CN1657984A - Manufacturing method of polaroid film, polaroid plate and optical laminate - Google Patents

Manufacturing method of polaroid film, polaroid plate and optical laminate Download PDF

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Publication number
CN1657984A
CN1657984A CN2005100094071A CN200510009407A CN1657984A CN 1657984 A CN1657984 A CN 1657984A CN 2005100094071 A CN2005100094071 A CN 2005100094071A CN 200510009407 A CN200510009407 A CN 200510009407A CN 1657984 A CN1657984 A CN 1657984A
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Prior art keywords
film
roller
widening
boric acid
light polarizing
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CN2005100094071A
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CN100472250C (en
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网谷圭二
藤本清二
松元浩二
山根尚德
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Sumitomo Chemical Co Ltd
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Sumitomo Chemical Co Ltd
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    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/30Polarising elements
    • G02B5/3025Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/04Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18Manufacture of films or sheets
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL 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
    • G02F1/00Devices 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
    • G02F1/01Devices 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 
    • G02F1/13Devices 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
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1335Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133528Polarisers
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL 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
    • G02F1/00Devices 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
    • G02F1/01Devices 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 
    • G02F1/13Devices 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
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1337Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers
    • G02F1/133753Surface-induced orientation of the liquid crystal molecules, e.g. by alignment layers with different alignment orientations or pretilt angles on a same surface, e.g. for grey scale or improved viewing angle

Abstract

A manufacturing method of a polarizing film which has fewer scratches and wrinkles and has no folding is provided. In the method for manufacturing a polarizing film by treating a PVA type film, it is characterized by which a widening roller is used in treatment liquid, the widening roller is located on the position where the maximum widening amount [beta] of the widening roller determined by the following mathematical expression (1) exceeds the expansion amount [gamma] in the width direction of film in the widening roller determined by the following mathematical expression (2) or the widening roller having a shape exceeding the expansion amount [gamma] is used: [beta]=B<SB>1</SB>*[alpha]*r/R .... (1), [gamma]=0.2055*B<SB>1</SB>*{exp(-0.0273*[theta]<SB>1</SB>)-exp(-0.0273*[theta])}.... (2). In the expressions, B<SB>1</SB>is a film width in contact with the roller, [alpha] is contact angle, r is radius of the roller, R is radius of curvature, [theta] is a running time in liquid until the film separates from the roller and [theta]<SB>1</SB>is a running time in liquid until the film is brought into contact with the roller.

Description

The manufacture method of light polarizing film, Polarizer and optical laminate
Technical field
The present invention relates to a kind of manufacture method, Polarizer of light polarizing film; and optical laminate; and particularly relevant for a kind of flaw or wrinkle less and do not have the light polarizing film manufacture method of folding line, the Polarizer of the diaphragm behind the lamination of on the one side at least of gained light polarizing film, having fitted, also have arbitrary separately or several phase retardation films of fitting, brightness promote the optical laminate that film, visual angle improve film and half penetrability reflectance coating.
Background technology
In the past, be that dichromatism (dichroism) pigment is adsorbed on polyvinyl alcohol (PVA) (polyalcohol) is that film and the orientation that makes are as light polarizing film.That is to say, be known that the iodine that iodine is used as the dichromatism pigment is light polarizing film, or be light polarizing film or the like the dyestuff that dichroic dye is used as the dichromatism pigment.These light polarizing film, usually, single face is more preferably two-sided upward through being the solid that resin aqueous solution constitutes by polyvinyl alcohol (PVA) at least, with the applying of Triafol T diaphragms such as (triacetate cellulose), becomes Polarizer.
Manufacture method as for light polarizing film, known method is to use nip rolls (nip roll), correcting roller (guideroll), polyvinyl alcohol (PVA) is the swelling that makes of film immersion in water after, with aforementioned dichromatism pigment dyeing, and the stretching of inciting somebody to action, being fixed on for the iodine that will adhere on the surface of film, is that film carries out boric acid processing, washing back dry (for example referring to Patent Document 1) with polyvinyl alcohol (PVA).At this moment, invest and handle the peripheral speed difference (peripheral speed difference) of bathing the front and back nip rolls,,, film is imported treating fluid also take out by the throughput direction of correcting roller change film to carry out the stretching of film.
Smooth rubber rollers (flat rubber roller) or propellers (spiral roller) (for example patent documentation 2) that the correcting roller is to use the surface to be made up of rubber layer.
In recent years, along with high-qualityization of the liquid crystal indicator that has used light polarizing film, expectation can make flaw and wrinkle is less than previous method, and does not have the light polarizing film of folding line.
The early stage openly communique spy of [patent documentation 1] Jap.P. opens flat 10-153709 communique.
The early stage openly communique spy of [patent documentation 2] Jap.P. opens the 2000-147252 communique.
Summary of the invention
The major subjects that desire of the present invention solves provides a kind of less flaw, wrinkle and does not have the light polarizing film manufacture method of folding line.
