CN1952695A - Production method of optical film - Google Patents

Production method of optical film Download PDF

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Publication number
CN1952695A
CN1952695A CNA2006101362823A CN200610136282A CN1952695A CN 1952695 A CN1952695 A CN 1952695A CN A2006101362823 A CNA2006101362823 A CN A2006101362823A CN 200610136282 A CN200610136282 A CN 200610136282A CN 1952695 A CN1952695 A CN 1952695A
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China
Prior art keywords
liquid crystal
film
crystal material
orientation
acrylic resin
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CNA2006101362823A
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Chinese (zh)
Inventor
穗崎宪二
佐藤晴义
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Eneos Corp
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Nippon Oil Corp
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Publication of CN1952695A publication Critical patent/CN1952695A/en
Pending legal-status Critical Current

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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
    • G02B5/3041Polarisers, 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 comprising multiple thin layers, e.g. multilayer stacks
    • G02B5/305Polarisers, 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 comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered 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
    • B32B27/08Layered 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
    • 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
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00Adhesives in the form of films or foils
    • C09J7/30Adhesives in the form of films or foils characterised by the adhesive composition
    • C09J7/38Pressure-sensitive adhesives [PSA]
    • C09J7/381Pressure-sensitive adhesives [PSA] based on macromolecular compounds obtained by reactions involving only carbon-to-carbon unsaturated bonds
    • C09J7/385Acrylic polymers
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/30Polarising elements
    • G02B5/3016Polarising elements involving passive liquid crystal elements
    • 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
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00Applications
    • C08L2203/16Applications used for films

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  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonlinear Science (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mathematical Physics (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Laminated Bodies (AREA)
  • Polarising Elements (AREA)
  • Liquid Crystal (AREA)

Abstract

Provided is a thin liquid crystal layer constituted optical film producing method which improves the production efficiency and yields remarkably without a supporting substrate. The optical film producing method is characterized in that, a laminated film is cut in half, which is overlapped in a sequence of repeeling film/curing acrylic resin layer/orientation fixed liquid crystal layer/curing acrylic resin layer/bond layer/separation film, and then the repeeling film is peeled.

