CN115243894A - Laminated optical film - Google Patents
Laminated optical film Download PDFInfo
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- CN115243894A CN115243894A CN202180019654.7A CN202180019654A CN115243894A CN 115243894 A CN115243894 A CN 115243894A CN 202180019654 A CN202180019654 A CN 202180019654A CN 115243894 A CN115243894 A CN 115243894A
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- SFHYNDMGZXWXBU-LIMNOBDPSA-N 6-amino-2-[[(e)-(3-formylphenyl)methylideneamino]carbamoylamino]-1,3-dioxobenzo[de]isoquinoline-5,8-disulfonic acid Chemical compound O=C1C(C2=3)=CC(S(O)(=O)=O)=CC=3C(N)=C(S(O)(=O)=O)C=C2C(=O)N1NC(=O)N\N=C\C1=CC=CC(C=O)=C1 SFHYNDMGZXWXBU-LIMNOBDPSA-N 0.000 description 2
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Images
Classifications
-
- 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
- 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
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
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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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- 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
- 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
- B32B7/02—Physical, chemical or physicochemical properties
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J201/00—Adhesives based on unspecified macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J7/00—Adhesives in the form of films or foils
- C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
- C09J7/38—Pressure-sensitive adhesives [PSA]
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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
-
- 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
-
- 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
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/08—Dimensions, e.g. volume
- B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
- B32B2309/105—Thickness
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Polarising Elements (AREA)
- Laminated Bodies (AREA)
- Adhesive Tapes (AREA)
- Adhesives Or Adhesive Processes (AREA)
Abstract
A laminated optical film according to one embodiment of the present invention includes a1 st optical film and a resin layer laminated on the 1 st optical film and formed of a resin, wherein σ 1 and σ 2 satisfy σ 1/σ 2 ≦ 0.45 when a standard deviation of a thickness of the resin layer is σ 1 and a standard deviation of a thickness of the 1 st optical film is σ 2.
Description
Technical Field
The present invention relates to a laminated optical film.
Background
As a laminated optical film, there is a film having an optical film (1 st optical film) and a resin layer laminated on the optical film. Such a laminated optical film can be produced by, for example, applying a resin for forming a resin layer to the optical film. Among the above coating methods, as a method for coating a resin, there is a technique described in patent document 1, for example.
Documents of the prior art
Patent literature
Patent document 1: japanese patent laid-open publication No. 2000-024565
Disclosure of Invention
Problems to be solved by the invention
When a resin layer is formed by applying a resin to an optical film, the thickness of the resin layer may vary depending on the thickness distribution of the optical film, and the quality of the laminated optical film may be deteriorated. For example, if the material of the resin layer is an adhesive, the optical film may be bonded to another member via the resin layer. In this case, the thickness of the resin layer varies, and the appearance of the laminated optical film may be poor or the optical characteristics may be poor.
The purpose of the present invention is to provide a laminated optical film having improved quality.
Means for solving the problems
The laminated optical film of the present invention includes a1 st optical film and a resin layer laminated on the 1 st optical film and formed of a resin, where σ 1 and σ 2 satisfy formula (a) where σ 1 is a standard deviation of a thickness of the resin layer and σ 2 is a standard deviation of a thickness of the 1 st optical film.
σ1/σ2≤0.45···(A)
Since the laminated optical film satisfies the formula (a), even if the 1 st optical film has a thickness distribution, the fluctuation in the thickness of the resin layer is reduced, and thus appearance defects and optical property defects are less likely to occur. As a result, the quality of the laminated optical film is improved.
The 1 st optical film and the resin layer may be long. In this case, the thickness distribution is easily generated in the 1 st optical film. However, with the above laminated optical film satisfying the above formula (a), even if a thickness distribution is generated in the 1 st optical film, the thickness fluctuation of the resin layer is reduced. Therefore, the present invention is effective for a laminated optical film in the case where the 1 st optical film and the resin layer are long.
The resin layer may be a coating layer.
0.014≤σ1≤0.020···(B)
0.066≤σ2≤0.088···(C)
The resin may be an adhesive or a bonding agent. In this case, the resin layer functions as an adhesive layer or an adhesive layer, and thus the laminated optical film can be bonded to another member, for example.
The resin layer may further include a2 nd optical film thereon.
Effects of the invention
According to the present invention, a laminated optical film having improved quality can be provided.
Drawings
Fig. 1 is a conceptual diagram illustrating a method for manufacturing a laminated optical film according to an embodiment.
Fig. 2 is a flowchart of an example of a method for manufacturing a laminated optical film according to an embodiment.
Fig. 3 is a graph showing an example of data for changing the coating draw ratio in the method for manufacturing a laminated optical film according to the embodiment.
Fig. 4 is a graph showing an example of data for changing the coating draw ratio in the method for manufacturing a laminated optical film according to the embodiment.
Fig. 5 is a graph showing an example of data for changing the coating draw ratio in the method for manufacturing a laminated optical film according to the embodiment.
[ FIG. 6 ]]FIG. 6 is a view showing the thickness t of the resin layer in FIGS. 3 to 5 ave And a plot of the change in the traction ratio adjustment value.
Fig. 7 is a graph showing changes in the coating draw ratio and the thickness t1 of the resin layer in fig. 3 to 5.
FIG. 8 is a schematic view showing another example of a laminated optical film.
FIG. 9 is a graph showing the results of the experiment.
FIG. 10 is a graph showing the average value of σ 1/σ 2 in a plurality of examples and comparative examples in an experiment.
