CN115113440A - Method for manufacturing oriented liquid crystal film - Google Patents
Method for manufacturing oriented liquid crystal film Download PDFInfo
- Publication number
- CN115113440A CN115113440A CN202210244594.5A CN202210244594A CN115113440A CN 115113440 A CN115113440 A CN 115113440A CN 202210244594 A CN202210244594 A CN 202210244594A CN 115113440 A CN115113440 A CN 115113440A
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- CN
- China
- Prior art keywords
- liquid crystal
- layer
- film
- adhesive
- oriented
- 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
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- 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
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- 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
- G02F1/1337—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers
- G02F1/13378—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers by treatment of the surface, e.g. embossing, rubbing or light irradiation
- G02F1/133788—Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers by treatment of the surface, e.g. embossing, rubbing or light irradiation by light irradiation, e.g. linearly polarised light photo-polymerisation
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- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
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- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
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- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
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- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10165—Functional features of the laminated safety glass or glazing
- B32B17/10431—Specific parts for the modulation of light incorporated into the laminated safety glass or glazing
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- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/55—Liquid crystals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/42—Polarizing, birefringent, filtering
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2310/00—Treatment by energy or chemical effects
- B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
- B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
- B32B2310/0837—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using actinic light
-
- 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
- G02F2202/00—Materials and properties
- G02F2202/28—Adhesive materials or arrangements
Landscapes
- Physics & Mathematics (AREA)
- Nonlinear Science (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Mathematical Physics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Polarising Elements (AREA)
- Liquid Crystal (AREA)
- Laminated Bodies (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
The invention provides a method for manufacturing an oriented liquid crystal film, which can manufacture an oriented liquid crystal film with small change of optical characteristics even if exposed to a high-temperature environment for a long time. The method for manufacturing the oriented liquid crystal film comprises the following steps: and a bonding step of bonding the oriented liquid crystal layer and the optical layer via an active energy ray-curable adhesive by a roll-to-roll method. The bonding step includes a coating step and an irradiation step. In the coating step, an adhesive having a temperature of 0 to 45 ℃ before curing is applied to at least one surface of the alignment liquid crystal layer and the optical layer. In the irradiation step, the laminate obtained by laminating the oriented liquid crystal layer and the optical layer with the adhesive before curing is irradiated with an active energy ray while a tension of 70N/1000mm wide to 550N/1000mm wide is applied in the transport direction of the laminate.
Description
Technical Field
The present invention relates to a method for manufacturing an oriented liquid crystal film including an oriented liquid crystal layer in which a liquid crystal compound is oriented.
Background
As an optical film (optical anisotropic element) having functions such as optical compensation of a liquid crystal display device and prevention of external light reflection of an organic EL display device, a liquid crystal film (oriented liquid crystal film) having an oriented liquid crystal layer in which a liquid crystal compound is oriented in a predetermined direction is used. The oriented liquid crystal film has a large birefringence Δ n as compared with a stretched polymer film, and therefore, is advantageous for thinning and weight reduction of an image display device (more specifically, a liquid crystal display device, an organic EL display device, and the like). In an image display device, an oriented liquid crystal film is bonded to an organic EL panel or a liquid crystal display panel as a laminate sheet in which a polarizer and the like are integrally laminated with each other through an adhesive or a bonding agent (see, for example, patent document 1).
The liquid crystal compound can be aligned in a predetermined direction by a shear force at the time of application to the substrate, an alignment regulating force of the alignment film, and the like, and by aligning the liquid crystal compound, an aligned liquid crystal film having various optical anisotropies can be obtained. For example, a homogeneously aligned liquid crystal layer in which nematic liquid crystal molecules having positive refractive index anisotropy are aligned in parallel on a substrate surface can be used as a positive a plate having refractive index anisotropy of nx > ny ═ nz.
In the case of using a thermotropic liquid crystal, a solution (liquid crystal composition) containing a liquid crystal compound is applied to a substrate, and the liquid crystal compound contained in the composition is heated so that the liquid crystal compound is in a liquid crystal state, whereby the liquid crystal compound is aligned. When the liquid crystalline composition contains a photopolymerizable liquid crystalline compound (liquid crystal monomer), the liquid crystalline compound is aligned, and then the aligned state is fixed by curing the liquid crystalline composition by light irradiation.
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication (Kokai) No. 2015-7700
Disclosure of Invention
Problems to be solved by the invention
The image display device is required to have higher durability, and the optical member constituting the image display device is also required to have less change in optical characteristics (more specifically, retardation and the like) when exposed to a high-temperature environment for a long time.
On the other hand, the optical characteristics of the oriented liquid crystal film may change in a high-temperature environment due to the influence of a layer disposed adjacent to the oriented liquid crystal layer. For example, when an oriented liquid crystal layer and an optical layer (more specifically, a polarizer, a transparent film, another oriented liquid crystal layer, or the like) are bonded via an adhesive layer, retardation change in a high-temperature environment hardly occurs, whereas when an oriented liquid crystal layer and an optical layer are bonded via an active energy ray-curable adhesive, retardation tends to increase in a high-temperature environment.
Further, the present inventors have found, through their studies, that the tendency of retardation to increase in the high-temperature environment described above becomes particularly remarkable when the alignment liquid crystal layer and the optical layer are bonded to each other by a roll-to-roll method with an active energy ray-curable adhesive interposed therebetween.
In view of the above problems, an object of the present invention is to provide a method for producing an oriented liquid crystal film capable of producing an oriented liquid crystal film having small changes in optical characteristics even when exposed to a high-temperature environment for a long time, the method comprising bonding an oriented liquid crystal layer and an optical layer to each other via an active energy ray-curable adhesive in a roll-to-roll manner.
Means for solving the problems
The method for producing an oriented liquid crystal film of the present invention is a method for producing an oriented liquid crystal film including an oriented liquid crystal layer in which a liquid crystal compound is oriented, and includes a bonding step of bonding the oriented liquid crystal layer and an optical layer together via an active energy ray-curable adhesive in a roll-to-roll manner. The bonding step includes a coating step and an irradiation step. In the coating step, the adhesive is coated on at least one of the surface of the alignment liquid crystal layer and the surface of the optical layer at a temperature of 0 to 45 ℃ before curing. In the irradiation step, the laminate obtained by laminating the oriented liquid crystal layer and the optical layer with the adhesive before curing is irradiated with an active energy ray while a tension of 70N/1000mm wide to 550N/1000mm wide is applied in a transport direction of the laminate.
In one embodiment of the method for producing an oriented liquid crystal film of the present invention, the irradiation step is performed so that the cumulative light amount is 450mJ/cm 2 ～1200mJ/cm 2 The laminate is irradiated with the active energy ray.
In one embodiment of the method for producing an oriented liquid crystal film of the present invention, the adhesive is applied to the surface at a temperature of 0 to 10 ℃ in the application step.
In one embodiment of the method for producing an oriented liquid crystal film of the present invention, the thickness of the layer formed by the adhesive after the irradiation step is 0.1 μm to 3.0 μm.
In one embodiment of the method for producing an oriented liquid crystal film of the present invention, the liquid crystal compound is uniformly oriented in the oriented liquid crystal layer.
In one embodiment of the method for producing an oriented liquid crystal film according to the present invention, the birefringence Δ n of the oriented liquid crystal layer after the bonding step is 0.03 or more.
In one embodiment of the method for producing an oriented liquid crystal film according to the present invention, the optical layer is a polarizer, a transparent film, or another oriented liquid crystal layer.
Effects of the invention
According to the method for producing an oriented liquid crystal film of the present invention, an oriented liquid crystal film having a bonding step of bonding an oriented liquid crystal layer and an optical layer via an active energy ray-curable adhesive by a roll-to-roll method can be produced, and the oriented liquid crystal film having little change in optical characteristics even when exposed to a high-temperature environment for a long time.
Drawings
Fig. 1 is an explanatory view for explaining an example of the method for producing an oriented liquid crystal film of the present invention.
Fig. 2 is a cross-sectional view showing an example of an oriented liquid crystal film in which an oriented liquid crystal layer and an optical layer are laminated with an adhesive interposed therebetween.
Fig. 3A, B, C and D are sectional views showing an example of the method for producing an oriented liquid crystal film shown in fig. 2, which are divided into steps.
Fig. 4 is a cross-sectional view showing an example of an aligned liquid crystal film in which an aligned liquid crystal layer and an optical layer are laminated with an adhesive interposed therebetween.
