Preferably, the unpolarized portion is a decolored portion. According to such a configuration, quality problems such as cracking, delamination (delamination), and paste overflow are avoided as compared with the case where the through-hole is formed mechanically (by a method of mechanically blanking using, for example, a thomson knife punching, a plotter, a water knife cutting, or the like). The decoloring section is preferably formed by bringing an alkaline solution into contact with a desired position of a polarizing plate (a resin film containing a dichroic substance). The non-polarizing portion formed by such a method may be a low concentration portion in which the content of the dichroic material is lower than the content of the dichroic material at other portions (non-contact portions). Since the content of the dichroic material itself in the low concentration portion is low, the transparency of the unpolarized portion can be maintained more favorably than in the case where the dichroic material is decomposed by laser light or the like to form the decolored portion.
The content of the dichroic material in the low concentration portion is preferably 1.0 wt% or less, more preferably 0.5 wt% or less, and even more preferably 0.2 wt% or less. The lower limit value of the content of the dichroic material in the low concentration portion is usually equal to or less than the detection limit value. The difference between the content of the dichroic material in the other portion and the content of the dichroic material in the low concentration portion is preferably 0.5 wt% or more, and more preferably 1 wt% or more. When iodine is used as the dichroic material, the iodine content is obtained from, for example, the X-ray intensity measured by fluorescent X-ray analysis using a calibration curve prepared by using a standard sample in advance.
As the alkaline compound contained in the alkaline solution, any appropriate compound may be used. Examples of the basic compound include hydroxides of alkali metals 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 aqueous ammonia. Among them, alkali metal and/or alkaline earth metal hydroxides are preferably used, and sodium hydroxide, potassium hydroxide and lithium hydroxide are more preferably used. The dichroic material can be ionized efficiently, and the decoloring section can be formed more simply. These basic compounds may be used alone or in combination of two or more.
As the solvent for the alkaline solution, water and alcohol are preferably used. 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. The liquid temperature of the alkaline solution is, for example, 20℃to 50 ℃. The contact time of the alkaline solution can be set according to the thickness of the polarizing plate, the type and concentration of the alkaline compound contained in the alkaline solution. The contact time is, for example, 5 seconds to 30 minutes, preferably 5 seconds to 5 minutes.
As the method of contacting the alkaline solution, any appropriate method can be employed. Examples of the method include a method of dropping, coating, and spraying an alkaline solution onto the polarizing plate, and a method of immersing the polarizing plate in an alkaline solution. When the polarizing plate is contacted with the alkaline solution, the polarizing plate may be protected with any appropriate protective material so that the alkaline solution does not contact a portion other than the desired portion. As such a protective material, for example, a protective film or a surface protective film is used. The protective film can be directly used as a protective film for a polarizing plate. The surface protective film is temporarily used when manufacturing the polarizing plate. The surface protective film is detached from the polarizing plate at any appropriate timing, and is therefore typically attached to the polarizing plate via an adhesive layer. As another specific example of the protective material, a photoresist or the like is given. In addition, a base material used in the step of producing the polarizing plate may be used as a protective material.
Preferably, the surface of the polarizing plate is coated with the surface protective film so that at least a part thereof is exposed when the polarizing plate is contacted with the alkaline solution. In the polarizing plate illustrated in the drawing, a surface protective film having small circular through holes is bonded to the polarizing plate, and the surface protective film is brought into contact with an alkaline solution, thereby producing the polarizing plate. In this case, the other side of the polarizing plate (the side where the surface protective film having the through-hole formed is not disposed) is preferably also protected.
In 1 embodiment, a polarizing film laminate obtained by laminating a surface protective film in a longitudinal shape on a polarizing plate (resin film) in a longitudinal shape is prepared and contacted with an alkaline solution. The surface protective film is formed with through holes at predetermined intervals along the longitudinal direction and/or the width direction thereof. The term "longitudinal" as used herein refers to an elongated shape having a length sufficiently long with respect to the width, and includes, for example, an elongated shape having a length 10 times or more, preferably 20 times or more, the width.
In the above-described longitudinal polarizing plate, the absorption axis may be set in any appropriate direction according to the purpose. The direction of the absorption axis may be, for example, the longitudinal direction or the width direction. A polarizing plate having an absorption axis in the longitudinal direction has an advantage such as excellent manufacturing efficiency. The polarizer having the absorption axis in the width direction has an advantage that it can be laminated with a retardation film having a slow axis in the longitudinal direction by roll-to-roll, for example. In 1 embodiment, the absorption axis is substantially parallel to the longitudinal direction or the width direction, and both ends of the polarizer in the width direction are divided and processed in parallel to the longitudinal direction. According to this configuration, the polarizing plate can be cut with reference to the end edge of the polarizing plate, and a plurality of polarizing plates having an unpolarized portion at a desired position and having an absorption axis in an appropriate direction can be easily manufactured. Further, the absorption axis of the polarizing plate may correspond to the extending direction in the above-described extending process.