Detailed Description
Embodiments of the present invention will be described below with reference to the drawings. The same elements are denoted by the same reference numerals, and redundant description thereof is omitted. The dimensional ratios in the drawings do not necessarily correspond to the dimensional ratios of the elements described.
Fig. 1 is a conceptual diagram illustrating a method of manufacturing a laminated optical film according to an embodiment. As shown in fig. 1, the laminated optical film 10 has an optical film (1 st optical film) 11 and a resin layer 12 laminated on the optical film 11. In the present embodiment, the optical film 11 and the resin layer 12 are long articles. The length of the laminated optical film 10 in the longitudinal direction is, for example, 20m or more, and may be 200m or more.
In the present embodiment, the optical film 11 is a base material in the laminated optical film 10. The optical film 11 is also a support member that supports the resin layer 12. The optical film 11 is, for example, a resin film. In this case, the optical film 11 is formed by, for example, extrusion molding. The optical film 11 may have flexibility, and may be a single-layer resin film or a laminate of resin films. Examples of the optical film 11 include triacetyl cellulose (TAC), polyethylene terephthalate (PET), polycycloolefin (COP). The optical film 11 may be an optical laminate such as a polarizing plate, a phase difference plate, a circularly polarizing plate (including an elliptically polarizing plate) in which a phase difference plate and a polarizing plate are bonded to each other through an adhesive layer, or a laminate in which a protective film or the like is laminated on a polarizing plate or a phase difference plate. The polarizing plate may be, for example, a laminate in which a polarizing film (polarizing sublayer) and a protective film are laminated. Similarly, the retardation plate may be a laminate in which a liquid crystal cured layer is formed on a resin film, or a laminate in which a retardation film (retardation sub-layer) and a protective film are laminated, for example. Examples of the thickness of the optical film 11 are 10 μm to 200 μm.
The resin layer 12 is laminated on the optical film 11. The thickness of the resin layer 12 is, for example, 0.1 to 10 μm, preferably 0.5 to 5 μm, and more preferably 1 to 3 μm. In the example shown in fig. 1, the resin layer 12 is a coating layer formed of a coating agent 12a. Examples of the coating agent 12a may be a resin-containing adhesive (hereinafter, referred to as "resin adhesive") or a resin-containing adhesive (hereinafter, referred to as "resin adhesive"). The resin binder or resin binder may be a material well known in the art related to the present invention. Examples of the resin adhesive include active energy ray-curable adhesives such as Ultraviolet (UV) curable resins, and water-based adhesives such as aqueous solutions of polyvinyl alcohol resins. Examples of the resin adhesive include adhesive compositions containing a (meth) acrylic resin, a rubber resin, a urethane resin, an ester resin, a silicone resin, a polyvinyl ether resin, or the like as a main component. The coating agent 12a may be a composition for forming a liquid crystal layer containing a polymerizable liquid crystal compound.
In the laminated optical film 10, the standard deviation of the thickness t1 of the resin layer 12 is represented by σ 1, and the standard deviation of the thickness t0 of the optical film 11 is represented by σ 2.σ 1 and σ 2 satisfy the following formula (1). σ 1 and σ 2 may be standard deviations of the thickness t1 and the thickness t0 along the longitudinal direction at a certain position (for example, a central position) in the width direction (direction orthogonal to the longitudinal direction).
σ1/σ2≤0.45···(1)
In the case where the above expression (1) is satisfied, further, σ 1 may satisfy the following expression (2) and σ 2 may satisfy the expression (3).
0.014≤σ1≤0.020···(2)
0.066≤σ2≤0.088···(3)
An example of the method for manufacturing the laminated optical film 10 shown in fig. 1 will be described with reference to fig. 1 and 2. Fig. 2 is a flowchart of an example of the method for manufacturing the laminated optical film 10.
The method for manufacturing the laminated optical film 10 includes a coating step S01, a thickness obtaining step S02, a calculating step S03, and a changing step S04. The thickness obtaining step S02, the calculating step S03, and the changing step S04 constitute a method for managing the thickness of the resin layer 12 according to one embodiment. The laminated optical film 10 is manufactured by repeating the basic cycle (basic cycle) including the coating step S01, the thickness obtaining step S02, the calculating step S03, and the changing step S04. Fig. 2 shows the steps included in the basic cycle. The respective steps will be explained.
[ coating Process ]
In the coating step S01, as shown in fig. 1, the long optical film 11 is conveyed. For example, the optical film 11 may be drawn from a roll of a long optical film 11 manufactured in advance and transported. Alternatively, the optical film 11 manufactured in the manufacturing process of the optical film 11 may be directly conveyed. For example, when the optical film 11 is a resin film, the optical film 11 may be formed by extrusion molding and transported. In the coating step S01, the coating agent 12a is applied to the conveyed optical film 11 by the coating device 20. Specifically, the coating agent 12a in the coating agent supply section 21 of the coating device 20 is applied to the optical film 11 by the coating roller 22. An example of the coating device 20 is a known gravure coating device. In this case, the application roller 22 is a gravure roller. As shown in fig. 1, the application roller 22 rotates, for example, in a direction opposite to the conveyance direction of the optical film 11.
In the coating step S01, the coating agent 12a is applied to the optical film 11 based on the coating draw ratio (%) set (or stored) in the control device 30. The coating draw ratio is the ratio (V1/V2) of the rotational speed V1 of the coating roller 22 to the conveyance speed V2 of the optical film 11. For example, when the rotation speed V1 is 60 m/min and the carrying speed V2 is 30 m/min, the coating draw ratio is 200%. In the present embodiment, the control device 30 controls the rotation speed V1 of the application roller 22 to adjust the application traction ratio. As described later, the coating draw ratio is appropriately changed by changing step S04. The initial application draw ratio at the start of the production of the laminated optical film 10 may be input to the control device 30 by the user in advance.