Fig. 5 is a cross-sectional view showing an example of an oriented liquid crystal film provided with an adhesive layer.
Fig. 6 is a cross-sectional view showing an example of an aligned liquid crystal film in which an aligned liquid crystal layer and an optical layer are laminated with an adhesive interposed therebetween.
Fig. 7 is a cross-sectional view showing an example of the layer configuration of the image display device.
Description of the symbols
17 laminated body
19. 40 adhesive layer
21 oriented liquid crystal layer
22. 41 optical layer
100. 101, 102, 103, 104 oriented liquid crystal film
Detailed Description
Preferred embodiments of the present invention will be described below. First, terms used in the present specification will be described. The thickness of the oriented liquid crystal layer, the thickness of the optical layer, and the thickness of the layer formed of an adhesive after irradiation with an active energy ray (after curing) (hereinafter, may be simply referred to as "adhesive layer") are arithmetic mean values of 10 measurement values obtained by observing a cross section obtained by cutting the layer in the thickness direction with a Transmission Electron Microscope (TEM), randomly selecting 10 measurement positions from a cross-sectional image, and measuring the thickness of the selected 10 measurement positions.
Hereinafter, the compound name may be followed by a "system" to collectively refer to the compound and its derivative. When a "system" is labeled after the compound name to indicate the polymer name, it means that the repeating unit of the polymer is derived from the compound or its derivative. The acrylic group and the methacrylic group may be collectively referred to as a "(meth) acrylic group" in some cases. The acrylate and the methacrylate may be collectively referred to as "(meth) acrylate" in some cases. Acryloyl and methacryloyl groups may be collectively referred to as "(meth) acryloyl" in some cases.
< method for producing oriented liquid crystal film >
The method for producing an oriented liquid crystal film according to the present embodiment is a method for producing an oriented liquid crystal film including an oriented liquid crystal layer in which a liquid crystal compound is oriented, and includes a bonding step of bonding the oriented liquid crystal layer and an optical layer via an active energy ray-curable adhesive by a roll-to-roll method. The bonding step includes a coating step and an irradiation step. In the coating step, an adhesive having a temperature of 0 to 45 ℃ before curing is applied to at least one surface of the alignment liquid crystal layer and the optical layer. In the irradiation step, the laminate obtained by laminating the oriented liquid crystal layer and the optical layer with the adhesive before curing is irradiated with an active energy ray while a tension of 70N/1000mm wide to 550N/1000mm wide is applied in the transport direction of the laminate.
According to the method for producing an oriented liquid crystal film of the present embodiment, it is possible to produce an oriented liquid crystal film having a small change in optical characteristics even when exposed to a high-temperature environment for a long time, while having a bonding step of bonding an oriented liquid crystal layer and an optical layer via an active energy ray-curable adhesive by a roll-to-roll method. The reason for this is presumed as follows.
In general, when a film product is produced from a film material by a roll-to-roll method, the film material is processed while applying tension to the film material in a transport direction in order to transport the film material. Therefore, a film product manufactured by the roll-to-roll method tends to have a shrinkage stress that is easily anisotropic between the longitudinal direction (the transport direction during manufacturing) and the width direction, and tends to have a residual stress. Thus, film products manufactured by the roll-to-roll method tend to have optical characteristics (e.g., retardation, etc.) that are easily changed in a high-temperature environment. As described above, this tendency is particularly remarkable when the oriented liquid crystal layer and the optical layer are bonded to each other by a roll-to-roll method via the active energy ray-curable adhesive.
In contrast, in the present embodiment, by setting the temperature of the adhesive in the coating step to be within a specific range and setting the tension applied to the laminate in the irradiation step to be within a specific range, the volume change (curing shrinkage) of the adhesive during curing is suppressed. As a result, the occurrence of residual stress due to curing shrinkage of the adhesive is suppressed, and therefore, an oriented liquid crystal film having small changes in optical characteristics even when exposed to a high-temperature environment for a long time (hereinafter, sometimes referred to as "excellent heating durability") can be produced.
The present embodiment will be described in detail below with reference to the drawings. For ease of understanding, the respective constituent elements are mainly schematically shown in fig. 1 to 7 to which reference is made, and the size, number, shape, and the like of the respective constituent elements shown in the drawings may be different from those of the actual drawings in some cases for convenience of drawing. For convenience of explanation, in the drawings to be explained later, the same components as those in the drawings explained earlier are denoted by the same reference numerals, and the explanation thereof may be omitted.
Fig. 1 is an explanatory view for explaining an example of the method for manufacturing an oriented liquid crystal film according to the present embodiment. As shown in fig. 1, an adhesive is applied to the surface of the alignment-containing liquid crystal layer film 10 (specifically, the surface of the alignment liquid crystal layer in the alignment-containing liquid crystal layer film 10) which is transported in a roll-to-roll manner by an application device 11, thereby forming an application layer 12 (application step). In fig. 1, a die coater is used as the coating device 11, but in the present invention, the coating device is not limited, and coating devices such as a gravure coater, a reverse coater, and a bar coater can be suitably used depending on the viscosity of the adhesive.
Next, the optical layer-containing film 13 guided by the guide roller 14 and conveyed between the first bonding roller 15 and the second bonding roller 16 and the alignment-containing liquid crystal layer film 10 are laminated via the coating layer 12 by passing between the first bonding roller 15 and the second bonding roller 16, thereby forming a laminated body 17. At this time, the laminate 17 is formed with the optical layer of the optical layer-containing film 13 in contact with the coating layer 12.
Next, the laminated body 17 is irradiated with an active energy ray (more specifically, ultraviolet ray, electron ray, or the like) by the active energy ray irradiation device 18 (irradiation step). In the irradiation step, the adhesive in the coating layer 12 is cured to form an adhesive layer 19, thereby obtaining an oriented liquid crystal film 100 in which the oriented liquid crystal layer-containing film 10 and the optical layer-containing film 13 are bonded via the adhesive layer 19. Examples of the light source of the active energy ray include: low-pressure mercury lamp, high-pressure mercury lamp, ultrahigh-pressure mercury lamp, metal halide lamp, xenon lamp, LED, and black lightLamps, chemical lamps, etc. The illuminance of the light source of the active energy ray is, for example, 100mW/cm 2 ～1000mW/cm 2 Preferably 400mW/cm 2 ～800mW/cm 2 . The surface of the alignment-containing liquid crystal layer film 10, the surface of the optical layer film 13, or both surfaces of the laminate 17 can be irradiated with active energy rays depending on the transmittance of the alignment-containing liquid crystal layer film 10 and the optical layer film 13 to be used.
In order to produce an oriented liquid crystal film having more excellent heat durability, the thickness of the adhesive layer 19 is preferably 3.0 μm or less, more preferably 2.8 μm or less. In order to produce an oriented liquid crystal film having excellent adhesion reliability, the thickness of the adhesive layer 19 is preferably 0.1 μm or more, and more preferably 0.5 μm or more. In order to produce an oriented liquid crystal film having more excellent heat durability while securing adhesion reliability, the thickness of the adhesive layer 19 is preferably 0.1 to 3.0. mu.m, more preferably 0.5 to 2.8. mu.m. The thickness of the adhesive layer 19 can be adjusted by changing the thickness of the coating layer 12.
In the bonding step described with reference to fig. 1, tension is applied to the alignment-containing liquid crystal layer film 10, the optical layer-containing film 13, and the laminate 17 by, for example, a dancer roll (not shown). The direction of applying tension is the transport direction for any of the alignment liquid crystal layer-containing film 10, the optical layer-containing film 13, and the laminate 17.
In order to produce an oriented liquid crystal film having more excellent heating durability while stably transporting the laminate 17, it is preferable that the laminate 17 is irradiated with active energy rays in a state where a tension of 77N/1000mm wide to 550N/1000mm wide is applied.
In order to produce an oriented liquid crystal film having more excellent durability against heating, the laminated body 17 is preferably provided with a cumulative light amount of 450mJ/cm 2 ～1200mJ/cm 2 Is irradiated with active energy rays, more preferably with a cumulative light amount of 450mJ/cm 2 ～1100mJ/cm 2 Is irradiated with an active energy ray under the condition (2), and more preferably, the cumulative light amount is 450mJ/cm 2 ～800mJ/cm 2 Is irradiated with active energy rays, more preferably with a cumulative light amount of 450mJ/cm 2 ～600mJ/cm 2 The condition (2) is irradiation with active energy rays.