Fig. 3 is a schematic plan view showing a specific example of a surface protective film in a longitudinal shape. The surface protective film 20 has the same width as the laminated polarizing plate in a longitudinal shape or has a width wider than the polarizing plate. The surface protection film 20 has small circular through holes 21, 21 … formed at substantially equal intervals in the longitudinal direction and the width direction. The arrangement pattern of the through holes can be determined in accordance with the desired polarizing plate. For example, the through-hole is arranged so as to correspond to a camera unit of the image display device when the obtained polarizing plate is cut (for example, cut and punched in the longitudinal direction and/or the width direction) to a predetermined size in order to be mounted on the image display device of a predetermined size. The shape of the through hole may correspond to the shape of the desired non-polarized portion.
As shown in fig. 4, lamination of the longitudinal polarizer and the longitudinal protective material (in the illustrated example, the surface protective film having the through-holes formed therein) is preferably performed by roll-to-roll. In the present specification, "roll-to-roll" refers to stacking films in a roll form while being aligned in the longitudinal direction while conveying the films.
Fig. 5 is a partial cross-sectional view of a polarizing film laminate in 1 embodiment of the present invention. The polarizing film laminate 10 includes: a polarizing plate 1; a 1 st surface protective film 20 disposed on one surface side (upper surface side in the illustrated example) of the polarizing plate 1; a protective film 30 disposed on the other surface side (in the example of the figure, the lower surface side) of the polarizing plate 1; and a 2 nd surface protective film 40. The polarizing film laminate 10 has exposed portions 11 and 11 … on one surface side (in the illustrated example, the upper surface side) of the polarizing plate 1. The exposed portion 11 is provided by forming a through hole 21 in the 1 st surface protective film 20.
Examples of the material for forming the surface protective film include aliphatic resins such as polyethylene terephthalate resins, cycloolefin resins such as norbornene resins, olefin resins such as polyethylene and polypropylene, polyamide resins, polycarbonate resins, and copolymer resins thereof. Preferably a resin of a lipid type (in particular, polyethylene terephthalate resin). This is because the elastic modulus is sufficiently high, and deformation of the through hole is less likely to occur even when tension is applied during conveyance and/or lamination, for example. The thickness of the surface protective film is typically 20 μm to 250. Mu.m, preferably 30 μm to 150. Mu.m.
As described above, the surface protective film is used to temporarily protect the polarizing plate, and therefore, there is no problem in practical use even if there is a deviation in the orientation of the forming resin thereof. For example, the in-plane retardation of the surface protective film at a wavelength of 590nm may have a range of 500nm to 3000 nm. The in-plane phase difference Re can be calculated by the formula: re= (nx-ny) x d. Where "nx" is a refractive index in a direction (slow axis direction) in which the refractive index in the plane becomes maximum, "ny" is a refractive index in a direction (fast axis direction) orthogonal to the slow axis in the plane, and "d" is a thickness (nm) of the film. In addition, the orientation angle of the surface protective film may have a range of-40 ° to +40°. The orientation angle is an angle formed by the slow axis of the surface protective film with respect to the absorption axis of the polarizing plate when the surface protective film and the polarizing plate are laminated.
As shown in fig. 3, the 1 st surface protective film has through holes arranged in a predetermined pattern. The position of the through hole corresponds to the position where the unpolarized section is formed. The shape of the through hole corresponds to the shape of the desired unpolarized section. The through-holes are formed by, for example, mechanical blanking (e.g., punch, thomson knife blanking, plotter, water knife cutting) or removal of a predetermined portion of the film (e.g., laser ablation or chemical dissolution).
The surface protective film is peeled off at any appropriate timing after, for example, contact with an alkaline solution.
Examples of the material for forming the protective film include cellulose resins such as diacetyl cellulose and triacetyl cellulose, olefin resins such as methacrylic resin, cycloolefin resin and polypropylene, resin resins such as polyethylene terephthalate resin, polyamide resin, polycarbonate resin, and copolymer resins thereof. The thickness of the protective film is preferably 10 μm to 100. Mu.m.
As the surface treatment layer, a treatment for the purpose of hard coat layer, antireflection treatment, diffusion, or antiglare may be applied to the surface on which the polarizing plates of the protective film are not laminated. Typically, the protective film may be bonded to the polarizer via an adhesive layer.