Present inventors are for producing flaw or the less light polarizing film of wrinkle, the careful result of self-criticism repeatedly, to widen roller as the correcting roller, the maximum amount of widening of widening roller is β, film film when widening roller and contact is γ in the swell increment of cross direction, be configured in and make on the position of β greater than γ by widening roller, or use and to make the widen roller of β greater than the shape of γ, find that flaw or wrinkle are less, and do not have folding line, if the roller of widening by foamed rubber system particularly is when being disposed in the swelling treating fluid again, reduce flaw or wrinkle and do not produce the effect of folding line better, to finish the present invention.
That is to say, light polarizing film manufacture method of the present invention, it is characterized in that, with polyvinyl alcohol (PVA) is that film carries out the swelling processing in regular turn, dyeing is handled, boric acid is handled and washing is handled, and the boric acid treatment step and/or before step in carry out in the light polarizing film manufacture method of uniaxial tension, wherein the correcting roller at least one treating fluid is for widening roller, ask the maximum amount of the widening β that widens roller with following formula (1), and when asking film and widening roller and contact with following formula (2), film is at the swell increment γ of cross direction, relation between β and the γ is set at (a) on the position that can reach β>γ, disposes and widen roller, or (b) use the roller of widening of the shape that can reach β>γ.
β=B 1×α×r/R .......(1)
(in the formula, B 1For with to widen the film that roller contacts wide, α is a contact angle of widening roller, and r is a radius of widening roller, and R is the radius-of-curvature of widening roller.)
γ=0.2055×B 1×{exp(-0.0273×θ 1)-exp(-0.0273×θ)} ......(2)
(in the formula, B 1Identical with above-mentioned definition, θ is that film leaves and widens the traveling time in liquid before the roller, θ 1Be the traveling time in liquid before film contact the widening roller.)
Again, be characterised in that widening roller is the sponge roller, the hardness of this sponge is 20~60 degree with JIS shore hardness C yardstick, and density is 0.4~0.6 gram/cubic centimeter, and surfaceness is 10~30S.
And, be characterized as and be configured in the swelling treating fluid widening roller.
Add, Polarizer of the present invention is to stick diaphragm in the one side at least of the light polarizing film of method manufacturing as described above.This diaphragm possesses phase retardation film is arranged, brightness promotes film, film is improved at the visual angle and the arbitrary function of half penetrability reflectance coating is also good.Or on the aforementioned Polarizer of the diaphragm of having fitted on single face at least, it is also good that the phase retardation film of having fitted, brightness promote film, optical laminate at least a in film and the half penetrability reflectance coating is improved at the visual angle.
Effect of the present invention is for obtaining than previous method still less flaw or wrinkle and do not have the light polarizing film of folding line.
Particularly dispose the roller of widening of foamed rubber system,, reduce flaw or wrinkle and do not produce the effect of folding line better if when being disposed in the swelling treating fluid again.
Polarizer of the present invention, optical laminate are used for liquid crystal indicator, whereby, can get the liquid crystal display of slim and high-qualityization.
For aforementioned and other purpose, feature and advantage of the present invention can be become apparent, preferred embodiment cited below particularly, and conjunction with figs. are described in detail below.
Description of drawings
Fig. 1 (A) is a planimetric map of widening roller.
Fig. 1 (B) is a sectional view of widening roller.
Fig. 2 is the planimetric map of widening state that shows film.
Fig. 3 illustration is widened the sectional view that roller is disposed at the pattern in the treatment trough.
Symbol description
H: camber R: radius-of-curvature
R: radius α: contact angle
B 1: the wide B of film of roller is widened in contact 2: wide to widen the film that roller widens
1,4: correcting roller 2,3: widen roller
5: treatment trough 6: treating fluid
Embodiment
Below, explain the present invention.
The polyvinyl alcohol (PVA) that forms polyvinyl alcohol (PVA) (PVA) film among the present invention is a resin, usually, is the resin illustration with the polyvinyl acetate after the saponification.As for the degree of saponification, about 85 ear percent (%) not, about 90 ear % is above is good, and about 99 ear %~100 are not good more than the ear %.As for polyvinyl acetate is resin, except being the polyvinyl acetate of same first polymkeric substance of vinyl acetate, also have vinyl acetate and can with the multipolymer of other monomer of copolymerization, for example comprise: ethylene-vinyl acetate copolymer or the like.But the monomer of copolymerization for example comprises, unsaturated carboxylic acid, alkene class, vinyl class, unsaturated sulfonic acid class or the like.As for polyvinyl alcohol (PVA) is the degree of polymerization of resin, is about 1000~10000, and about 1500~5000 degree is good.
Making these polyvinyl alcohol (PVA) is that the resin sex change is also good, for example, can use polyvinyl alcohol formal (polyvinyl formal), polyvinyl acetal (polyvinyl acetal), polyvinyl butyral (polyvinyl butyral) with the aldehydes sex change.Usually, used thickness is about 20 microns (μ m)~100 μ m, and about 30 μ m~better polyvinyl alcohol (PVA) of 80 μ m is the unstretching film of resin molding, as the beginning of light polarizing film manufacturing. material.Industrial, wide to be about 1500 millimeters (mm)~4000mm comparatively practical with film.