[ thickness acquisition step ]
In the thickness obtaining step S02, the thickness t of the resin layer 12 is obtained ave . The thickness t of the resin layer 12 obtained in the thickness obtaining step S02 of the present embodiment ave Is the average thickness of the resin layer 12 within the specified range of the optical film 11. The predetermined range is set to a region having a constant length along the transport direction of the optical film 11 (or a region having a constant length passing below the measuring device M1 or the measuring device M2).
In the thickness obtaining step S02, as shown in fig. 1, the control device 30 obtains the thickness t of the resin layer 12 from the measurement results of the measuring devices M1 and M2 disposed upstream and downstream of the coating device 20 in the transport direction of the optical film 11 ave . The measuring device M1 and the measuring device M2 will be explained.
The measuring device M1 measures the thickness t0 of the optical film 11. The measuring device M2 measures the thickness t2 of the laminated optical film 10 including the resin layer 12. Therefore, the method for manufacturing the laminated optical film 10 according to one embodiment may include a step of obtaining the thickness of the optical film 11 before the coating step S01, and a step of measuring the thickness of the laminated optical film 10 after the coating step S01.
The measuring instruments M1 and M2 are not limited as long as they can measure the thickness of the measurement object (the optical film 11 and the laminated optical film 10). The measuring devices M1 and M2 are exemplified by spectroscopic interference type laser displacement meters (for example, SI-T series manufactured by KEYENCE). The measuring devices M1 and M2 input the measurement results (thickness t0 and thickness t 2) to the control device 30. The input method is not limited. For example, the measurement result may be input to the control device 30 by wire or wirelessly.
In the present embodiment, the controller 30 controls the measuring device M1 and the measuring device M2. Specifically, controller 30 controls measuring device M1 and measuring device M2 such that measuring device M1 and measuring device M2 perform measurement at predetermined intervals, respectively. Thus, the measurement results of the measuring instruments M1 and M2 are sequentially input to the control device 30 at the predetermined intervals. The predetermined interval may be the same as the predetermined interval or may be smaller than the predetermined interval so that the difference Δ d1 to be described later can be calculated at the predetermined interval. The predetermined interval is an interval previously input to control device 30 by the user.
For the thickness t of the utilization control device 30 ave An example of the method of calculating (a) will be described.
The control device 30 calculates a difference Δ d1 between the measurement result of the measuring device M2 and the measurement result of the measuring device M1. The difference Δ d1 is a difference between the measurement result of the measuring device M2 and the measurement result of the measuring device M1 at the same portion (referred to as "measurement position x" for convenience of description) of the optical film 11. The difference Δ d1 may be calculated using the measurement result at the measurement position x based on the installation distance between the measuring device M1 and the measuring device M2 and the transport speed of the optical film 11 in the measurement results of the measuring device M1 and the measuring device M2. The difference Δ d1 is the thickness t1 of the resin layer 12 at the measurement position x of the optical film 11. Control device 30 calculates difference Δ d1 at every predetermined interval. The designated interval is an interval input to the control device 30 in advance by the user. The controller 30 obtains the thickness t by averaging a plurality of differences Δ d1 included in a predetermined range among the differences Δ d1 sequentially calculated from the start of production of the laminated optical film 10 ave . In the present embodiment, the predetermined range is a region having a certain length (length along the transport direction of the optical film 11) which is input to the control device 30 in advance by the user. The numerical value of the difference Δ d1 used in the averaging is determined by the length of the specified range and the number of updates of the difference Δ d1 (corresponding to the specified interval in the present embodiment).
[ calculating procedure ]
In calculation step S02, controller 30 calculates thickness t ave And a difference Δ d2 from the target thickness (predetermined thickness). For example, the calculation step S02 is performed every time the thickness acquisition step S02 is performed.
[ Change procedure ]
In changing step S04, controller 30 sets thickness t based on difference Δ d2 ave The coating draw ratio in the coating step S01 is changed so as to match the target thickness. In the present embodiment, it is preferred that,the control device 30 performs the changing step S04 at a cycle (hereinafter referred to as a "correction cycle") larger than the predetermined interval at which the difference Δ d1 is calculated. For example, the correction period may be a natural number multiple (e.g., 3 times, 4 times, etc.) of 2 or more of the predetermined interval. The correction period may be input to the control device 30 in advance by a user. For example, the changing step S04 may be performed each time the calculating step S03 is performed.
For example, control device 30 may control thickness t based on a traction ratio adjustment value obtained by multiplying difference Δ d2 by a preset correction gain (adjustment ratio) ave The coating draw ratio in the coating step S01 is changed so as to match the target thickness. The correction gain may be input to the control device 30 in advance by a user. The correction gain can be changed by a user depending on the manufacturing state during the manufacture of the laminated optical film 10. The correction gain may be 1 time, but is preferably 10 to 70 times, more preferably 20 to 50 times, and further preferably 30 to 40 times.
An example of a method of changing the coating draw ratio using the draw ratio adjustment value will be described. In this example, in the nth (N is an integer of 2 or more) changing step S04, the sum of the (N-1) traction ratio adjustment value calculated in the changing step S04 up to the (N-1) th and the traction ratio adjustment value calculated in the nth changing step is further calculated as a correction value, and a new coating traction ratio is set in the form of the sum of the correction value and the initial coating traction ratio (the coating traction ratio set to perform the 1 st coating step S01).