In order to produce an oriented liquid crystal film having more excellent heat durability, the temperature of the adhesive applied in the application step is preferably 0 to 25 ℃, more preferably 0 to 10 ℃.
In order to stably convey the alignment-containing liquid crystal layer film 10, the optical layer-containing film 13, and the laminate 17, the conveying speed thereof is preferably 1 m/min to 100 m/min, and more preferably 5 m/min to 50 m/min.
The time from the application of the adhesive to the alignment liquid crystal layer-containing film 10 in the application step to the irradiation of the active energy ray to the laminate 17 in the irradiation step is, for example, 0 to 300 seconds.
In order to produce an oriented liquid crystal film having more excellent heating durability, the following condition 1 is preferably satisfied, the following condition 2 is more preferably satisfied, the following condition 3 is further preferably satisfied, and the following condition 4 is further preferably satisfied.
Condition 1: the temperature of the adhesive to be coated in the coating process is 0 to 25 ℃, and in the irradiation process, the cumulative light amount is 450mJ/cm 2 ～1200mJ/cm 2 The laminated body 17 is irradiated with an active energy ray under the condition(s).
Condition 2: the temperature of the adhesive to be coated in the coating process is 0 to 25 ℃, and in the irradiation process, the cumulative light amount is 450mJ/cm 2 ～800mJ/cm 2 The laminated body 17 is irradiated with an active energy ray under the condition(s).
Condition 3: the temperature of the adhesive to be coated in the coating process is 0 to 10 ℃, and in the irradiation process, the cumulative light amount is 450mJ/cm 2 ～1200mJ/cm 2 The laminated body 17 is irradiated with an active energy ray under the condition(s).
Condition 4: the temperature of the adhesive to be coated in the coating process is 0-10 deg.C, and in the irradiation process, the accumulated light amount is 450mJ/cm 2 ～800mJ/cm 2 The laminated body 17 was irradiated with an active energy ray under the following conditions.
An example of the method for producing an oriented liquid crystal film according to the present embodiment is described above with reference to fig. 1, but the present invention is not limited to the above example. For example, in the above example, the adhesive is applied to the alignment liquid crystal layer, but in the present invention, the adhesive may be applied to the optical layer, or may be applied to both the alignment liquid crystal layer and the optical layer.
Next, a configuration example of an alignment liquid crystal film obtained by the manufacturing method of the present embodiment will be described.
Fig. 2 is a cross-sectional view showing an example of an aligned liquid crystal film obtained by the manufacturing method of the present embodiment. The alignment liquid crystal film 101 shown in fig. 2 includes: a support base 20, an oriented liquid crystal layer 21 laminated on the support base 20, and an optical layer 22 laminated on the oriented liquid crystal layer 21 via an adhesive layer 19.
An example of a method for manufacturing the alignment liquid crystal film 101 shown in fig. 2 will be described with reference to fig. 1 and fig. 3A to D. Fig. 3A to D are cross-sectional views for each step showing an example of the method for manufacturing the alignment liquid crystal film 101 shown in fig. 2.
First, an alignment-containing liquid crystal layer film 10 in which an alignment liquid crystal layer 21 is laminated on a support substrate 20 is prepared (fig. 3A). The alignment-containing liquid crystal layer film 10 is obtained by, for example, applying a liquid crystalline composition containing a liquid crystal compound onto a supporting substrate 20, aligning the liquid crystal compound in a predetermined direction, and then fixing the alignment state.
Next, an adhesive is applied to the surface of the oriented liquid crystal layer 21 by the application device 11 (see fig. 1), thereby forming the coating layer 12 (fig. 3B).
Next, the alignment liquid crystal layer-containing film 10 and the optical layer-containing film 13 including the supporting substrate 23 and the optical layer 22 are laminated between the first laminating roller 15 and the second laminating roller 16 (see fig. 1) with the coating layer 12 interposed therebetween, thereby forming a laminated body 17 (fig. 3C). At this time, the laminate 17 is formed in a state where the optical layer 22 is in contact with the coating layer 12.
Next, the laminate 17 is irradiated with an active energy ray by an active energy ray irradiation apparatus 18 (see fig. 1) to cure the adhesive in the coating layer 12, thereby forming an adhesive layer 19, and then the support base 23 is peeled from the optical layer 22. Through the above steps, the alignment liquid crystal film 101 shown in fig. 3D can be obtained. In addition, the support substrate 23 may be used as it is as an alignment liquid crystal film in a state where the support substrate 23 is attached to the optical layer 22 without peeling.
In order to produce an oriented liquid crystal film having more excellent heating durability, the absolute value of the difference between the retardation of the oriented liquid crystal layer 21 in fig. 3A and the retardation of the oriented liquid crystal layer 21 in fig. 3D is preferably 3.2nm or less. The lower limit of the absolute value of the difference is not particularly limited and may be 0nm, but the absolute value of the difference is preferably 1.5nm or more from the viewpoint of reduction in production cost. The absolute value of the difference can be adjusted by, for example, changing at least one of the temperature of the adhesive to be applied in the application step, the tension applied to the laminate 17 in the irradiation step, and the cumulative light amount of the active energy rays irradiated to the laminate 17 in the irradiation step.
The oriented liquid crystal film 101 can be used as an optical member as it is. In this case, the supporting substrate 20 constitutes a part of the alignment liquid crystal film 101. In addition, the support substrate 20 may be peeled off from the oriented liquid crystal layer 21 like the oriented liquid crystal film 102 shown in fig. 4. An appropriate pressure-sensitive adhesive layer 30 may be laminated on the surface of the oriented liquid crystal layer 21 exposed by peeling off the support substrate 20 as in the oriented liquid crystal film 103 shown in fig. 5, or an optical layer 41 may be laminated through an adhesive layer 40 as in the oriented liquid crystal film 104 shown in fig. 6.
The adhesive constituting the adhesive layer 30 is not particularly limited, and an adhesive containing a base polymer such as an acrylic polymer, a silicone polymer, a polyester, a polyurethane, a polyamide, a polyether, a fluorine polymer, or a rubber polymer can be suitably selected and used. In particular, an acrylic pressure-sensitive adhesive, a rubber pressure-sensitive adhesive, or the like is preferable, which is excellent in transparency, exhibits appropriate wettability, cohesiveness, adhesiveness, weather resistance, heat resistance, and the like. The thickness of the pressure-sensitive adhesive layer 30 may be appropriately set depending on the kind of the adherend, and is, for example, 5 μm to 500 μm.
The pressure-sensitive adhesive layer 30 is laminated on the oriented liquid crystal layer 21 by, for example, bonding a pressure-sensitive adhesive formed in a sheet shape in advance to the surface of the oriented liquid crystal layer 21. After the adhesive composition is applied to the alignment liquid crystal layer 21, the adhesive layer 30 may be formed by drying, crosslinking, or photo-curing the solvent. In order to improve the adhesion (anchoring force) between the oriented liquid crystal layer 21 and the adhesive layer 30, the adhesive layer 30 may be laminated after forming a surface treatment such as corona treatment or plasma treatment or an easy-adhesion layer on the surface of the oriented liquid crystal layer 21.
As shown in fig. 5, a release liner 31 is preferably temporarily attached to the surface of the pressure-sensitive adhesive layer 30. The release liner 31 protects the surface of the pressure-sensitive adhesive layer 30, for example, until the pressure-sensitive adhesive-attached oriented liquid crystal film 103 is bonded to an image display unit 50 (see fig. 7) described later. As a constituent material of the release liner 31, a plastic film made of acrylic, polyolefin, cyclic polyolefin, polyester, or the like can be suitably used. The thickness of the release liner 31 is, for example, 5 μm to 200 μm. The surface of the release liner 31 is preferably subjected to a mold release treatment. Examples of the release agent used for the release treatment include: silicone materials, fluorine materials, long-chain alkyl materials, fatty acid amide materials, and the like.
In the production of the oriented liquid crystal film 104 shown in fig. 6, the oriented liquid crystal layer 21 and the optical layer 22 may be bonded with an adhesive, and then the oriented liquid crystal layer 21 and the optical layer 41 may be bonded with an adhesive, or the oriented liquid crystal layer 21 and the optical layer 22 may be bonded with an adhesive, after the oriented liquid crystal layer 21 and the optical layer 41 are bonded with an adhesive. The alignment liquid crystal layer 21 and the optical layer 22, and the alignment liquid crystal layer 21 and the optical layer 41 may be bonded together with an adhesive. A pressure-sensitive adhesive layer (not shown) may be further laminated on the optical layer 22 or the optical layer 41, or a release liner (not shown) may be temporarily attached to the surface of the pressure-sensitive adhesive layer.