With this film that does not stretch in regular turn with swelling handle, dyeing is handled, boric acid is handled, washing is handled, final drying is handled and the polyvinyl alcohol (PVA) that obtains is a light polarizing film, its thickness is about for example degree of 5~50 μ m.
Though light polarizing film of the present invention is to be monadic stretching membrane with the polyvinyl alcohol (PVA) after dichromatism pigment absorption and the orientation, its method for making is divided into two kinds haply.The one method is, is that film behind the uniaxial tension, carries out following solution-treated in regular turn in air or inert gas with polyvinyl alcohol (PVA): swelling is handled, dyeing is handled, boric acid is handled and washing is handled, and carries out dried at last.Second method is that film swelling in aqueous solution is handled for the polyvinyl alcohol (PVA) that will not stretch, and carry out following solution-treated in regular turn: dyeing is handled, boric acid is handled and washing is handled, carry out dried at last, in the step of boric acid treatment step and/or its front, carry out uniaxial tension with wet type, carry out drying at last.
In any method, uniaxial tension can a step carry out, and carries out also goodly with plural step, but carries out to good with a plurality of steps.The method that stretches, can adopt known method, for example invest the peripheral speed difference between two nip rolls of transport membrane and stretch between the roller that stretches, as the hot-rolling pulling method put down in writing in No. 2731813 communique of Japanese patent gazette, tentering (tenter) pulling method or the like.And though the order of step is as above-mentioned basically, the number that right processing is bathed or treatment conditions or the like are also unrestrictedly.In addition, certainly freely the step of not putting down in writing in the above-mentioned steps is inserted because of other purpose.With the example of this step, comprise that boric acid is handled after, with the dip treating (iodide processing) of not borated iodide aqueous solution or boronic acid containing but contain aqueous solution dip treating (zinc processing) of zinc chloride or the like not.
The purpose of swelling step is being removed the foreign matter on striping surface, is removing plasticizer in the striping, is investing the next step easy dyeing, is being made film plasticization or the like.Its treatment conditions fix in the scope that can reach these purposes, and are extremely to dissolve in the scope of base material film, devitrificationization problems such as (devitrification) not taking place.When making the film swelling that in ready gas, stretches, with film immersion at for example about 20 ℃~70 ℃, in preferably 30 ℃~60 ℃ the aqueous solution.The dip time of film is about 30 seconds~and 300 seconds, more preferably 60 seconds~240 seconds degree.During former (original) film swelling that beginning the time is not stretched, with film immersion at for example about 10 ℃~50 ℃, in preferably 20 ℃~40 ℃ the aqueous solution.The dip time of film is about 30 seconds~and 300 seconds, more preferably 60 seconds~240 seconds degree.
In the swelling treatment step, because film easily produces problems such as wrinkle on film in the cross direction swelling, to widen roller (expander roll), propellers, crowned roll (crown roll), cloth guider (cloth guider), curved rod (bend bar), pincers cloth formula stenter (tenter clip) or the like and be disposed at ad-hoc location described later, while it is preferable to remove the wrinkle transport membrane.For making the conveying of film in the bath reach the purpose of stabilization, current during swelling is bathed are with perforated water spray control in the water, or and with edge follow-up mechanism (EPC, edge position control: can detect the edge of membrane and prevent the device that film crawls) or the like also for effectively.In this step, because film also can enlarge at its direct of travel in swelling, in order not produce the lax of film at throughput direction, for example can taking, the means of control and treatment groove front and back conveying roller rotating speed or the like are good.And, the swelling of using is handled and is bathed, except pure water, use the aqueous solution of the boric acid (spy of Japanese Patent Laid Open Publication communique opens in the flat 10-153709 communique and puts down in writing) added 0.01 weight %~10 weight % scopes, chloride (spy of Japanese Patent Laid Open Publication communique opens in the flat 06-281816 communique and puts down in writing), mineral acid, inorganic salts, water-miscible organic solvent, alcohols or the like also can.
With the staining procedure of dichromatism pigment, for the purpose of the orientation that will adsorb the dichromatism pigment on film and make or the like is implemented.Treatment conditions are decided to be in reaching the scope of this purpose, and do not produce in the scope of problems such as base material film extremely dissolves, devitrificationization.When iodine is used as the dichromatism pigment, about 10 ℃~45 ℃, in preferably 20 ℃~35 ℃ the temperature, and, the weight ratio of iodine/potassium iodide/water is in about 0.003~0.2/ about 0.1~10/100 the concentration range, to flood preferably 60 seconds~300 seconds approximately 30 seconds~600 seconds.With other iodide, for example zinc iodide or the like replaces potassium iodide to use also good.Also use other iodide and potassium iodide also good again.In addition, make iodide compound in addition, for example boric acid, zinc chloride, cobalt chloride or the like coexistence is also good.When adding boric acid, because of iodine contain and following boric acid is handled and is separated.With respect to 100 weight list of water for for, staining trough is to be made as content of iodine to be about more than 0.003 unit of weight.