Another example of the method of changing the coating draw ratio using the draw ratio adjustment value will be described. For convenience of description, the coating draw ratio before the change is referred to as a1 st coating draw ratio, and the coating draw ratio after the change is referred to as a2 nd coating draw ratio. In this example, control device 30 sets the sum of the draw ratio adjustment value and the 1 st application draw ratio as the 2 nd application draw ratio.
The laminated optical film 10 manufactured as described above may be attached to another member, for example, or may be sold as a product by further curing the resin layer 12.
The control device 30 may be configured to realize each function of the control device 30 described from the coating step S01 to the changing step S04. The control device 30 may have a function of receiving the measurement results from the measuring instruments M1 and M2 and the input of various data by the user, and may display various data (thickness t) ave Difference Δ d2, traction ratio adjustment value, etc.). Examples of the data input by the user are the target thickness and various parameters described above (for example, a designated interval, a correction period, a correction gain, and the like). The control device 30 may be a dedicated device for manufacturing the laminated optical film 10. Alternatively, a program for realizing the various functions described above may be executed by a personal computer, and the personal computer may be caused to function as the control device 30.
A method of changing the coating draw ratio by the control device 30 will be described in more detail with reference to fig. 3 to 5. Fig. 3 is a graph showing an example of data for changing the coating draw ratio in the method for manufacturing the laminated optical film 10 according to the embodiment.
The data shown in fig. 3 to 5 are data of a hypothetical example in which the laminated optical film 10 was produced under the following conditions, and the data up to the elapsed time of 60 seconds in the hypothetical example is extracted in fig. 3 to 5.
Target thickness: 1.5 μm
Initial coating draw ratio: 200 percent of
Length of the specified range: 1.4m
The interval is specified: 1 second
Conveying speed: 21 m/min (0.35 m/s)
And (3) correction period: 15 seconds (equivalent to a length of 5.25 m)
And (3) correcting gain: 35
The thickness shown in fig. 3 to 5 is, for example, the thickness of the resin layer 12 calculated as the difference between the thickness t2 and the thickness t1 when the thickness t0 and the thickness t2 are measured using the measuring instrument M1 and the measuring instrument M2 shown in fig. 1.
Assuming 1.4m as the specified range and 21 m/min as the carrying speed, as shown in FIG. 3, a straight line is obtainedAt the time of the data up to data No.5, the thickness t was calculated as the average value of the difference Δ d1 between data No.1 and No.5 ave . Since the length of the specified range is 1.4m, in the example shown in FIG. 3, the area of the optical film 11 corresponding to data Nos. 2 to 6 is set as the next specified range, and the thickness t is calculated ave . Thereafter, the thickness t was calculated while sequentially shifting the predetermined range by 0.35m (corresponding to an elapsed time of 1 second) each time ave . At each time, the thickness t is calculated ave Then, the difference Δ d2 is calculated, and the traction ratio adjustment value is calculated. FIG. 6 shows the thickness t in FIGS. 3 to 5 ave And a plot of the change in the traction ratio adjustment value. The horizontal axis of fig. 6 represents the transport distance of the optical film 11. The left vertical axis of fig. 6 represents the thickness t ave (μ n), and the right vertical axis represents the traction ratio adjustment value.
Since the correction cycle is 15 seconds, a new coating draft ratio is set based on the draft ratio adjustment value at the time point when the data of data No.15 is obtained, as shown in fig. 3. Specifically, the traction ratio adjustment value corresponds to the correction value because the 1 st changing step S04 is performed at the time when the data of data No.15 is obtained. Therefore, by adding-22.4 as a correction value (corresponding to the traction ratio adjustment value) to 200% of the coating traction ratio up to data No.15, 177.6 calculated therefrom was set as the next coating traction ratio. Thereafter, as shown in fig. 4, at the time point when the data of the data No.30 is obtained, a new coating draft ratio is set based on the draft ratio adjustment value. Specifically, the traction ratio adjustment value when data No.30 subjected to modification step S04 of the 2 nd time is obtained is-7, and therefore-29.4 obtained by adding-7 to-22.4, which is the correction value calculated in modification step S04 of the 1 st time, is calculated as the correction value. 170.6 calculated by adding-29.4 to 200% of the initial coating draw ratio was set as the next coating draw ratio. The coating draw ratio is set in the same manner as described below.
Fig. 7 is a graph showing changes in the coating traction ratio and the thickness t1 of the coating layer in fig. 3 to 5. The left vertical axis of fig. 7 represents the coating draw ratio (%), and the right vertical axis represents the thickness t1 of the resin layer 12.
As shown in fig. 3 to 5 and 7, the coating draw ratio was changed at a transport distance of 5.25 m. Thereby, the thickness t1 of the resin layer 12 also changes, and the thickness t1 converges to 1.5 μm, which is a target thickness.
In the explanation based on the data exemplified in fig. 3 to 5, the method of adjusting the coating traction ratio using the correction value is explained. However, the coating traction ratio may be adjusted without using the correction values shown in fig. 3 to 5. A method of adjusting the coating draw ratio in this case will be described.
Since the adjustment value of the draw ratio at the time point when the data No.15 of the first modification step S04 was obtained was-22.4, 177.6, which was calculated by adding-22.4 to 200% of the initial coating draw ratio, was set as the next coating draw ratio. Since the adjustment value of the draw ratio when the data No.30 of the 2 nd changing step S04 was obtained was-7, 170.6 calculated by adding-7 to 177.6 was set as the next application draw ratio. The coating draw ratio is set in the same manner as described below.