Next, materials used in the method for producing an oriented liquid crystal film according to the present embodiment will be described.
[ liquid Crystal composition ]
Examples of the liquid crystal compound contained in the liquid crystal composition include rod-like liquid crystal compounds and discotic liquid crystal compounds. Since uniform alignment is facilitated by the alignment regulating force of the supporting substrate 20, a rod-like liquid crystal compound is preferable as the liquid crystal compound. The rod-like liquid crystal compound may be a polymer. For example, the rod-like liquid crystal compound may be a liquid crystal polymer (more specifically, a main chain type liquid crystal polymer, a side chain type liquid crystal polymer, or the like), or may be a polymer of a polymerizable liquid crystal compound. If the liquid crystal compound (monomer) before polymerization shows liquid crystallinity, it may not show liquid crystallinity after polymerization.
The liquid crystal compound is preferably thermotropic liquid crystal which exhibits liquid crystallinity by heating. Thermotropic liquid crystals undergo phase changes among crystalline phases, liquid crystal phases, and isotropic phases with temperature changes. The liquid crystal compound contained in the liquid crystal composition may be any of nematic liquid crystal, smectic liquid crystal, and cholesteric liquid crystal. A chiral agent may be added to the nematic liquid crystal to impart cholesteric alignment properties.
Examples of the rod-like liquid crystal compound exhibiting thermotropic properties include: azomethine compounds, azoxy compounds, cyanobiphenyl compounds, cyanophenyl ester compounds, benzoate compounds, phenyl cyclohexanecarboxylate compounds, cyanophenylcyclohexane compounds, cyano-substituted phenylpyrimidine compounds, alkoxy-substituted phenylpyrimidine compounds, phenyldioxane compounds, tolane compounds, and alkenylcyclohexylbenzonitrile compounds.
Examples of the polymerizable liquid crystal compound include: polymerizable liquid crystal compounds capable of fixing the alignment state of rod-like liquid crystal compounds using a polymer binder, polymerizable liquid crystal compounds having a polymerizable functional group capable of fixing the alignment state of liquid crystal compounds by polymerization, and the like. Among them, a photopolymerizable liquid crystal compound having a photopolymerizable functional group is preferable.
The photopolymerizable liquid crystal compound (liquid crystal monomer) has a mesogen group and at least one photopolymerizable functional group in one molecule. The temperature at which the liquid crystal monomer exhibits liquid crystallinity (liquid crystal phase transition temperature) is preferably 40 to 200 ℃, more preferably 50 to 150 ℃, and still more preferably 55 to 100 ℃.
Examples of mesogenic groups of the liquid crystal monomer include: biphenyl, phenylbenzoate, phenylcyclohexane, oxyazophenyl, azophenyl, phenylpyrimidine, diphenylethynyl, diphenylbenzoate, dicyclohexyl, cyclohexylphenyl, bitriphenyl, and the like. The terminal of these cyclic units may be substituted with cyano, alkyl, alkoxy, halogen, or the like.
Examples of the photopolymerizable functional group include: (meth) acryloyl groups, epoxy groups, vinyl ether groups, and the like. Among them, (meth) acryloyl groups are preferable. The liquid crystal monomer preferably has two or more photopolymerizable functional groups in one molecule. By using a liquid crystal monomer containing two or more photopolymerizable functional groups, a crosslinked structure is introduced into a liquid crystal layer after photocuring, and thus the durability of an oriented liquid crystal film tends to be improved.
As the liquid crystal monomer, any suitable liquid crystal monomer can be used. For example, International publication No. 00/37585, U.S. Pat. No. 5211877, U.S. Pat. No. 4388453, International publication No. 93/22397, European patent No. 0261712, German patent No. 19504224, German patent No. 4408171, British patent No. 2280445, Japanese patent laid-open publication No. 2017-206460, International publication No. 2014/126113, International publication No. 2016/114348, International publication No. 2014/010325, examples of the liquid crystal monomer include compounds described in Japanese patent laid-open Nos. 2015-200877, 2010-31223, 2011/050896, 2011-207765, 2010-31223, 2010-270108, 2008/119427, 2008-107767, 2008-273925, 2016/125839 and 2008-273925. The expressiveness of birefringence and the wavelength dispersion of retardation can also be adjusted by selecting a liquid crystal monomer.
The liquid crystalline composition may contain a compound (alignment control agent) for controlling the alignment of the liquid crystal monomer in a predetermined direction, in addition to the liquid crystal monomer. For example, when a side chain type liquid crystal polymer is contained in a liquid crystalline composition, a liquid crystal compound (monomer) can be vertically aligned. In addition, the liquid crystal compound can be aligned in a cholesteric manner by adding a chiral agent to the liquid crystal composition.
The liquid crystalline composition may contain a photopolymerization initiator. In the case where the liquid crystal monomer is cured by ultraviolet irradiation, the liquid crystalline composition preferably contains a photo radical polymerization initiator (photo radical generator) that generates radicals by light irradiation in order to promote photocuring. The photo cation generator and the photo anion generator may be used depending on the kind of the liquid crystal monomer (kind of the photopolymerizable functional group). The photopolymerization initiator is used in an amount of, for example, 0.01 to 10 parts by weight based on 100 parts by weight of the liquid crystal monomer. In addition to the photopolymerization initiator, a sensitizer or the like can be used.
A liquid crystalline composition can be prepared by mixing a liquid crystal monomer, and various alignment control agents, polymerization initiators, and the like used as needed with a solvent. The solvent is not particularly limited as long as it can dissolve the liquid crystal monomer and does not attack (or has low corrosiveness) the support base 20, and includes: halogenated hydrocarbon compounds such as chloroform, dichloromethane, carbon tetrachloride, dichloroethane, tetrachloroethane, trichloroethylene, tetrachloroethylene, chlorobenzene, and o-dichlorobenzene; phenol compounds such as phenol and p-chlorophenol; aromatic hydrocarbon compounds such as benzene, toluene, xylene, methoxybenzene and 1, 2-dimethoxybenzene; ketone solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, cyclopentanone, 2-pyrrolidone, and N-methyl-2-pyrrolidone; ester solvents such as ethyl acetate and butyl acetate; alcohol solvents such as t-butyl alcohol, glycerin, ethylene glycol, triethylene glycol, ethylene glycol monomethyl ether, diethylene glycol dimethyl ether, propylene glycol, dipropylene glycol, and 2-methyl-2, 4-pentanediol; amide solvents such as dimethylformamide and dimethylacetamide; nitrile solvents such as acetonitrile and propionitrile; ether solvents such as diethyl ether, dibutyl ether, and tetrahydrofuran; and cellosolve solvents such as ethyl cellosolve and butyl cellosolve. A mixed solvent of two or more solvents may be used.
The solid content concentration of the liquid crystalline composition is, for example, 5 to 60% by weight. The liquid crystalline composition may contain additives such as a surfactant and a leveling agent.
[ supporting base Material ]
The support base 20 and the support base 23 are not particularly limited as long as they are substrates that can be transported by a roll-to-roll method, and are preferably film substrates (more specifically, resin film substrates and the like) from the viewpoint of ease of transportation. The support base material 20 and the support base material 23 may be made of the same kind of material or may be made of different kinds of materials. The thickness of the support base 20 and the thickness of the support base 23 are not particularly limited, and are, for example, 1 μm to 500 μm. The thickness of the support base material 20 and the thickness of the support base material 23 may be the same or different. The support substrate 20 has a first main surface and a second main surface, and the liquid crystal composition is applied to the first main surface.
The resin material constituting the resin film substrate is not particularly limited as long as it is insoluble in the solvent of the liquid crystalline composition and has heat resistance at the time of heating for aligning the liquid crystalline composition, and examples thereof include: polyesters such as polyethylene terephthalate and polyethylene naphthalate; polyolefins such as polyethylene and polypropylene; cyclic polyolefins such as norbornene polymers; cellulose polymers such as cellulose diacetate and cellulose triacetate; an acrylic polymer; a styrenic polymer; a polycarbonate; a polyamide; polyimide, and the like.