In 1 embodiment, the alkaline solution may be removed from the polarizer after contact with the polarizer using any suitable method. According to such an embodiment, for example, the transmittance of the non-polarizing portion can be more reliably prevented from decreasing with the use of the polarizing plate. Specific examples of the method for removing the alkaline solution include washing, wiping removal by a waste cotton yarn head or the like, suction removal, natural drying, heat drying, air drying, and reduced pressure drying. Preferably, the alkaline solution is washed. Examples of the cleaning liquid used for the cleaning include water (pure water), alcohols such as methanol and ethanol, and mixed solvents thereof. Preferably, water is used. The number of times of washing is not particularly limited, and may be plural times. In the case of removing the alkaline solution by drying, the drying temperature thereof is, for example, 20 to 100 ℃.
Preferably, after the resin film is contacted with the alkaline solution, alkali metal and/or alkaline earth metal contained in the resin film is reduced in a contact portion with the alkaline solution. By reducing the alkali metal and/or alkaline earth metal, a non-polarized portion having excellent dimensional stability can be obtained. Specifically, even in a humidified environment, the shape of the unpolarized section formed by contact with the alkaline solution can be maintained.
By contacting with the alkaline solution, an alkali metal hydroxide and/or an alkaline earth metal hydroxide can remain in the contact portion. In addition, by contact with an alkaline solution, a metal salt (e.g., borate) of an alkali metal and/or an alkaline earth metal can be formed at the contact portion. These metal salts can generate hydroxide ions, and the generated hydroxide ions act (decompose and reduce) on a dichroic substance (for example, an iodine complex) present around the contact portion, thereby expanding the unpolarized region. Thus, consider: the desired shape of the unpolarized section can be maintained by reducing the alkali metal and/or alkaline earth metal salt to suppress the expansion of the unpolarized region with the lapse of time.
The content of the alkali metal and/or alkaline earth metal in the non-polarizing portion is preferably 3.6 wt% or less, more preferably 2.5 wt% or less, further preferably 1.0 wt% or less, and particularly preferably 0.5 wt% or less. The alkali metal and/or alkaline earth metal content can be obtained from, for example, an X-ray intensity measured by fluorescent X-ray analysis, and a calibration curve prepared by using a standard sample in advance.
As the method for reducing the alkali metal and/or alkaline earth metal, a method of bringing an acidic solution into contact with a contact portion with an alkaline solution is preferably used. According to such a method, the alkali metal and/or alkaline earth metal is efficiently transferred to the acidic solution, and the content thereof can be reduced. The contact with the acidic solution may be performed after the removal of the alkaline solution, or may be performed without the removal of 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. Among these, the acidic compound contained in the acidic solution is preferably an inorganic acid, and more preferably hydrochloric acid, sulfuric acid, or nitric acid. These acidic compounds may be used alone or in combination of two or more.
As the solvent for the acidic solution, water and alcohol are preferably used. 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 liquid temperature of the acidic solution is, for example, 20℃to 50 ℃. The contact time of the acidic solution is, for example, 5 seconds to 5 minutes. The method for contacting the acidic solution may be the same as the method for contacting the alkaline solution described above. In addition, the acidic solution may be removed from the polarizer. The method for removing the acidic solution may be the same as the method for removing the alkaline solution described above.
C-2. Inspection of unpolarized portions
After forming the unpolarized portion, the unpolarized portion is inspected by the inspection method described above. In the inspection, the surface protective film may be laminated on the polarizing plate, or may be peeled off. In addition, it is preferable that the polarizing plate is in a state in which the protective film is attached to at least one polarizing plate at the time of inspection.
In 1 embodiment, after forming the unpolarized section, inspection of the unpolarized section is continuously performed. In the case where the polarizing plate is elongated, after the non-polarizing portion is formed, the non-polarizing portion is inspected without winding up the polarizing plate. For example, after forming a non-polarized portion in a polarizing film laminate as shown in fig. 5, the laminate is subjected to a non-polarized portion inspection step in its original state. In this way, by continuously performing inspection after forming the non-polarized portion (specifically, by determining whether the size of the formed non-polarized portion is larger or smaller than a predetermined size), it is possible to detect, for example, a defect in the contact process with the alkaline solution (for example, the state of the through hole of the surface protective film, the state of impregnation of the alkaline solution) in advance.
Preferably, when a surface protective film is laminated on a polarizing plate to be inspected (particularly, when a surface protective film is laminated on the image capturing side), image capturing is performed without interposing other optical members such as the polarizing filter. As described above, there is a case where the surface protective film varies in the orientation of the resin forming the surface protective film, and the variation in the contrast ratio becomes larger by sandwiching the polarizing filter. Thus, the contrast ratio can be stably satisfied by photographing without interposing a polarization filter.
After inspection, the polarizing plate may be provided as a polarizing plate in practical use. In 1 embodiment, the polarizing plate has an adhesive layer for bonding with other members. Preferably, a release film is temporarily fixed to the surface of the adhesive layer, and the adhesive layer is protected until actual use, and can be formed into a roll as shown in fig. 6.