In the laminated optical film 10, σ 1 and σ 2 satisfy formula (1). Therefore, in the laminated optical film 10, the fluctuation in the thickness t1 of the resin layer 12 is reduced with respect to the fluctuation in the thickness t0 of the optical film 11. Therefore, the laminated optical film 10 is excellent in appearance and optical characteristics, and the quality of the laminated optical film 10 is improved. As σ 1/σ 2 is smaller, the appearance, optical characteristics, and the like of the laminated optical film 10 are better, and therefore σ 1/σ 2 is preferably 0.29 or less.
The point that equation (1) is satisfied is more effective when the optical film 11 and the resin layer 12 are long articles (for example, long articles having a length in the long direction of, for example, 2m or more, 5m or more, 10m or more, or 20m or more).
When the resin layer 12 is an adhesive or a pressure-sensitive adhesive made of a resin, the resin layer 12 functions as an adhesive layer or a pressure-sensitive adhesive layer. Therefore, the laminated optical film 10 can be bonded to another member.
In the case where σ 1 satisfies expression (2) and σ 2 satisfies expression (3), the fluctuation of the thickness t1 is smaller with respect to the fluctuation of the thickness t0. Therefore, the appearance and optical characteristics of the laminated optical film 10 are further improved.
In the method for manufacturing the laminated optical film 10, the thickness of the resin layer 12 is obtained, and the coating draw ratio is changed based on the difference Δ d2 from the target thickness. In the method for manufacturing the laminated optical film 10, the coating step S01, the thickness obtaining step S02, the calculating step S03, and the changing step S04 may be automatically performed by the control device 30 while repeating the coating step S01, the thickness obtaining step S02, the calculating step S03, and the changing step S04. That is, the control device 30 can automatically acquire, calculate, and the like data necessary for changing the coating draw ratio. In this case, the thickness (actual thickness or average thickness) of the resin layer 12 can be automatically monitored, and the thickness can be based on the obtained thickness (thickness t in the present embodiment) of the resin layer 12 ave ) And the coating draw ratio is automatically changed. In other words, the coating draw ratio is automatically changed so that the thickness t2 of the resin layer 12 is converged to the target thickness. As a result, the laminated optical film 10 including the resin layer 12 having the target thickness can be stably manufactured. Further, since the application draw ratio is adjusted so as to automatically set the thickness of the resin layer 12 to the target thickness, the fluctuation in the thickness of the resin layer 12 is also reduced. Therefore, the laminated optical film 10 satisfying the above formula (1) can be manufactured. As a result, the quality of the laminated optical film 10 can be improved.
In the method for manufacturing the laminated optical film 10, the thickness t1 of the resin layer 12 can be converged to a target thickness more quickly than in the case where the coating draw ratio is empirically changed, and therefore, labor saving is achieved and materials can be effectively used.
Even in the case of the same coating draw ratio, some fluctuation occurs in the thickness of the resin layer 12 in reality. Therefore, by using the thickness t as the average thickness ave As the thickness of the resin layer 12, the coating draw ratio can be adjusted while reducing the influence of the above-described fluctuation. By performing the changing step S04 at a cycle longer than the predetermined interval, which is the measurement interval of the thickness, the application draw ratio can be adjusted based on the thickness of the resin layer 12 in a stable state after changing to a new application draw ratio. In addition, the above-described stability and tracking can be consideredThe length of the predetermined range, the predetermined interval, the correction period, and the like are set so as to obtain the resin layer 12 having the target thickness.
The embodiments of the present invention have been described above. However, the present invention is not limited to the illustrated embodiments, and is intended to include the scope given by the scope of the claims, and all modifications within the meaning and scope equivalent to the scope of the claims.
For example, the period (correction period) for performing the changing step may be the same as the above-described predetermined interval, and the thickness of the coating layer used for calculating the traction ratio adjustment value may be the actual thickness of the coating layer (thickness t1 in fig. 1). The material of the coating layer is not limited to the adhesive and the binder.
In the above embodiment, for the sake of convenience of explanation, a description has been given of a method of calculating the difference Δ d2, the traction ratio adjustment value, and the like, and then calculating the application traction ratio to be changed. However, control device 30 may directly calculate a new coating traction ratio based on the measurement results input from measuring devices M1 and M2. In this case, the new coating traction ratio is calculated based on the difference Δ d2, the traction ratio adjustment value, and the like.
The embodiment using the measuring device M1 and the measuring device M2 for obtaining the thickness of the resin layer 12 is explained. However, it is also possible to directly measure the thickness of the coating layer, for example, using a thickness measuring device. Alternatively, the thickness of the resin layer 12 may be calculated using a predetermined thickness of a certain base material and the measurement result of the measuring device M2.
The coating draw ratio can be changed by, for example, adjusting the conveyance speed of the substrate.
The resin layer 12 is not limited to a layer formed of a resin adhesive or a resin binder. The resin layer 12 is not limited to the coating layer. For example, the resin layer 12 may be a protective film made of resin. The optical film 11 and the resin layer 12 are not limited to long articles, and may be, for example, single sheets.
The laminated optical film may be the laminated optical film 10A shown in fig. 8. The laminated optical film 10A has an optical film 11, a resin layer 12, and an optical film (2 nd optical film) 13. The resin layer 12 and the optical film 13 are laminated on the optical film 11 in the order of the resin layer 12 and the optical film 13. The optical film 13 is the same as the optical film 11. The laminated optical film 10A is, for example, a laminated optical film in which an optical film 13 is laminated on a resin layer 12 included in the laminated optical film 10 shown in fig. 1. Examples of the laminated optical film 10A include an optical laminate such as a polarizing plate, a phase difference plate, a circularly polarizing plate (including an elliptically polarizing plate) in which a phase difference plate and a polarizing plate are bonded to each other through an adhesive layer, and a laminate in which a polarizing plate or a phase difference plate is laminated with a protective film or the like. The phase difference plate may be a laminated body having a liquid crystal cured layer. The optical film 11 and the optical film 13 may be selected according to the optical characteristics of the laminated optical film 10A.