Water-soluble dichroic dye is used as the dichromatism pigment and when using, temperature is for example at 20 ℃~80 ℃, and in preferably 30 ℃~70 ℃ scopes, and the weight ratio of dichroic dye and water is about in 0.001~0.1/100 the concentration range, flooded about 30 seconds~600 seconds, 60 seconds~300 seconds better.It is also good that the aqueous solution of employed dichroic dye contains dyeing assistant or the like, and inorganic salts, interfacial agent that contain sodium sulphate or the like for example or the like are also good.Dichroic dye uses also good separately, and the dichroic dye more than 2 kinds uses simultaneously also can.
In staining trough, stretch film also good as described above.Be stretched as to utilize and make before and after the staining trough nip rolls tool periphery speed difference or the like method and carry out.And, identical with the swelling step, also can be arranged in the dye bath and/or the dye bath gateway with widening roller (expander roll), propellers (spiral roll), crowned roll (crown roll), cloth guider (cloth guider), curved rod or the like.
It is to contain in the aqueous solution of about 1~10 unit of weight of boric acid at the water with respect to 100 unit of weights that boric acid is handled, and will be that film floods with the polyvinyl alcohol (PVA) of dichromatism pigment dyeing.When the dichromatism pigment was iodine, making iodide content was that 1~30 weight percent is good.
The compound that can be used as iodide comprises potassium iodide, zinc iodide or the like.And with the compound beyond the iodide, for example zinc chloride, cobalt chloride, zirconium chloride, sodium thiosulfate, potassium sulfite, sodium sulphate or the like coexistence is also good.
This boric acid to be handled in order reaching and to be utilized water-fastization or the form and aspect adjustment of building bridge to implement.For will be by building bridge and during water-fastization, optionally can be beyond boric acid, or and boric acid together, use glyoxal, glutaraldehyde or the like bridging agent.
In addition, handle the situation that titles such as being called as water-fastization processing, bridge formation processing, immobilization processing are also arranged with the water-fast boric acid that turns to purpose.And the boric acid that is adjusted into purpose with form and aspect is handled, and also has to be called as that complementary color is handled, the situation of titles such as dyeing processing again.
This boric acid is handled, and can suitably change concentration, the processing bath temperature of boric acid and iodide according to its purpose.
For the boric acid that reaches water-fastization is handled and is handled for the boric acid that reaches the form and aspect adjustment, though not special the differentiation, can following condition enforcement.
When former film is carried out swelling, dyeing, boric acid processing, if it is to utilize to build bridge when generation is water-fast to turn to purpose that boric acid is handled, employed boric acid is handled to bathe, water with respect to 100 unit of weights, contain about 3~10 unit of weights of boric acid, about 1~20 unit of weight of iodide, and, carry out in preferably 55 ℃~65 ℃ usually about 50 ℃~70 ℃.Dip time is generally about 30~600 seconds, and preferably 60~420 seconds, more preferably 90~300 seconds.
In addition, with the film that stretches in advance dye, when boric acid is handled, boric acid is handled the temperature of bathing and is generally 50 ℃~85 ℃, and 55 ℃~80 ℃ preferable.
After having carried out handling, carry out being adjusted into the boric acid of purpose and handle also good with form and aspect with the water-fast boric acid that turns to purpose.When for example dichroic dye was iodine, for this purpose, employed boric acid processing bath was the water with respect to 100 unit of weights, contains about 1~5 unit of weight of boric acid, about 3~30 unit of weights of iodide, and carries out in 10 ℃~45 ℃ temperature usually.Dip time is generally 3~300 seconds, preferably 10~240 seconds.
The boric acid that is adjusted into purpose with form and aspect is handled compared with handling with the water-fast boric acid that turns to purpose, carries out in lower boric acid concentration, higher iodide concentration, lower temperature usually.
These boric acid processing are carried out also good, usually, more with the situation that 2~5 steps are carried out with several steps.At this moment, the aqueous solution of employed each boric acid treatment trough is formed, temperature can be same as above-mentioned scope, and difference is also good.The above-mentioned processing with the boric acid that is adjusted into purpose with form and aspect with the water-fast boric acid that turns to purpose handled, and each carries out also good with several steps.
In the boric acid treatment step, as staining procedure, the stretching of carrying out film is also good.Final total stretching ratio is about 4.5~7.0 times, preferably 5.0~6.5 times.
Boric acid can be washed after handling.The polyvinyl alcohol (PVA) that washing for example will be treated to after will handling with the boric acid that water-fastization and/or form and aspect are adjusted into purpose is a film, is immersed in the water, and with the spraying spray of water, or dipping and spraying and usefulness.Water temperature during water treatment is generally 2~40 ℃ degree, and dip time is about 2~120 seconds for good.Washing back drying is to carry out 60~600 seconds in about 40~100 ℃ of kiln temperatures.
In each step after the stretch processing, to carry out Tension Control also good for the tension force that makes film becomes each substantial certain specific tensile.
When in the dyeing treatment step, stretch finishing, in after the boric acid treatment step and the washing processing in carry out Tension Control.Before the dyeing treatment step, stretch in the step when finishing, then carry out Tension Control in the step after dyeing processing and boric acid treatment step.