The support substrate 20 may have an alignment ability for aligning the liquid crystal compound in a predetermined direction. For example, by using a stretched film as the support substrate 20, the liquid crystal compound can be uniformly aligned along the stretching direction thereof. The stretch ratio of the stretched film may be, for example, 1.1 to 5 times as large as the degree that the orientation ability can be exhibited. The stretched film may be a biaxially stretched film. Even in the case of a biaxially stretched film, if a film having a stretch ratio different between the longitudinal direction and the transverse direction is used, the liquid crystal compound can be oriented in a direction having a large stretch ratio. The stretched film may be an obliquely stretched film. By using an obliquely stretched film as the support substrate 20, the liquid crystal compound can be aligned in a direction not parallel to any of the longitudinal direction and the width direction of the support substrate 20.
The support substrate 20 may have an alignment film on the first main surface. The alignment film may be appropriately selected depending on the kind of the liquid crystal compound, the material of the support substrate 20, and the like. As the alignment film for uniformly aligning the liquid crystal compound in a predetermined direction, an alignment film obtained by rubbing a polyimide-based or polyvinyl alcohol-based alignment film can be suitably used. In addition, a photo alignment film may be used. The resin film as the support base material 20 may be subjected to rubbing treatment without providing an alignment film.
The support substrate 20 may be provided with an alignment film for vertically aligning the liquid crystal compound. As an alignment agent for forming an alignment film having vertical alignment properties (vertical alignment film), there can be mentioned: lecithin, stearic acid, cetyltrimethylammonium bromide, octadecylamine hydrochloride, a monocarboxylic acid chromium complex, an organosilane (more specifically, a silane coupling agent, a siloxane compound, or the like), perfluorodimethylcyclohexane, tetrafluoroethylene, polytetrafluoroethylene, or the like.
[ alignment liquid Crystal layer ]
In the case where the liquid crystal compound is a thermotropic liquid crystal, the liquid crystal composition is applied to the first main surface of the support substrate 20, and the liquid crystal compound is aligned in a liquid crystal state by heating.
The method for applying the liquid crystal composition to the supporting base material 20 is not particularly limited, and spin coating, die coating, kiss roll coating (kiss roll coat), gravure coating, reverse coating, spray coating, meyer bar coating, knife roll coating, air knife coating, and the like can be used. After the liquid crystalline composition is applied, the solvent is removed, whereby a liquid crystalline composition layer is formed on the supporting substrate 20. The thickness of the coating layer formed by coating the liquid crystalline composition is preferably adjusted so that the thickness of the liquid crystalline composition layer after removal of the solvent is 0.1 to 20 μm.
The liquid crystal composition layer formed on the supporting substrate 20 is heated to form a liquid crystal phase, and the liquid crystal compound is aligned to form an aligned liquid crystal layer 21. Specifically, the liquid crystalline composition is applied to the supporting substrate 20, and then heated to a temperature not lower than the N (nematic phase) -I (isotropic liquid phase) transition temperature of the liquid crystalline composition, thereby bringing the liquid crystalline composition into an isotropic liquid state. Then, the mixture is slowly cooled as necessary to exhibit a nematic phase. In this case, it is desirable to temporarily maintain the temperature at which the liquid crystal phase is present, and to grow the liquid crystal phase domain into a single domain. Alternatively, the liquid crystal compound may be aligned in a predetermined direction by applying the liquid crystal composition to the support substrate 20 and then maintaining the temperature within the temperature range in which the nematic phase is expressed for a certain period of time.
The heating temperature for aligning the liquid crystal compound in the predetermined direction may be appropriately selected depending on the kind of the liquid crystal composition, and is, for example, 40 to 200 ℃. If the heating temperature is too low, the transition to the liquid crystal phase tends to be insufficient, and if the heating temperature is too high, the alignment defect may increase. The heating time may be adjusted so that the liquid crystal domains grow sufficiently, and is, for example, 30 seconds to 30 minutes.
It is preferable to cool to a temperature of not higher than the glass transition temperature after aligning the liquid crystal compound by heating. The cooling method is not particularly limited, and for example, the cooling method may be carried out by taking the product out of a heating atmosphere to room temperature. Forced cooling such as air cooling or water cooling may be performed.
The oriented photopolymerizable liquid crystal compound is irradiated with light to perform photocuring in a state where the photopolymerizable liquid crystal compound (liquid crystal monomer) has liquid crystal regularity. The light to be irradiated may be any light that can polymerize the photopolymerizable liquid crystal compound, and ultraviolet light or visible light having a wavelength of 250 to 450nm is usually used. When the liquid crystalline composition contains a photopolymerization initiator, light having a wavelength at which the photopolymerization initiator has sensitivity may be selected. As the irradiation light source, a low-pressure mercury lamp, a high-pressure mercury lamp, an ultrahigh-pressure mercury lamp, a metal halide lamp, a xenon lamp, an LED, a black light lamp, a chemical lamp, or the like can be used. In order to accelerate the photocuring reaction, the light irradiation is preferably performed in an inert gas atmosphere such as nitrogen.
When the liquid crystal composition is photocured, the liquid crystal compound can be aligned in a predetermined direction by using polarized light in the predetermined direction. As described above, when the liquid crystal compound is aligned by the alignment regulating force of the support substrate 20, the irradiation light may be unpolarized light (natural light).
The irradiation intensity of the irradiation light may be appropriately adjusted depending on the composition of the liquid crystalline composition, the amount of the photopolymerization initiator added, and the like. The irradiation energy (accumulated light amount) is, for example, 20mJ/cm 2 ～10000mJ/cm 2 Preferably 50mJ/cm 2 ～5000mJ/cm 2 More preferably 100mJ/cm 2 ～800mJ/cm 2 . In order to promote the photocuring reaction, light irradiation may be performed under heating conditions.
The polymer obtained by photocuring the liquid crystal monomer by light irradiation is non-liquid crystalline and does not undergo phase transition due to temperature change. Therefore, the liquid crystal layer after photocuring in a state where the liquid crystal monomers are aligned in a predetermined direction is generally less likely to have a change in molecular alignment. In addition, the oriented liquid crystal film has a very large birefringence Δ n compared to a film formed of a non-liquid crystal material, and thus, the thickness of an optically anisotropic element having a desired retardation is significantly reduced. The thickness of the oriented liquid crystal layer 21 may be set in accordance with a target retardation value or the like, and is, for example, 0.1 to 20 μm, preferably 0.2 to 10 μm, and more preferably 0.5 to 7 μm.
The optical characteristics of the alignment liquid crystal layer 21 are not particularly limited. The in-plane retardation and the thickness direction retardation of the oriented liquid crystal layer 21 may be appropriately set according to the application and the like. In the oriented liquid crystal layer 21, when the liquid crystal compound is uniformly oriented, the in-plane retardation of the oriented liquid crystal layer 21 is, for example, 20nm to 1000 nm. When the oriented liquid crystal layer 21 is an 1/4 wave plate, the in-plane retardation is preferably 100nm to 180nm, more preferably 120nm to 150 nm. When the oriented liquid crystal layer 21 is an 1/2 wave plate, the in-plane retardation is preferably 200nm to 340nm, more preferably 240nm to 300 nm. In the oriented liquid crystal layer 21, when the liquid crystal compound is vertically oriented, the in-plane retardation of the oriented liquid crystal layer 21 is substantially 0 (for example, 5nm or less, preferably 3nm or less), and the absolute value of the retardation in the thickness direction is, for example, 30nm to 500 nm.
When the liquid crystal compound is uniformly aligned in the aligned liquid crystal layer 21, the birefringence Δ n of the aligned liquid crystal layer 21 after the bonding step is preferably 0.03 or more in order to reduce the thickness of the optically anisotropic element. In the case where the liquid crystal compound is uniformly aligned in the aligned liquid crystal layer 21, the birefringence Δ n of the aligned liquid crystal layer 21 after the bonding step is preferably 0.5 or less in order to easily adjust the in-plane retardation of the aligned liquid crystal layer 21. The birefringence Δ n of the aligned liquid crystal layer 21 can be adjusted by, for example, changing the kind of liquid crystal compound used for formation of the aligned liquid crystal layer 21.