Examples
The present invention will be described more specifically below by way of examples and comparative examples, but the present invention is not limited to these examples. Unless otherwise specified, "%" and "parts" in the following description mean mass% and parts by mass. For convenience of explanation, in the examples and comparative examples described below, elements corresponding to the respective elements in the above-described embodiments are given the same reference numerals, and redundant explanations are omitted.
[ preparation of the 1 st liquid crystal layer with substrate layer and the 2 nd liquid crystal layer with substrate layer ]
(preparation of composition (1) for Forming photo-alignment layer)
The following components were mixed, and the resulting mixture was stirred at a temperature of 80 ℃ for 1 hour, thereby obtaining a composition (1) for forming a photo-alignment layer.
Photo-alignment material (5 parts):
[ chemical formula 1]
Solvent (95 parts): cyclopentanone
(preparation of composition (2) for Forming alignment layer)
2-butoxyethanol was added to a commercially available Sun SE-610 (manufactured by Nissan chemical industries, ltd.) as an alignment polymer to obtain an alignment layer forming composition (2). In the obtained composition (2) for forming an alignment layer, the content ratio of the solid content to the total amount of the composition was 1%, and the content ratio of the solvent to the total amount of the composition was 99%. The amount of solid components in Sun SE-610 was converted to the concentration described in the product specification sheet.
(preparation of composition (A-1) for Forming liquid Crystal layer)
The following components were mixed, and the resulting mixture was stirred at 80 ℃ for 1 hour to obtain a composition (a-1) for forming a liquid crystal layer. The polymerizable liquid crystal compound A1 and the polymerizable liquid crystal compound A2 are synthesized by the method described in jp 2010-31223 a.
Polymerizable liquid crystal compound A1 (80 parts):
[ chemical formula 2]
Polymerizable liquid crystal compound A2 (20 parts):
[ chemical formula 3]
Polymerization initiator (6 parts):
2-dimethylamino-2-benzyl-1- (4-morpholinophenyl) butan-1-one (IRGACURE 369, manufactured by Ciba Speciality Chemicals Inc.)
Solvent (400 parts): cyclopentanone
(preparation of composition (B-1) for Forming liquid Crystal layer)
The following components were mixed, and the resulting mixture was stirred at 80 ℃ for 1 hour and then cooled to room temperature to obtain a composition (B-1) for forming a liquid crystal layer.
Polymerizable liquid crystal compound LC242 (manufactured by BASF) (19.2%):
[ chemical formula 4]
Polymerization initiator (0.5%):
IRGACURE (registered trademark) 907 (manufactured by BASF JAPAN Co., ltd.)
Reaction additive (1.1%):
laromer (registered trademark) LR-9000 (manufactured by BASF JAPAN Co., ltd.)
Solvent (79.1%): propylene glycol 1-monomethyl ether 2-acetate
(production of retardation film A)
A polyethylene terephthalate (PET) film having a thickness of 100 μm was treated with a corona treatment device at an output of 0.3kW and a treatment speed of 3 m/min. The composition (1) for forming a photo-alignment layer was applied to the surface subjected to corona treatment by a bar coater, dried at 80 ℃ for 1 minute, and irradiated with polarized UV light (SPOT CURE SP-7, manufactured by USHIO Motor Co., ltd.) at a rate of 100mJ/cm 2 The accumulated light amount of (2) was subjected to polarized UV exposure to obtain a photo-alignment layer. The thickness of the obtained photo-alignment layer was measured by a laser microscope (LEXT, manufactured by Olympus corporation), and it was 100nm.
Next, the liquid crystal layer-forming composition (A-1) was applied onto the photo-alignment layer using a bar coater, and after drying at 120 ℃ for 1 minute, ultraviolet rays (wavelength: 365nm, cumulative amount of light at wavelength 365nm in a nitrogen atmosphere: 1000 mJ/cm) were irradiated using a high-pressure mercury lamp (UNICURE VB-15201BY-A, manufactured BY USHIO Motor Co., ltd.) 2 ) Thereby, a liquid crystal layer as a retardation layer was formed, and a retardation plate a was obtained. The thickness of the liquid crystal layer was 2 μm.
(production of retardation film B)
Triacetyl cellulose (TAC) films having a thickness of 80 μm were treated using a corona treatment device under conditions of an output of 0.3kW and a treatment speed of 3 m/min. The composition (2) for forming an alignment layer was applied to the surface subjected to corona treatment by a bar coater and dried at 90 ℃ for 1 minute to obtain an alignment layer. The thickness of the obtained alignment layer was measured by a laser microscope (LEXT, manufactured by Olympus corporation), and found to be 34nm.
Then, using a bar coaterThe composition (B-1) for forming a liquid crystal layer was applied onto the alignment layer, and after drying at 90 ℃ for 1 minute, ultraviolet rays (wavelength: 365nm, cumulative light amount at wavelength 365 nm: 1000mJ/cm under nitrogen atmosphere) were irradiated using a high-pressure mercury lamp (UNICURE VB-15201BY-A, manufactured BY USHIO Motor Co., ltd.) 2 ) Thereby, a liquid crystal layer as a retardation layer was formed, and a retardation plate B was obtained. The thickness of the liquid crystal layer was 1 μm.