When the boric acid treatment step is made up of the boric acid treatment step of plural number, at first or two sections boric acid treatment steps that begin at first aforementioned films is stretched, carry out next boric acid of the boric acid treatment step of stretch processing and handled beginning, to water-washing step, in each step, carry out Tension Control, or from first to the boric acid treatment step of the 3rd section step, aforementioned films is stretched, from carrying out next boric acid step of the boric acid treatment step that overstretching handles, to each step of water-washing step, carry out Tension Control, any actually mode is preferable, industrial, at first or in two sections boric acid treatment steps that begin at first, aforementioned films is stretched, and next boric acid that has carried out the boric acid treatment step of stretch processing is handled and is begun to water-washing step, and it is preferable to carry out Tension Control in each step.
After boric acid is handled, when carrying out above-mentioned iodide processing or zinc processing, also carry out Tension Control at these steps.
In each step, tension force can be identical or different.
Tension force for film in the Tension Control is also without particular limitation, and per unit width is about 150 newton/meter (N/m)~2000N/m, and being set at of can doing to suit in the scope of 600N/m~1500N/m is good.Tension force is if be lower than 150N/m, and film easily produces wrinkle, on the other hand, if surpass 2000N/m, the film meeting problem that generation time reduces owing to the abrasion of fracture or bearing (bearing).Wherein, the tension force of film per unit width is by in every step, and near the wide tension value that records with tension detector of the film the inlet calculates.
In addition, when carrying out Tension Control, though the situation that has some inevitably to stretch and shrink, among the present invention, this phenomenon is not contained in the stretch processing.
Among the present invention, at least one correcting roller in the treating fluid is for widening roller, try to achieve with following formula (1) and to widen the roller maximum amount of widening β, the film of being tried to achieve with following formula (2) is when widening roller and contact, with the swell increment γ of film at cross direction, the relation of β and γ is set at (a) and disposes on the position that can reach β>γ and widen roller, and/or (b) uses the roller of widening of the shape that can reach β>γ.
β=B 1×α×r/R .......(1)
(in the formula, B 1For with to widen the film that roller contacts wide, α is a contact angle of widening roller, and r is a radius of widening roller, and R is the radius-of-curvature of widening roller)
γ=0.2055×B 1×{exp(-0.0273×θ 1)-exp(-0.0273×θ)} ......(2)
(in the formula, B 1Identical with above-mentioned definition, θ is that film leaves the preceding traveling time in liquid of widening roller, θ 1Be the traveling time in liquid before film contact the widening roller.)
Fig. 1 shows the key diagram of widening roller.Fig. 1 (A) is a planimetric map, and Fig. 1 (B) is a sectional view.
Widening roller is to make slightly to be circular-arc, and its radius-of-curvature is represented with H with R, camber.The radius of widening roller is represented with α r with the face length of α, surface of contact with r, film and the contact angle of widening roller.
Fig. 2 is the planimetric map of widening situation of expression film, and widens the wide B of being of film that roller contact 1, the film after the roller contact site is widened, widened is wide with B 2Expression.
Fig. 3 example illustrates and will widen the mode sectional drawing that roller is configured in treatment trough.Film is to see through to be disposed at airborne correcting roller 1,4, and is disposed at widening roller 2,3 and carry and treated liquid is handled in the treating fluid 6 of treatment trough 5.Film enters treating fluid at the A point, the B point with widen that roller 2 contacts and leave at the C point, the D point with widen that roller 3 joins and leave at the E point, leave treating fluid at the F point then.At the film of widening roller 2, leave that to widen the time θ that advances in liquid before the rod be the time of advancing between A~C, film is the traveling time θ in liquid before roller is widened in contact 1Be the time of advancing between A~B.At the film of widening roller 3, leave that to widen the time θ that advances in liquid before the rod be the time of advancing between A~E, film is the traveling time θ in liquid before roller is widened in contact 1Be the time of advancing between A~D.
β changes according to the shape, position of widening roller, and γ is according to shape, the position of widening roller, even the transporting velocity of film and changing.The transporting velocity of film is set because of other treatment conditions mostly, for the situation that makes β>γ conversion transporting velocity less.Usually, select the roller of widening of reservation shape, adjust its allocation position, then repeat when insufficient to adjust, satisfy the right position of widening roller of β>γ with decision and put and/or shape.
Widen roller and widen roller (foamed rubber is widened roller) for good with foamed rubber system, be about 20~60 degree in JIS shore hardness (Shore Hardness) the C yardstick (scale) of the hardness of this sponge with JIS K 6301 determination of test method, 25~40 degree are preferable, and density is about 0.4~0.6 gram/cubic centimeter (g/cm 3), preferably 0.42~0.57g/cm 3, and surfaceness represents that with the equispaced S on the local summit of the coarse curve of JIS B 0601 (surfaceness) about 10~30S is good with 15~25S.
Widening roller, to be used in the swelling treatment step good especially, at this moment, is good to use foamed rubber to widen the roller rod again.In the swelling treatment step, polyvinyl alcohol (PVA) is a film because of having absorbed body lotion (bath liquid) swelling on length and width two directions, but particularly in the swelling of cross direction, does not apply tension force if do not stop always, can produce wrinkle or folding line.Widen roller if use foamed rubber, because its light weight, the tension force that is applied to film can significantly reduce, simultaneously, based on its high surfaceness, the reason that the film grip is higher, widen power even also can give full play at low-tension, and also can bring into play to the limit for another role's of widening roller the function of crawling of preventing, not only wrinkle tails off, and does not also have folding line.