[ optical layer ]
The optical layers 22 and 41 are not particularly limited. As the optical layer 22 and the optical layer 41, for example, a generally used optical film having optical isotropy or optical anisotropy can be used without limitation. Specific examples of the optical layer 22 and the optical layer 41 include: a transparent film (more specifically, a retardation film, a polarizer protective film, etc.), a functional film (more specifically, a polarizer, a viewing angle enlarging film, a viewing angle restricting (privacy) film, a brightness improving film, etc.), and the like. The optical layer 22 and the optical layer 41 may be a single layer or a laminate. The optical layers 22 and 41 may be an alignment liquid crystal layer (other alignment liquid crystal layer). The optical layer 22 may be a polarizing plate having a transparent protective film bonded to one or both surfaces of a polarizer. When the polarizing plate has a transparent protective film on one surface, the polarizer may be bonded to the oriented liquid crystal layer 21, or the transparent protective film may be bonded to the oriented liquid crystal layer 21. The optical layer 22 and the optical layer 41 may be made of the same material or different materials. The thickness of the optical layer 22 and the thickness of the optical layer 41 can be adjusted as appropriate depending on the desired optical performance, and are, for example, 0.1 to 1000 μm, preferably 0.1 to 100 μm. The thickness of the optical layer 22 and the thickness of the optical layer 41 may be the same or different.
[ adhesive layer ]
The adhesive constituting the adhesive layer 19 and the adhesive layer 40 is not particularly limited as long as it is an active energy ray-curable adhesive which is optically transparent, and examples thereof include: epoxy resin adhesives, silicone resin adhesives, acrylic resin adhesives, polyurethane adhesives, polyamide adhesives, polyether adhesives, and the like. The adhesive layer 19 and the adhesive layer 40 may be composed of the same type of adhesive or may be composed of different types of adhesives. The preferable range of the thickness of the adhesive layer 40 is the same as the preferable range of the thickness of the adhesive layer 19 described above. The thickness of the adhesive layer 19 and the thickness of the adhesive layer 40 may be the same or different.
The active energy ray-curable adhesive is an adhesive that can undergo radical polymerization, cationic polymerization, or anionic polymerization by irradiation with an active energy ray such as an electron beam or ultraviolet ray. Among these, a photo radical polymerizable adhesive, a photo cation polymerizable adhesive, or a hybrid adhesive using both photo cation polymerization and photo radical polymerization is preferable because it can be cured at low energy.
Examples of the monomer of the photo radical polymerizable adhesive include a compound having a (meth) acryloyl group and a compound having a vinyl group. Among them, compounds having a (meth) acryloyl group are preferable. The compound having a (meth) acryloyl group includes (meth) acrylic acid C 1-20 Alkyl (meth) acrylates such as chain alkyl esters, alicyclic alkyl (meth) acrylates, and polycyclic alkyl (meth) acrylates; a hydroxyl group-containing (meth) acrylate; epoxy group-containing (meth) acrylates such as glycidyl (meth) acrylate, and the like. The photo radical polymerizable adhesive may contain a nitrogen-containing monomer such as hydroxyethyl (meth) acrylamide, N-methylol (meth) acrylamide, N-methoxymethyl (meth) acrylamide, N-ethoxymethyl (meth) acrylamide, or (meth) acryloylmorpholine. The photo radical polymerizable adhesive may contain a polyfunctional monomer such as tripropylene glycol diacrylate, 1, 9-nonanediol diacrylate, tricyclodecane dimethanol diacrylate, cyclic trimethylolpropane formal acrylate, dioxane ethylene glycol diacrylate or polyoxyethylene glycol diacrylate as a crosslinking component.
Examples of the curable component of the photo cation polymerizable adhesive include compounds having an epoxy group and an oxetane group. The compound having an epoxy group is not particularly limited as long as it has at least two epoxy groups in the molecule, and various curable epoxy compounds generally known can be used. Preferable epoxy compounds include compounds having at least two epoxy groups and at least one aromatic ring in a molecule (aromatic epoxy compounds), compounds having at least two epoxy groups in a molecule and at least one of which is formed between two adjacent carbon atoms constituting an alicyclic ring (alicyclic epoxy compounds), and the like. The cationic polymerizable adhesive may contain a radical polymerizable compound such as a compound having a (meth) acryloyl group to prepare a hybrid adhesive.
In order to obtain an adhesive with a small cure shrinkage ratio, it is preferable to adjust the blending of the adhesive so that the number of bonds formed when the adhesive is cured is reduced. In order to reduce the number of bonds, it is preferable to use a monomer having a high molecular weight per reactive functional group (e.g., (meth) acryloyl group, etc.). Examples of the monomer having a high molecular weight per reactive functional group include an alkyl (meth) acrylate having an alkyl group having 10 or more, 12 or more, 14 or more, 16 or more, or 18 or more carbon atoms (e.g., isostearyl acrylate), and a polyoxyethylene glycol diacrylate having 5 or more, 7 or more, or 9 or more oxyethylene groups per molecule.
In addition, even when the adhesive before curing contains an oligomer having a weight average molecular weight of 1000 or more, an adhesive having a small cure shrinkage rate can be obtained. Examples of the oligomer having a weight average molecular weight of 1000 or more (hereinafter sometimes referred to as "specific oligomer") include oligomers (acrylic oligomers) formed from monomers having a (meth) acryloyl group. The acrylic oligomer may have a cationically polymerizable functional group (e.g., epoxy group).
The weight average molecular weight of a particular oligomer can be determined by Gel Permeation Chromatography (GPC). In the present specification, the weight average molecular weight of a specific oligomer is a standard polystyrene conversion value measured under the following conditions, if not specified at all.
(conditions for measuring molecular weight)
GPC measurement apparatus: HLC-8120GPC, manufactured by Tosoh corporation "
Sample concentration: 2.0g/L (tetrahydrofuran solution)
Sample injection amount: 20 μ L
A chromatographic column: tosoh corporation "TSKgel, SuperAWM-H + SuperAW4000
+superAW2500”
Column size: 6.0mmI.D. times 150mm each
Eluent: tetrahydrofuran (THF)
Flow rate: 0.4 mL/min
A detector: differential Refractometer (RI)
Column temperature (measurement temperature): 40 deg.C
The photocurable adhesive preferably contains a photopolymerization initiator. The photopolymerization initiator may be appropriately selected depending on the kind of reaction. For example, it is preferable to blend a photo radical polymerization initiator that generates radicals by light irradiation as a photopolymerization initiator in the photo radical polymerizable adhesive. It is preferable to blend a photo cation polymerization initiator (photo acid generator) which generates a cation species or a lewis acid by light irradiation as a photopolymerization initiator in the photo cation polymerizable adhesive. The hybrid adhesive preferably contains a photo cation polymerization initiator and a photo radical polymerization initiator.
The content of the photopolymerization initiator is, for example, 0.1 to 10 parts by weight, preferably 0.5 to 3 parts by weight, based on 100 parts by weight of the monomer. If necessary, a photosensitizer may be added to the photocurable adhesive. The photosensitizer is used in an amount of, for example, 0.001 to 10 parts by weight, preferably 0.01 to 3 parts by weight, based on 100 parts by weight of the monomer.
The adhesive may contain appropriate additives as needed. Examples of additives include: silane coupling agents, coupling agents such as titanium coupling agents, bonding accelerators such as ethylene oxide, ultraviolet absorbers, deterioration prevention agents, dyes, processing aids, ion trapping agents, antioxidants, tackifiers, fillers, plasticizers, leveling agents, foaming inhibitors, antistatic agents, heat-resistant stabilizers, hydrolysis-resistant stabilizers and the like.
[ use ]
The oriented liquid crystal film obtained by the production method of the present embodiment can be used as an optical film for a display for the purpose of, for example, improving visibility.
The oriented liquid crystal film obtained by the production method of the present embodiment may be a circularly polarizing plate in which a polarizing plate as the optical layer 22 is bonded to one surface of the oriented liquid crystal layer 21 via the adhesive layer 19. The circularly polarizing plate may have two or more layers of aligned liquid crystal layers.
The polarizing plate may be constituted by only one polarizer, or a transparent protective film may be attached to one or both surfaces of the polarizer as described above. Examples of the polarizer include: a polarizer obtained by uniaxially stretching a hydrophilic polymer film such as a polyvinyl alcohol film, a partially formalized polyvinyl alcohol film, or an ethylene-vinyl acetate copolymer partially saponified film, while adsorbing a dichromatic substance such as iodine or a dichromatic dye; and polyene-based oriented films such as dehydrated polyvinyl alcohol and desalted polyvinyl chloride.