(example 1)
< experiment E1 for producing laminated optical film >
An experiment for producing the laminated optical film 10 was performed using the retardation plate a prepared as described above as the optical film 11. Specifically, the surface of the retardation plate A on the liquid crystal layer side was subjected to corona treatment (800W, 10m/min). Using the apparatus described in FIGS. 1 and 2, a UV-curable resin (viscosity: 44 mPas, refractive index (589 nm): 1.51) was applied to the corona-treated surface so that the target thickness was 1.5 μm, thereby obtaining a laminated optical film 10. "refractive index (589 nm)" means the refractive index for a wavelength of 589 nm. The same expression is also applied to the refractive index below. The viscosity was a value at 25 ℃ (the same applies hereinafter).
Specifying an interval: 1 second
Length of the specified range: 1.3m
Conveying speed: 20 m/min
And (3) correction period: 15 seconds
And (3) correcting gain: 35
The thickness of the retardation plate a (optical film 11) and the thickness of the laminated optical film 10 were measured using the measuring instruments M1 and M2 shown in fig. 1, and from the obtained results, the standard deviation σ 2 of the thickness t0 of the retardation plate a and the standard deviation σ 1 of the thickness t1 of the resin layer 12 (difference between the measurement result of the measuring instrument M2 and the measurement result of the measuring instrument M1) were calculated.
In example 1, 5 retardation plates a were prepared, and the above-described experiment E1 for producing a laminated optical film was performed by performing the above-described operations on each of them. That is, in example 1, 5 times of the manufacturing experiment E1 of the laminated optical film was performed. In each manufacturing experiment E1, the standard deviation σ 2 and the standard deviation σ 1 were calculated.
(example 2)
A production experiment E1 of a laminated optical film was performed under the same conditions as in example 1, except that a UV curable resin having a viscosity of 104mPa · s and a refractive index (589 nm) of 1.54 was used and coating was performed so that the target thickness was 1.5 μm. In example 2, 7 retardation plates a (optical films 11) were prepared, and an optical film manufacturing experiment E1 was performed for each of them. In each manufacturing experiment E1, the standard deviation σ 2 of the thickness t0 of the retardation plate a and the standard deviation σ 1 of the thickness t1 of the resin layer 12 were calculated in the same manner as in example 1.
(example 3)
A production experiment E1 of a laminated optical film was performed under the same conditions as in example 1, except that the retardation plate B prepared above was used as the optical film 11. In example 3, 10 retardation plates B (optical films) were prepared, and an optical film manufacturing experiment E1 was performed for each of them. In each manufacturing experiment E1, the standard deviation σ 2 of the thickness t0 of the retardation plate B and the standard deviation σ 1 of the thickness t1 of the resin layer 12 were calculated in the same manner as in example 1.
(example 4)
A portion 30m of the initial coating portion (japanese: coating portion 30 m) was removed through the slit over the entire length of the laminated optical film obtained in the same manner as in example 3, to obtain a laminated optical film 10. In example 4, 8 retardation plates B (optical films) were prepared, and an experiment for producing the laminated optical film 10 was performed by performing the above-described operations on each of them. The experiment of example 4 was the same as that of example 3, except that 30m of the initially coated portion was removed by the slit over the entire length of the laminated optical film obtained in the same manner as in example 3, as described above, and therefore the experiment of example 4 was also referred to as production experiment E1. In each manufacturing experiment E1, the standard deviation σ 2 of the thickness t0 of the retardation plate B (optical film) and the standard deviation σ 1 of the thickness t1 of the resin layer 12 were calculated in the same manner as in example 3.
The results of examples 1 to 4 are shown in Table 1. "No." in table 1 is a number for distinguishing the manufacturing experiment E1 of each of the laminated optical films of examples 1 to 4, and in table 1, each manufacturing experiment E1 shows σ 2/σ 1 calculated based on the standard deviation σ 2 and the standard deviation σ 1, and also shows the average σ 2/σ 1 of all the manufacturing experiments E1 of examples 1 to 4.
[ Table 1]
Comparative example 1
< experiment E2 for producing laminated optical film >
The surface of the prepared retardation plate a (optical film 11) on the liquid crystal layer side was subjected to corona treatment (800w, 10m/min). A UV-curable resin (viscosity: 44 mPas, refractive index (589 nm): 1.51) was applied to the corona-treated surface under the following conditions so that the target thickness was 1.5. Mu.m, thereby obtaining a laminated optical film 10. At this time, although the same apparatus as in example 1 was used, the user (the person in charge of manufacturing the laminated optical film) empirically adjusted the coating draw ratio based on the measurement results of the measuring device M1 and the measuring device M2.
In comparative example 1, 3 retardation plates a (optical films 11) were prepared, and an optical film manufacturing experiment E2 was performed on each of them. In each manufacturing experiment E2, the standard deviation σ 2 of the thickness t0 of the retardation plate a and the standard deviation σ 1 of the thickness t1 of the resin layer 12 were calculated in the same manner as in example 1.
Comparative example 2
An experiment E2 for producing a laminated optical film was carried out under the same conditions as in comparative example 1, except that a UV curable resin having a viscosity of 104mPa · s and a refractive index (589 nm) of 1.54 was used and the coating was carried out to a target thickness of 1.5 μm. In comparative example 2, 2 pieces of retardation plates a (optical films 11) were prepared, and an optical film manufacturing experiment E2 was performed for each of them. In each manufacturing experiment E2, the standard deviation σ 2 of the thickness t0 of the retardation plate a and the standard deviation σ 1 of the thickness t1 of the resin layer 12 were calculated in the same manner as in the case of comparative example 1.