Widening roller is not only to handle due to being used in swelling, also can be used for other processing.
The light polarizing film that so produces can get Polarizer with solid applying diaphragm at least on single face.
Is that the polyester of the class of the film formed of resin, polyethylene terephthalate, poly-naphthalene potassium acid second diester, polybutylene terephthalate is that film, the polycarbonate that resin is formed is that film, the cycloolefin that resin is formed is the film that resin is formed as for diaphragm by the cellulose acetate of the class of for example Triafol T or cellulose diacetate.Commercially available thermoplasticity cycloolefin is a resin, for example, " Topas " (trade mark login) that Germany that (Ticona) company of Supreme Being section sells, " ARTON " (trade mark login) that JSR Corp. of Japan sells, " ZEONOR " (trade mark login) or " ZEONEX " (trade mark login) that the Zeon incorporated company of Japan sells, " APEL " that Mitsui Chemicals Inc. sells (trade mark login) or the like.With system this type of cycloolefin behind the film is that resin is made diaphragm, can use solvent cast (solvent cast) method, dissolve known method system film such as extrusion method.It is resin molding that cycloolefin behind the commercially available system film is also arranged, for example ponding chemical industry incorporated company " Escena " or " SCA40 " that sell or the like.
Problems such as though diaphragm thickness is with Bao Weijia, thin excessively, intensity reduces, and processability is not good, and on the other hand, blocked up words produce then that transparency is not good, necessary set time (curing time) is long behind the lamination.Therefore, the suitable thickness of diaphragm is for for example 5~200 μ m, and is preferable with 10~150 μ m, and 20~100 μ m are better.
In order to make the then property raising of solid and light polarizing film and/or diaphragm, it is also good to impose surface treatments such as corona (corona) processing, flame treatment, plasma (plasma) processing, ultraviolet ray irradiation, priming paint (primer) coating, saponification processing on light polarizing film and/or the diaphragm.
Can implement anti-dizzy (anti-glare) processing, antireflection (anti-reflection) processing, strengthened coat (hard-coat) processing, anti-charged processing, antifouling processing or the like surface treatment alone or in combination to diaphragm.And it is also good that diaphragm and/or diaphragm sealer are that phenol is that compound, benzene half azoles are that compound or the like ultraviolet light absorber or benzenephosphonic acid are that compound, phthalic acid ester compounds or the like have a moldable compound.
All can in single face or two sides that relevant diaphragm is affixed on light polarizing film.
Light polarizing film and diaphragm with hydrosolvent be solid, organic solvent be solid, hot melt solid, solvent-free be solids such as solid and lamination.With hydrosolvent is solid, comprise that polyvinyl alcohol (PVA) is that resin aqueous solution, water are that two-liquid type amine ethyl formate is emulsion fluid (emulsion) solid or the like, with organic solvent is solid, comprise that two-liquid type amine ethyl formate is solid or the like, with inorganic solvent is solid, comprises that a liquid type amine ethyl formate is solid or the like.By the commissure saponification of light polarizing film is handled or the like, be film when being used as diaphragm with the acetate fiber after the hydrophilic treatment, being fit to polyvinyl alcohol (PVA) is that resin aqueous solution is as solid.For being used as polyvinyl alcohol (PVA) that solid uses is for the resin, comprise the tygon ethyl ester saponification of the same first polymkeric substance that is an ethene ethyl ester processing and obtain vinyl alcohol with outside first polymkeric substance, also have with the ethene ethyl ester and can with the multipolymer saponification of other monomer of copolymerization to handle and obtain vinyl alcohol be multipolymer, moreover, also having the polyvinyl alcohol (PVA) after these hydroxylic moiety sex change is polymkeric substance or the like.Interpolation multivalence aldehyde, soluble epoxide compound, melamine are that compound or the like is also good on this solid.
The method that light polarizing film and diaphragm are fitted is also without particular limitation, for example can evenly be coated with solid on the surface of light polarizing film or diaphragm, and the opposing party's film is also once more with methods such as applyings such as roller, dryings on the coated face.
Usually, solid modulation back is coated with in 15~40 ℃ temperature, and binding temperature is generally in 15~30 ℃ scope, carry out dried after the applying to remove contained moisture equal solvent in the solid, at this moment, general about 30~85 ℃ of baking temperature, and preferable in 40~80 ℃ the scope.Afterwards, about 15~85 ℃, be preferably 20~50 ℃, better is in 35~45 ℃ the temperature environment, and it is also good that the curing of carrying out approximately 1~90 makes the solid sclerosis usually.Because if the very long productivity that easily makes of this setting up period worsens, setting up period was about about 30 days, right 1~7 day preferable.
So, see through solid, fitted diaphragm to obtain Polarizer at the single or double of light polarizing film.