Among these, a polyvinyl alcohol (PVA) polarizer is preferred in that a polyvinyl alcohol film such as polyvinyl alcohol or partially formalized polyvinyl alcohol is adsorbed with a dichroic material such as iodine or a dichroic dye and oriented in a predetermined direction, from the viewpoint of having a high degree of polarization. For example, a PVA-based polarizer is obtained by subjecting a polyvinyl alcohol-based film to iodine dyeing and stretching. The PVA-based resin layer may be formed on the resin substrate, and iodine dyeing and stretching may be performed in a state of a laminate.
In the circularly polarizing plate, at least one layer of the alignment liquid crystal layer is preferably uniformly aligned with the liquid crystal compound. In the circularly polarizing plate, the orientation direction of the liquid crystal compound in the oriented liquid crystal layer in which the liquid crystal compound is uniformly oriented is arranged so as to be neither parallel nor perpendicular to the absorption axis direction of the polarizer.
In the case where the circularly polarizing plate has only one alignment liquid crystal layer, the alignment liquid crystal layer 21 is, for example, an 1/4-wave plate, and the angle formed by the absorption axis direction of the polarizing plate as the optical layer 22 and the alignment direction (generally, the slow axis direction) of the liquid crystal compound is set to 45 °. The angle formed by the absorption axis direction of the polarizing plate and the alignment direction of the liquid crystal compound may be 35 ° to 55 °, 40 ° to 50 °, or 43 ° to 47 °.
In a configuration in which a polarizing plate as the optical layer 22 and an 1/4 wave plate as the oriented liquid crystal layer 21 are laminated such that the angle formed by the optical axes of the two plates becomes 45 °, an oriented liquid crystal layer in which a liquid crystal compound is vertically oriented is further provided as the optical layer 41 (see fig. 6). By laminating the oriented liquid crystal layer 21 as an 1/4-wave plate and the optical layer 41 functioning as a normal C-plate in this order on the polarizing plate, it is possible to form a circularly polarizing plate capable of blocking reflected light from external light also coming from an oblique direction. A vertically aligned liquid crystal layer (positive C plate) and a uniformly aligned liquid crystal layer (1/4 wave plate as a positive a plate) may be stacked in this order on the polarizing plate.
In the case where the oriented liquid crystal film 104 shown in fig. 6 is a circularly polarizing plate in which an oriented liquid crystal layer 21 and an oriented liquid crystal layer 41 are laminated in this order on a polarizing plate as an optical layer 22, both the oriented liquid crystal layer 21 and the optical layer 41 may be uniformly oriented liquid crystal layers. In this case, it is preferable that the oriented liquid crystal layer 21 disposed on the side closer to the optical layer 22 is an 1/2 wave plate, and the optical layer 41 disposed on the side farther from the optical layer 22 is a 1/4 wave plate. In this layer structure, the 1/2-plate is preferably arranged so that the angle formed by the slow axis direction of the 1/2-plate and the absorption axis direction of the polarizing plate is 75 ° ± 5 °, and the angle formed by the slow axis direction of the 1/4-plate and the absorption axis direction of the polarizing plate is 15 ° ± 5 °. The circularly polarizing plate having such a layer functions as a circularly polarizing plate in a wide wavelength range of visible light, and therefore coloring of reflected light can be reduced.
< image display device >
Fig. 7 is a cross-sectional view showing an example of the layer configuration of the image display device, and an alignment liquid crystal film (an alignment liquid crystal film obtained by the manufacturing method of the present embodiment) including an alignment liquid crystal layer 21 is bonded to the surface of the image display unit 50 through a pressure-sensitive adhesive layer 30. The alignment liquid crystal film may include two or more alignment liquid crystal layers. The image display unit 50 may be a liquid crystal unit, an organic EL unit, or the like.
As described above, the heating durability of the oriented liquid crystal layer 21 of the oriented liquid crystal film obtained by the production method of the present embodiment is improved. Accordingly, in the image display device 200 shown in fig. 7, even when exposed to a high-temperature environment for a long time, the change in retardation of the oriented liquid crystal layer 21 is small, and therefore, the change in visibility is small, and the heating durability is excellent.
Examples
The present invention will be described in more detail below by referring to examples of producing an oriented liquid crystal film, but the present invention is not limited to the following examples.
< preparation of adhesive A-1 >
The components shown in table 1 were mixed in the content ratios shown in table 1 to prepare an ultraviolet-curable adhesive a-1. In table 1, each numerical value of the content ratio is a content ratio with respect to the total amount of the adhesive.
In addition, the meanings of the terms in table 1 are as follows.
HEAA: hydroxyethyl acrylamide (HEAA (registered trademark) manufactured by KJ chemical Co., Ltd.)
M-5700: acrylate monomer (Aronix (registered trademark) M-5700, manufactured by Toya Synthesis Co., Ltd.)
P2H-A: phenoxydiethylene glycol acrylate (Light acrylate (registered trademark) P2H-A, Kyoeisha chemical Co., Ltd.)
M-220: acrylate monomer ("Aronix (registered trademark) M-220", manufactured by Toya Synthesis Co., Ltd.)
1,9 ND-A1.9-nonanediol diacrylate (Light acrylate (registered trademark) 1,9ND-A, Co., Ltd.)
UP-1190: acrylic oligomer (ARUFON (registered trademark) UP-1190, manufactured by Toyo Synthesis Co., Ltd., weight average molecular weight: 1700)
Omnirad 907: photo radical polymerization initiator ("Omnirad (registered trademark) 907" manufactured by IGM Resins Co., Ltd.)
DETX-S: photo radical polymerization initiator (KAYACURE DETX-S, manufactured by Japan Chemicals Co., Ltd.)
TABLE 1
< preparation of laminate L-1 >
A photopolymerizable liquid crystal compound exhibiting a nematic liquid crystal phase ("Paliocolor (registered trademark) LC 242" manufactured by BASF corporation) was dissolved in cyclopentanone to prepare a solution having a solid content concentration of 30 wt%. To this solution were added a surfactant (BYK (registered trademark) -360, manufactured by Big Chemie Japan) and a photopolymerization initiator (Omnirad (registered trademark) 907, manufactured by IGM Resins) to prepare a liquid crystalline composition. The amounts of the surfactant and the photopolymerization initiator added were 0.01 part by weight and 3 parts by weight, respectively, based on 100 parts by weight of the photopolymerizable liquid crystal compound.
As the Film substrate, a transversely stretched Film ("ZeonoR Film (registered trademark) ZT 12-50135", manufactured by Zeon corporation, Japan, having a thickness of 52 μm and an in-plane retardation of 50nm) was used. The liquid crystalline composition was applied onto the surface of a film base material by a bar coater so that the thickness after heating became 1.4 μm, and the film base material was heated at 100 ℃ for 3 minutes to align the liquid crystalline compound. Next, the liquid crystalline composition on the film substrate was cooled to room temperature (25 ℃ C.), and then irradiated with a cumulative light amount of 400mJ/cm in a nitrogen atmosphere 2 The film substrate was photocured to obtain a laminate L-1 having a uniformly aligned liquid crystal layer formed on the film substrate.
The in-plane retardation of the oriented liquid crystal layer in the obtained laminate L-1 was measured. Specifically, first, an acrylic pressure-sensitive adhesive sheet having a thickness of 15 μm was bonded to the surface of the oriented liquid crystal layer of the laminate L-1, and then the pressure-sensitive adhesive sheet was bonded to a glass plate to obtain a laminate with a glass plate. Next, the film base material was peeled off from the laminate with glass plates, and a measurement sample was obtained. Next, the in-plane retardation of the measurement sample (oriented liquid crystal layer) at a wavelength of 590nm was measured using a phase difference meter ("KOBRA (registered trademark) 21-ADH", manufactured by prince measuring instruments). Hereinafter, the in-plane retardation measured here is referred to as Re 1. Re1 was 140 nm.
< production of oriented liquid Crystal film >
[ production of oriented liquid Crystal film of example 1 ]
A film (MCP-N (100) manufactured by Dainippon printing Co., Ltd., hereinafter referred to as "laminate L-2") having a vertically aligned liquid crystal layer (thickness: 3 μm, in-plane retardation: 0nm) as an optical layer on a substrate was prepared. In addition, laminate L-1 was produced by the above-described method.