Description

The manufacture method of optical thin film
Technical field
The present invention relates to be used for the manufacture method of the optical thin film of various optical elements.
Background technology
In recent years, the optical thin film that uses for liquid crystal indicator also requires higher permanance except requiring excellent optical property.Particularly, require to satisfy the rigorous environment test of having supposed various service conditions for the liquid crystal indicator of mobile devices such as mobile phone usefulness, vehicle mounted.
The film (film) that comprises the oriented layer of liquid-crystal compounds, particularly comprise and fixed nematic structure, twisted-nematic structure or to the film of the liquid crystal material of row hydridization (nematic hybrid) structure, the colorimetric compensation that uses as liquid crystal display cells, viewing angle compensation have the performance of excellence with element and as optical activity optical element etc., help high performance, the lighting of various display elements.As the manufacture method of these films, proposed will form on the orientation substrate the layer that comprises liquid crystal material be transferred to method (for example, with reference to patent documentation 1~3) on the light-transmitting substrate of double as supporting substrate.
In addition, as being used to bear the countermeasure of liquid crystal display with the desired too harsh endurancing of element, and, also proposed not use the manufacture method (for example, with reference to patent documentation 4) of the optical thin film that comprises liquid crystal material of supporting substrate film for further slimming, lighting.According to this manufacture method, by bonding agent will by the liquid crystal material that forms of orientation on the orientation substrate form layer temporarily be transferred on the releasable substrate after, by peeling off this releasable substrate, can make the optical thin film that forms by the liquid crystal material layer that does not have the supporting substrate film.
Patent documentation 1: the spy opens flat 4-57017 communique
Patent documentation 2: the spy opens flat 4-177216 communique
Patent documentation 3: the spy opens flat 6-242434 communique
Patent documentation 4: the spy opens flat 8-278491 communique
Usually, when using with element as liquid crystal display, further laminated phase-difference film, polaroid on the optical thin film that forms by the liquid crystal material layer.At this moment, in order to give full play of optical property, usually following carrying out: be not to fit (roller is to the applying of roller) continuously between the MD (flow direction) of long film, but will be cut between the thin slice of given size with desirable angle applying (thin slice is to the applying of thin slice).In addition, in order to enhance productivity as much as possible, after on the one side of the optical thin film that forms by the liquid crystal material layer, giving continuously in advance to be used in the final products fit to the adhesive phase of liquid crystal indicator, be cut into given size, then " thin slice is to the applying of thin slice " operation of enforcement and phase-contrast film, polaroid.
That is, will be cut into given size by the optical thin film that the liquid crystal material layer/adhesive phase/diffusion barrier that forms on the releasable substrate (separator film) constitutes after, must peel off the releasable substrate.At this moment, peel off easily,, can peel off earlier mostly between adhesive phase/diffusion barrier,, aspect production efficiency, have big problem so operating efficiency and productive rate are poor even will peel off the releasable substrate because the peeling force between adhesive phase/diffusion barrier is little.
Summary of the invention
The inventor etc. are according to above-mentioned present situation, carried out conscientiously research, the result is by to the laminate film with the sequential cascade of the immobilized liquid crystal material layer of releasable film/curing acrylic resin bed/orientation/curing acrylic resin bed/adhesive phase/diffusion barrier, implemented to peel off the releasable film after the hemisect (halfcut), successfully increase substantially production efficiency, thereby finished the present invention.
Promptly, the present invention the 1st relates to a kind of manufacture method of optical thin film, it is characterized in that: the laminate film with the sequential cascade of the immobilized liquid crystal material layer of releasable film/curing acrylic resin bed/orientation/curing acrylic resin bed/adhesive phase/diffusion barrier is implemented hemisect, peel off the releasable film then.
The present invention the 2nd relates to the manufacture method of the present invention's the 1st described optical thin film, it is characterized in that: implement hemisect so that at least the releasable film cut fully.
The present invention the 3rd relates to the manufacture method of the present invention's the 1st described optical thin film, it is characterized in that: implement hemisect so that at least diffusion barrier cut fully.
The present invention the 4th relates to the manufacture method of the present invention's the 1st~3 described optical thin film, it is characterized in that: be orientated immobilized liquid crystal material layer by forming at liquid crystal aligning under the temperature more than the liquid crystal tr pt, the high molecule liquid crystal material that becomes glassy state under the temperature below the liquid crystal tr pt.