Among the present invention, function, the brightness that can have on the diaphragm as phase retardation film promote the function of film, the function of reflectance coating, the function of half penetrability reflectance coating, the function of diffusion barrier, the function of optical compensation films or the like optical function.At this moment, for example, on the surface of diaphragm; the optical film of the function by phase retardation film, brightness being promoted film, reflectance coating, half penetrability reflectance coating, diffusion barrier, optical compensation films or the like is lamination in addition; can have this a little functions, in addition, also can make diaphragm itself give such function.And, make diaphragm itself have a plurality of functions, diffusion barrier of the function of similar tool brightness lifting film or the like is also good.
For example, on the said protection film, specially permit the stretch processing of being put down in writing in No. 2841377 communique or the like, or Japanese patent gazette speciallys permit processing of being put down in writing in No. 3168850 communique or the like or the like, can invest the function of phase retardation film by implementing Japanese patent gazette.And; on the said protection film; spy with the Japanese Patent Laid Open Publication communique opens 2002-169025 number or the special method of putting down in writing in the 2003-29030 communique of opening; by forming minute aperture; cholesterol shape more than 2 layers (cholesteric) liquid crystal layer that the centre wavelength of selection reflection is different and overlapping can invest the function that brightness promotes film again.By forming metallic film in said protection film, can invest the function of reflectance coating or half penetrability reflectance coating with steam deposition or splash (sputtering).Contain atomic resin solution by coating on diaphragm, can invest the function of diffusion barrier.By the orientation that on said protection film, is coated with discotic mesogenic (discotic liquid crystal) property compound or the like liquid crystal compounds and makes, can invest the function of optical compensation films again.In addition, use suitable solid, trade name is that to promote film, trade name be that film is improved at the visual angle of WV film (Fuji Photo film incorporated company (Fujifilm) system) or the like, trade name is phase retardation film of Sumikalight (trade mark login) (Sumiotomo Chemical Co., Ltd's system) or the like or the like, directly is fitted on the light polarizing film commercially available optics function film also good in the brightness of DBEF (Minnesota Mining and Manufacturing Co.'s system) or the like.
[embodiment]
Below, though illustrative embodiments being described more specifically the present invention, right the present invention only is defined in this a little embodiment.
Embodiment 1
With thickness is polyvinyl alcohol film (Wei Nilun (Vinylon) VF-PS#7500 of 75 μ m, the degree of polymerization 2400, saponification degree 99.9 is not more than the ear %) according to following swelling groove, staining trough, the 1st boric acid treatment trough, the order of the second boric acid treatment trough, rinsing bowl is carried successively to make light polarizing film.
Using in the swelling groove as shown in Figure 3, is that the hardness of 37.5 millimeters (mm), sponge is JIS shore hardness C yardstick 25 degree with radius r, and density is 0.42g/cm 3, and the sponge of surfaceness 20S is widened roller as 2 correcting rollers in the treating fluid.With the roller of NBR rubber (acrylonitrile butadiene rubber) system of radius 35mm, surfaceness 0.6S, rubber hardness (JIS shore hardness A yardstick) 80 degree as the correcting roller in other gas, in other treating fluid.
The 1st radius-of-curvature (R) of widening roller (2 among Fig. 3) is made as 1303mm, camber (H) 35mm, the 2nd radius-of-curvature (R) of widening roller (3 among Fig. 3) is made as 1813mm, camber (H) 25mm, the contact angle α of arbitrary roller all is configured to the position of 1.5rad (radian).
The transporting velocity of polyvinyl alcohol film is made as 0.34 meter/minute, and at this moment, film leaves the 1st to be widened before the roller, and the traveling time θ in liquid is 20 seconds, touches the 1st and widens before the roller, the time θ that advances in liquid 1Be 11 seconds, film leaves the 2nd to be widened before the roller, and the traveling time θ in liquid is 66 seconds, touches the 1st and widens before the roller, the time θ that advances in liquid 1It is 57 seconds.
The treating fluid of swelling groove is about 30 ℃ pure water, continues to remain on unlikely relaxing in the tense situation for making polyvinyl alcohol film when carrying, and need make its sufficient swelling.Dip time is about 80 seconds.
At this moment, widen the wide B of film that roller contacts with the 1st 1Be 369mm, widen the wide B of film that roller contacts with second 1Be 407mm.
If ask these to widen the maximum amount of the widening β of roller with formula (1), then the 1st to widen roller be 15.9mm, the 2nd to widen roller be 12.6mm, if the cross direction swell increment γ of film when asking film and each to widen roller to contact by formula (2), the 1st to widen roller be 12.2mm, the 2nd to widen roller be 3.8mm, is all β>γ for arbitrary expansion roller.
Observe advancing and the result of surface state of film, there is no the generation of wrinkle, folding line or flaw, and can get really extension travel condition for stable film.
Then, the weight ratio that impregnated in iodine/potassium iodide/water is that one side dyes in the aqueous solution of 0.02/1.5/100, and one side is carried out uniaxial tension (stretching ratio is 4.0 times).Afterwards, the weight ratio that impregnated in potassium iodide/boric acid/water is in the 10/5/100 about 60 ℃ aqueous solution, and one side is carried out boric acid and handled, and one side is carried out uniaxial tension and become 5.9 times until total stretching ratio of former film.In addition, stretching makes the nip rolls that is disposed at before and after the treatment trough have the circumferential speed difference to carry out.