Industrial applicability
The polarizing plate obtained by the production method of the present invention is suitable for use in camera-equipped image display devices (liquid crystal display devices, organic EL devices) such as mobile phones including smart phones, notebook PCs, tablet PCs, and the like.
Claims (5)
1. A method for manufacturing a polarizing plate having a non-polarizing portion, wherein the method for manufacturing a polarizing plate having a non-polarizing portion comprises a step of forming a non-polarizing portion in a polarizing plate, and
an inspection step of inspecting the polarizing plate having the unpolarized section,
the inspection step includes a step of irradiating light to a region including the unpolarized portion of the polarizing plate having the unpolarized portion, and photographing a transmitted light image of the polarizing plate,
the contrast ratio of the unpolarized portion to other portions in the transmitted light image, that is, the unpolarized portion/other portions, is 1.5 or more,
the unpolarized portion is determined based on the contrast ratio of the transmitted light image,
a surface protective film is laminated on the photographing side of the polarizing plate,
the in-plane phase difference of the surface protection film is 500 nm-3000 nm when the wavelength of the surface protection film is 590nm,
the imaging is performed so that the polarization filter is not interposed between the light source unit for irradiating the light and the imaging unit, and the surface protective film includes a polyethylene terephthalate resin.
2. The manufacturing method according to claim 1, wherein,
after the step of forming the unpolarized section, the inspection step is continuously performed.
3. The manufacturing method according to claim 1, wherein,
in the inspection step, the unpolarized portion that does not satisfy a predetermined criterion is detected as a formation failure for at least one selected from the shape accuracy of the unpolarized portion, the roughness of the contour, and the steepness of the contour.
4. The manufacturing method according to claim 1, wherein,
in the inspection step, the non-polarized portion that does not satisfy a predetermined criterion is detected as a formation failure for all items of the shape accuracy of the non-polarized portion, the roughness of the contour, and the steepness of the contour.
5. The manufacturing method according to claim 3 or 4, wherein,
the shape accuracy is roundness.
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| JP2015197685A JP6795883B2 (en) | 2015-10-05 | 2015-10-05 | Polarizer manufacturing method |
| JP2015-197685 | 2015-10-05 | ||
| CN201610873657.8A CN106990470B (en) | 2015-10-05 | 2016-09-30 | Method for inspecting polarizing plate and method for manufacturing polarizing plate |
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| CN201610873657.8A Division CN106990470B (en) | 2015-10-05 | 2016-09-30 | Method for inspecting polarizing plate and method for manufacturing polarizing plate |
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| CN113341494B true CN113341494B (en) | 2023-05-16 |
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| CN202110529999.9A Active CN113341495B (en) | 2015-10-05 | 2016-09-30 | Method for manufacturing polarizing plate having non-polarizing portion |
| CN201610873657.8A Active CN106990470B (en) | 2015-10-05 | 2016-09-30 | Method for inspecting polarizing plate and method for manufacturing polarizing plate |
| CN202110529378.0A Active CN113341494B (en) | 2015-10-05 | 2016-09-30 | Method for manufacturing polarizing plate having non-polarizing portion |
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| JP6795883B2 (en) * | 2015-10-05 | 2020-12-02 | 日東電工株式会社 | Polarizer manufacturing method |
| JP6986614B2 (en) * | 2015-10-05 | 2021-12-22 | 日東電工株式会社 | How to manufacture a transducer |
| CN109872670B (en) * | 2017-12-05 | 2021-11-05 | 京东方科技集团股份有限公司 | Display screen, display device, display circuit and brightness compensation method thereof |
| WO2020121907A1 (en) * | 2018-12-11 | 2020-06-18 | 住友化学株式会社 | Polarizing film and method for manufacturing same |
| WO2021029190A1 (en) * | 2019-08-13 | 2021-02-18 | 東洋紡株式会社 | Transferring film laminate, and method for producing same |
| WO2021161881A1 (en) * | 2020-02-14 | 2021-08-19 | 日東電工株式会社 | Optical multilayer body with adhesive layer, image display device, method for producing said optical multilayer body with adhesive layer, and method for producing said image display device |
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| KR102663367B1 (en) | 2024-05-03 |
| CN113341495A (en) | 2021-09-03 |
| KR20240060758A (en) | 2024-05-08 |
| CN113341494A (en) | 2021-09-03 |
| KR20240060757A (en) | 2024-05-08 |
| KR20170040745A (en) | 2017-04-13 |
| CN113341495B (en) | 2022-12-06 |
| JP2017072647A (en) | 2017-04-13 |
| JP6795883B2 (en) | 2020-12-02 |
| CN106990470A (en) | 2017-07-28 |
| CN106990470B (en) | 2021-06-04 |
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