In addition, the present invention the 5th relates to the manufacture method of the present invention's the 1st~3 described optical thin film, it is characterized in that: be orientated immobilized liquid crystal material layer by the crosslinked layer that obtains of the liquid crystal material with reactive group of liquid crystal aligning is constituted.
In addition, in above-mentioned record, "/" represents the interface of each layer, below equally the record.
Below, the present invention is described in detail.
The immobilized liquid crystal material layer of the orientation of the liquid crystal that uses among the present invention is the layer by using the immobilized method of liquid crystal material will be in state of orientation to be fixed, as immobilized method, can list: for the high molecule liquid crystal material time, become the fixing method of vitrifacation state from the state of orientation quenching; After making low molecule or high molecule liquid crystal material orientation, make the previous reaction radical reaction and immobilized method etc. with reactive group.
As the previous reaction group, can list vinyl, (methyl) acryloyl group, vinyl oxygen base, epoxy radicals, oxa-cyclobutyl, carboxyl, hydroxyl, amino, isocyanate group, anhydride group etc., react with the method that is suitable for various groups.
The liquid crystal material that can use in the liquid crystal material layer according to purpose purposes, the manufacture method of liquid crystal film, no matter be low molecular weight liquid crystal material, high molecule liquid crystal material, can be selected from wide region, but preferred high molecule liquid crystal material.In addition, no matter the molecular shape of liquid crystal material is bar-shaped or discoid.Also can use the disc liquid-crystal compounds that for example demonstrates plate-like (discotic) nematic liquid crystal.
As the liquid crystal phase of the liquid crystal material layer before the immobilization, can list nematic phase, twisted-nematic phase, cholesteric phase, hydridization and equate to row (hybrid nematic) phase, hydridization twisted-nematic phase, plate-like nematic phase, smectic.
As aforementioned high molecule liquid crystal material, can use various backbone chain type high molecule liquid crystal materials, side chain type high molecule liquid crystal material or their potpourri.As backbone chain type high molecule liquid crystal material, can list macromolecule liquid crystal materials such as polyesters, polyamide-based, polycarbonate-based, polyimide, polyurethanes, polybenzimidazoles class, poly-benzoxazoles, polybenzothiozole class, poly-azomethine class, polyesteramide class, polyestercarbonate class, polyester-imide class, or their potpourri etc.In addition, as side chain type high molecule liquid crystal material, can list the material that polyacrylate, polymethacrylate, tygon base class, polysiloxane-based, polyethers, poly-malonate class, polyesters etc. have the skeletal chain of straight chain shape or ring texture and combine the high molecule liquid crystal material of internal compensation group as side chain, or their potpourri.Wherein, from synthetic, orientation is easy etc., preferably as the polyesters of backbone chain type high molecule liquid crystal material.
As the low molecular weight liquid crystal material, can list at the end of saturated benzene carboxylic acid, unsaturated benzene carboxylic acid, biphenyl carboxylic acids class, aromatic hydrocarbyl carboxylic acids, schiff's base type class, bisdiazo methine compounds, azo-compound class, azoxy compounds, cyclohexane ester compounds class, sterol compound class etc. and introduce the previous reaction group and demonstrated the composition that added cross-linked compound in the compound that is showing liquid crystal liquid crystal property in the compound of liquid crystal liquid crystal property and the aforesaid compound and formed etc.In addition, as disc liquid-crystal compounds, can list the luxuriant and rich with fragrance class of benzo [9,10], ト Le Network セ Application class etc.
In addition, in not hindering the scope that demonstrates liquid crystal liquid crystal property, also can be in liquid crystal material the compounding all cpds, these compounds have functional group or the position that outside stimuluss such as heat of being subjected to or light can be reacted by cross-linking reaction etc.Functional group as the energy cross-linking reaction can list aforementioned various reactive groups etc.
The immobilized liquid crystal material layer of the orientation of liquid crystal can followingly be formed: the composition etc. that adopts all cpds that will contain the foregoing liquid crystal material, add as required is applied to method on the orientation substrate with molten condition, with the formation such as method to the orientation substrate such as the solution coat of said composition etc., be coated on filming on the orientation substrate through super-dry, thermal treatment (orientation of liquid crystal), use the method for aforementioned fixation such as rayed and/or heat treated orientation as required, will be orientated and fix and form.