Add, the weight ratio of potassium iodide/boric acid/water be in the 10/3/100 about 40 ℃ aqueous solution approximately dipping carried out the 2nd boric acid in 30 seconds and handle.After the 2nd boric acid is handled, approximately washed 10 seconds with about 10 ℃ pure water.After the washing, with about 60 ℃ of dryings 2 minutes, obtaining the iodine that thickness is about 28 μ m was light polarizing film.
Do not see flaw or wrinkle on the light polarizing film of gained.
Two sided coatings polyvinyl alcohol (PVA) in the light polarizing film of gained is a solid; with the diaphragm (triacetate cellulose membrane of handling through saponification on the surface; " FUJITAC (trade mark login) T80UNL "; Fuji Photo film incorporated company system) be affixed on the two sides, with about 60 ℃ temperature drying 5 minutes as Polarizer.
Can obtain not having the Polarizer of flaw or wrinkle.
Comparative example 1
Be that 28mm, radius of curvature R are that 3008mm, camber H are that the hardness of 15mm, sponge is that 25 degree, density are 0.42g/cm with JIS shore hardness C yardstick with the radius r 3, and the sponge of surfaceness 20S widens roller and widens roller as the 1st, is configured to the position that contact angle α is 1.1 radians, and the transporting velocity of film is made as 0.68 meter/minute, and in addition, all the other conditions are identical with embodiment 1, the making light polarizing film.
At this moment, film leaves the 1st to be widened before the roller, and the traveling time θ in liquid is 9 seconds, touches the 1st and widens before the roller, the time θ that advances in liquid 1Be 6 seconds, film leaves the 2nd to be widened before the roller, and the traveling time θ in liquid is 34 seconds, touches the 1st and widens before the roller, the time θ that advances in liquid 1It is 30 seconds.
At this moment, widen the wide B of film that roller contacts with the 1st 1Be 360mm, widen the wide B of film that roller contacts with second 1Be 390mm.
If ask these to widen the maximum amount of the widening β of roller with formula (1), then the 1st to widen roller be 3.7mm, the 2nd to widen roller be 12.1mm, if the cross direction swell increment γ of film when asking film and each to widen roller to contact by formula (2), the 1st to widen roller be 4.9mm, the 2nd to widen roller be 3.7mm, widens for the 1st to be β<γ for the roller, widens for the 2nd to be β>γ for the roller
Observe advancing and the result of surface state of film, widen the roller film from the 1st and produced wrinkle, folding line,, can't widen just that roller eliminates the 2nd in case folding line has taken place.
Can observe wrinkle or folding line on the light polarizing film of gained.

Claims (6)

1. the manufacture method of a light polarizing film is characterized in that:
In the manufacture method of a light polarizing film, it is that film carries out swelling processing, a dyeing processing in regular turn, a boric acid is handled and a washing processing that this light polarizing film manufacture method comprises a polyvinyl alcohol (PVA), and this boric acid treatment step and/or before step in carry out a uniaxial tension, wherein the correcting roller at least one treating fluid is for widening roller; And
This maximum amount of widening of widening roller is β, film is when this is widened roller and contacts, film is γ in the swell increment of cross direction, relation between β and the γ is set at (a) and disposes on the position that can reach β>γ and widen roller, or (b) use the roller of widening of the shape can reach β>γ, wherein β tries to achieve with following formula (1), and γ tries to achieve with following formula (2)
β=B 1×α×r/R .......(1)
(in the formula, B 1For with to widen the film that roller contacts wide, α is a contact angle of widening roller, and r is a radius of widening roller, and R is the radius-of-curvature of widening roller)
γ=0.2055×B 1×{exp(-0.0273×θ 1)-exp(-0.0273×θ)} ......(2)
(in the formula, B 1Identical with above-mentioned definition, θ is that film leaves the preceding traveling time in liquid of widening roller, θ 1Be the traveling time in liquid before film contact the widening roller).
2. the manufacture method of light polarizing film as claimed in claim 1, it is characterized in that: this widens roller is the sponge roller, and the hardness of sponge is 20~60 degree at JIS shore hardness C yardstick, and density is 0.4~0.6 gram/cubic centimeter, and surfaceness is 10~30S.
3. the manufacture method of light polarizing film as claimed in claim 1 is characterized in that: this is widened roller be configured in the swelling treating fluid.
4. Polarizer is characterized in that: this Polarizer be as in 3 of the claims 1 to the as described in each one side at least of the light polarizing film of method manufacturing stick a diaphragm.
5. Polarizer as claimed in claim 4 is characterized in that: this diaphragm is to have possessed phase retardation film, brightness to promote arbitrary function that film, visual angle improve film and half penetrability reflectance coating.
6. an optical laminate, it is characterized in that: this optical laminate has been fitted as claim 4 a described Polarizer, and is selected from phase retardation film, brightness and promotes film, visual angle and improve at least a in film and the half penetrability reflectance coating.
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