The adhesive A-1 (temperature: 25 ℃) was applied to the surface of the oriented liquid crystal layer of the laminate L-1 so that the thickness of the layer (adhesive layer) formed of the cured adhesive A-1 became 1.0. mu.m. Subsequently, the surface of the laminate L-2 on the oriented liquid crystal layer side was bonded to the coating layer formed of the adhesive A-1 to obtain a laminate L-3.
Next, in accordance with a roll-to-roll bonding process, the adhesive a-1 in the laminate L-3 is photocured while a tension is applied to the laminate L-3. Specifically, in an atmosphere at a temperature of 25 ℃, the laminate L-3 was applied with an illuminance of 600mW/cm in a state where a 538N/1000mm wide tension was applied in a direction perpendicular to the in-plane direction of the alignment direction of the homogeneously aligned liquid crystal layer in the laminate L-1 2 In a cumulative light quantity of 600mJ/cm 2 The adhesive A-1 was photo-cured by irradiation with ultraviolet rays under the conditions of (1). The laminate L-2 was irradiated with ultraviolet light. Further, the orientation direction of the homogeneously-oriented liquid crystal layer in the laminate L-1 is the stretching direction of the film base material (transversely stretched film) of the laminate L-1. In this way, in the roll-to-roll bonding process, the direction perpendicular to the in-plane alignment direction of the uniformly aligned liquid crystal layer is the transport direction of the laminate L-3. Subsequently, the substrate of the laminate L-2 was peeled off from the laminate L-3 to obtain an aligned liquid crystal film of example 1.
[ production of oriented liquid Crystal films of examples 2 to 4 ]
Alignment liquid crystal films of examples 2 to 4 were produced in the same manner as in example 1 except that the amount of accumulated light in the case of photocuring the adhesive was changed as shown in table 2 described below.
[ production of oriented liquid Crystal films of examples 5 to 7 and comparative example 1 ]
The alignment liquid crystal films of examples 5 to 7 and comparative example 1 were produced in the same manner as in example 1, except that the temperature of the adhesive at the time of applying the adhesive was changed as shown in table 3 described below. For reference, table 3 also shows details of the above-described embodiment 1.
[ production of oriented liquid Crystal films in example 8, example 9, and comparative example 2 ]
Alignment liquid crystal films of example 8, example 9 and comparative example 2 were produced in the same manner as in example 1, except that the tension applied to the laminate L-3 was changed as shown in table 4 described below. For reference, table 4 also shows details of the above-described embodiment 1.
< evaluation >
[ retardation change before and after adhesion ]
An acrylic pressure-sensitive adhesive sheet having a thickness of 15 μm was bonded to the surface of the homeotropic alignment liquid crystal layer of the alignment liquid crystal film to be evaluated (any one of the alignment liquid crystal films of examples 1 to 9, comparative example 1, and comparative example 2), and then the pressure-sensitive adhesive sheet was bonded to a glass plate to obtain a laminate with glass plates. Next, the film base material was peeled off from the laminate with glass plates, and a sample for evaluation was obtained. Next, the in-plane retardation of the evaluation sample (homogeneously aligned liquid crystal layer) at a wavelength of 590nm was measured using a phase difference meter ("KOBRA (registered trademark) 21-ADH", manufactured by prince measuring instruments). Hereinafter, the in-plane retardation measured here is referred to as Re 2. The retardation change (unit: nm) before and after the adhesion was calculated according to the formula "retardation change before and after the adhesion | Re2-Re1 |". In addition, | Re2-Re1| represents the absolute value of the difference between Re2 and Re 1. When the retardation change before and after adhesion was 3.2nm or less, it was evaluated as "the retardation change before and after adhesion can be suppressed". On the other hand, when the retardation change before and after adhesion exceeded 3.2nm, the evaluation was "the retardation change before and after adhesion could not be suppressed".
In addition, with the aligned liquid crystal film of example 1, the birefringence Δ n was calculated from the thickness of Re2 and the uniformly aligned liquid crystal layer according to the formula "birefringence Δ n ═ Re 2/thickness of uniformly aligned liquid crystal layer", and as a result, the birefringence Δ n of the uniformly aligned liquid crystal layer was 0.10.
[ delay Change Rate before and after heating durability test ]
The evaluation sample used for the evaluation of [ retardation change before and after adhesion ] was put into an air circulating oven at 85 ℃ for 120 hours. Next, the sample for evaluation was taken out of the oven, and the in-plane retardation of the sample for evaluation (homogeneously aligned liquid crystal layer) at a wavelength of 590nm was measured using a phase difference meter ("KOBRA (registered trademark) 21-ADH", manufactured by prince measuring instruments). Hereinafter, the in-plane retardation measured here is referred to as Re 3. The retardation change rate (unit:%) before and after the heat durability test was calculated according to the formula "100 × | Re3-Re2|/Re2 before and after the heat durability test". In addition, | Re3-Re2| represents the absolute value of the difference between Re3 and Re 2. When the retardation change rate before and after the heat durability test was 3.5% or less, the evaluation was "the change in optical properties can be suppressed even when exposed to a high-temperature environment for a long time". On the other hand, when the retardation change rate before and after the heat durability test exceeded 3.5%, it was evaluated as "the change in optical properties when exposed to a high temperature environment for a long time could not be suppressed".
In addition, no interlayer peeling occurred in any of the evaluation samples after the heating durability test, and the adhesion reliability was ensured.
In the above examples and comparative examples, the retardation change before and after bonding and the retardation change rate before and after the heating durability test are shown in tables 2 to 4 together with the production conditions and the like. In tables 2 to 4, "Δ Re" represents the change in retardation before and after bonding, and "Re change rate" represents the change in retardation before and after the heat durability test.
TABLE 2
TABLE 3
TABLE 4
In examples 1 to 9, the temperature of the adhesive at the time of applying the adhesive was 0 to 45 ℃ and the tension applied to the laminate L-3 was 70N/1000mm wide to 550N/1000mm wide. In examples 1 to 9, the rate of change in retardation before and after the heating durability test was 3.5% or less. Thus, the oriented liquid crystal films of examples 1 to 9 were able to suppress the change in optical properties even when exposed to a high-temperature environment for a long time.
In comparative example 1, the temperature of the adhesive when the adhesive was applied exceeded 45 ℃. In comparative example 2, the tension applied to the laminate L-3 exceeded 550N/1000mm in width. In comparative examples 1 and 2, the rate of change in retardation before and after the heat durability test exceeded 3.5%. Thus, the oriented liquid crystal films of comparative examples 1 and 2 could not suppress the change in optical characteristics when exposed to a high temperature environment for a long time.
As shown by the above results, according to the method for manufacturing an oriented liquid crystal film of the present invention, an oriented liquid crystal film having little change in optical characteristics even when exposed to a high-temperature environment for a long time can be manufactured.
Claims (7)
1. A method for producing an oriented liquid crystal film having an oriented liquid crystal layer in which a liquid crystal compound is oriented,
which comprises a bonding step of bonding an oriented liquid crystal layer and an optical layer via an active energy ray-curable adhesive in a roll-to-roll manner,
the bonding step includes:
a coating step of coating the adhesive on at least one surface of the alignment liquid crystal layer and the optical layer at a temperature of 0 to 45 ℃ before curing; and
and an irradiation step of irradiating the laminate, which is obtained by laminating the oriented liquid crystal layer and the optical layer with the adhesive before curing, with an active energy ray while applying a tension of 70N/1000mm wide to 550N/1000mm wide in a transport direction of the laminate.
2. The method for manufacturing an oriented liquid crystal film according to claim 1,
in the irradiation step, the cumulative light quantity is 450mJ/cm 2 ～1200mJ/cm 2 The laminate is irradiated with the active energy ray.
3. The method of manufacturing an oriented liquid crystal film according to claim 1 or 2,
in the coating step, the adhesive is coated on the surface at a temperature of 0 to 10 ℃.
4. The method of manufacturing an oriented liquid crystal film according to claim 1 or 2,
the thickness of the layer formed by the adhesive after the irradiation step is 0.1 to 3.0 μm.
5. The method of manufacturing an oriented liquid crystal film according to claim 1 or 2,
in the alignment liquid crystal layer, the liquid crystal compound is uniformly aligned.
6. The method of manufacturing an oriented liquid crystal film according to claim 5,
the birefringence Δ n of the oriented liquid crystal layer after the bonding step is 0.03 or more.
7. The method for producing an oriented liquid crystal film according to claim 1 or 2, wherein the optical layer is a polarizer, a transparent film, or another oriented liquid crystal layer.
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