Comparative example 3
A production experiment E2 of a laminated optical film was performed under the same conditions as in comparative example 1, except that the retardation plate B (optical film 11) prepared above was used. In comparative example 3, the standard deviation σ 2 of the thickness t0 of the retardation plate B and the standard deviation σ 1 of the thickness t1 of the resin layer 12 were calculated in the same manner as in comparative example 1.
Comparative example 4
A manufacturing experiment E2 of a laminated optical film was performed under the same conditions as comparative example 1, except that a cycloolefin polymer (COP) film having a thickness of 13 μm was used as the optical film 11. In comparative example 4, 3 COP films (optical films 11) were prepared, and a production experiment E2 for laminating optical films was performed for each of them. In each manufacturing experiment E2, the standard deviation σ 2 of the thickness t0 of the COP film and the standard deviation σ 1 of the thickness t1 of the resin layer 12 were calculated in the same manner as in the case of comparative example 1.
The results of comparative examples 1 to 4 are shown in Table 2. "No." in table 2 is a number for distinguishing the manufacturing experiment E2 of each of the laminated optical films of comparative examples 1 to 4, and in table 2, each manufacturing experiment E2 shows σ 2/σ 1 calculated based on the standard deviation σ 2 and the standard deviation σ 1, and also shows the average σ 2/σ 1 of all the manufacturing experiments E2 of comparative examples 1 to 4.
[ Table 2]
FIG. 9 is a graph showing the results of examples 1 to 4 and comparative examples 1 to 4. In fig. 9, σ 1 is plotted against σ 2 in each of the production experiments E1 in examples 1 to 4 shown in table 1 and each of the production experiments E2 in comparative examples 1 to 4 shown in table 2. If the thickness distribution is generated in the thickness t0 of the optical film 11, the thickness distribution of the thickness t1 of the resin layer 12 is affected. Therefore, in fig. 9, as described above, the standard deviation σ 1 of the thickness t1 of the resin layer 12 is plotted against the standard deviation σ 2 of the thickness t0 of the optical film 11. The line L1 and the line L2 shown in fig. 9 are each a line expressed by the following formula.
Line L1: σ 1/σ 2=0.45
Line L2: σ 1/σ 2=0.29
A region hatched in fig. 9 (hereinafter, referred to as a "hatched region") is a region satisfying the above equations (2) and (3). In the region satisfying the expressions (2) and (3), the amount of change from the initial application draw ratio is particularly small.
In fig. 9, σ 1/σ 2 is small in a lower right region (a region where σ 1 is large and σ 2 is small). Therefore, as can be seen from fig. 9, in examples 1 to 4 in which the coating draft ratio was automatically adjusted, the fluctuation in the thickness of the resin layer 12 was small. That is, it can be understood that a higher quality laminated optical film 10 can be manufactured by automatically adjusting the coating draw ratio. Further, it is found that by appropriately setting the initial application draw ratio, the laminated optical film 10 having small variations in the thickness of the resin layer 12 can be manufactured.
Fig. 10 is a graph showing the average value of σ 1/σ 2 in all the production experiments E1 performed in examples 1 to 4 shown in table 1, and the average value of σ 1/σ 2 in all the production experiments E2 performed in comparative examples 1 to 4 shown in table 2. Error bar B1 in the graph of fig. 10 indicates the range of the deviation from the average value of σ I/σ 2 corresponding to each manufacturing experiment E1 in examples 1 to 4 shown in table 1. Error bar B2 in the graph of fig. 10 indicates the range of deviation from the average value of σ 1/σ 2 corresponding to each manufacturing experiment E2 in comparative examples 1 to 4 shown in table 2. As can be understood from fig. 9 and 10, the laminated optical film 10 satisfying the formula (1) can be manufactured by the manufacturing method described in the above embodiment.
(example 5)
As example 5, the following experiment was further performed. A production experiment E1 was performed under the same conditions as in example 1 except that a cycloolefin polymer (COP) film having a thickness of 13 μm was used as the optical film 11, and a laminated optical film 10 was obtained. σ 1/σ 2 for the obtained laminated optical film 10 was 0.33. Example 5 also satisfies formula (1).
Description of the symbols
10. 10A 8230, laminated optical films; 11 \ 8230and optical films (No. 1 optical film); 12 \ 8230and resin layer; 12a 8230; 13 8230a optical film (2 nd optical film); 22\8230acoating roller; 30-8230and a control device.
Claims (6)
1. A laminated optical film is provided with
1 st optical film, and
a resin layer formed of a resin and laminated on the 1 st optical film,
wherein σ 1 and σ 2 satisfy formula (1) where σ 1 is a standard deviation of the thickness of the resin layer and σ 2 is a standard deviation of the thickness of the 1 st optical film,
σ1/σ2≤0.45···(1)。
2. the laminated optical film according to claim 1, wherein the 1 st optical film and the resin layer are long strips.
3. A laminated optical film according to claim 1 or 2, wherein the resin layer is a coating layer.
4. The laminated optical film according to any one of claims 1 to 3, wherein σ 1 satisfies the following formula (2), and σ 2 satisfies the formula (3),
0.014≤σ1≤0.020···(2)，
0.066≤σ2≤0.088···(3)。
5. a laminated optical film according to any one of claims 1 to 4, wherein the resin is an adhesive or bonding agent.
6. A laminated optical film according to any one of claims 1 to 5, further comprising a2 nd optical film on the resin layer.
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| JP2021144210A (en) | 2021-09-24 |
| WO2021182055A1 (en) | 2021-09-16 |
| TW202140278A (en) | 2021-11-01 |
| CN115243894B (en) | 2024-05-28 |
| KR20220148882A (en) | 2022-11-07 |
| JP6967679B2 (en) | 2021-11-17 |
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