The solvent that uses during for the preparation of the solution that uses in the method for the aforementioned solution of coating, so long as can dissolve the liquid crystal material that uses among the present invention, composition, the dissolving that can heat up in a steamer under proper condition, just there is no particular limitation, usually the preferred acetone that uses, MEK, ketones such as isophorone, butyl cellosolve, own ethoxy-ethanol, methoxyl-ether alcohol classes such as 2-propyl alcohol, glycol dimethyl ether, glycol ethers such as diethylene glycol dimethyl ether, ethyl acetate, acetate methoxyl propyl ester, ester classes such as ethyl lactate, phenol, phenols such as chlorophenol, N, dinethylformamide, N, the N-dimethyl acetamide, amide-types such as N-Methyl pyrrolidone, chloroform, tetrachloroethane, halogenated hydrocarbons such as dichloro-benzenes etc., their mixed stocker.In addition, film uniformly, can in solution, add surfactant, defoamer, levelling agent etc. in order on orientation substrate, to form.In addition, based on painted purpose, in not hindering the scope that demonstrates liquid crystal liquid crystal property, also can add dichroic dye, common dyestuff, pigment etc.
Coating process is so long as the inhomogeneity method of guaranteeing to film with regard to there is no particular limitation, can adopt known method.For example, can list rolling method, mould is coated with method, dip coating, curtain formula rubbing method, spin-coating method etc.After coating, can introduce and adopt well heater, blow method such as Wen Feng and remove (drying) operation of desolvating.
The film of coating is generally 0.1 μ m~50 μ m at the thickness of drying regime, is preferably 0.2 μ m~20 μ m, more preferably 0.3 μ m~10 μ m.Beyond this scope, it is insufficient etc. that the optical property deficiency of the liquid crystal material layer of gained, the orientation of liquid crystal material become, so not preferred.
Then, adopt thermal treatment etc. to form the orientation of liquid crystal as required after, the immobilization that is orientated.Thermal treatment is by being heated to the temperature range that liquid crystal phase manifests, can making liquid crystal aligning by the original auto-orientation that has of liquid crystal material.Heat treated condition is according to the liquid crystal phase transition dynamic temperature degree (transition temperature) of the liquid crystal material that uses, and top condition, boundary value are different, cannot treat different things as the same, and are generally 10~300 ℃, are preferably 30~250 ℃ scope.Temperature is low excessively, and then the orientation of liquid crystal may insufficient carrying out, and in addition, at high temperature, liquid crystal material may decompose, and brings harmful effect to orientation substrate.In addition, heat treatment time is generally 3 seconds~60 minutes, is preferably 10 seconds~30 minutes scope.If heat treatment time less than 3 seconds, then may fully not finished the orientation of liquid crystal, in addition, if heat treatment time surpasses 60 minutes, the production efficiency extreme difference that becomes then is so any situation is not preferred.After liquid crystal material has been finished liquid crystal aligning by thermal treatment etc., under this state, use the method for the liquid crystal material that is suitable for using that the liquid crystal material layer on the orientation substrate is fixed.
As aforementioned orientation substrate, can the illustration polyimide, the film of polyamide, polyamidoimide, polyphenylene sulfide, polyphenylene oxide, polyetherketone, polyetheretherketone, polyethersulfone, polysulfones, polyethylene terephthalate, PEN, polyarylate, tri acetyl cellulose, epoxy resin, phenolics etc.
Even these films are not used for processing that orientation can be manifested according to manufacture method, the liquid crystal material that the present invention is used also demonstrates enough orientation energy, but when being orientated the energy deficiency or display orientation can not wait, can use following film: these films stretch under suitable heating; Use the so-called friction treatment of wiping pellicular front on a direction such as rayon cloth; The alignment films that is formed by known alignment agents such as polyamide, polyvinyl alcohol (PVA), silane coupling agents is set on film, carries out friction treatment; Carry out monox icocline side vapor deposition treatment, perhaps with their appropriate combination etc., demonstrate orientation can film.
In addition, as orientation substrate, also can use the sheet metal of the aluminium that is provided with the fine ditch of many rules on the surface, iron, copper etc., various glass plates etc.
Wherein, there is no particular limitation as the orientation process direction of orientation substrate film, can by carry out in any direction above-mentioned each handle and suitably select.Especially, when using the liquid crystal film that forms on the long orientation substrate, wish to select the angle of regulation, in an inclined direction carry out orientation process as required with respect to the MD direction of this long continuous film.By on the angle direction of regulation, carrying out orientation process, when coming stacked liquid crystal film with the axle configuration that can bring into play optimised optical properties, from can under the state of the MD unanimity that makes long film, fit on (so-called roller to roller fit) or improve goods obtain aspect such as efficient, have splendid advantage.
Then, the method that the liquid crystal material layer that forms on the orientation substrate film is transferred on the releasable film is described.
As the releasable film that uses among the present invention; can the illustration tygon; polypropylene; olefine kind resins such as poly 4-methylpene-1, polyamide; polyimide; polyamidoimide; polyetherimide; polyetherketone; polyetheretherketone; polyethersulfone; the polyketone thioether; polysulfones; polystyrene; polyphenylene sulfide; polyphenylene oxide; polyethylene terephthalate; polybutylene terephthalate; polyarylate; polyacetal; the unilateral stretching polyester; polycarbonate; polyvinyl alcohol (PVA); polymethylmethacrylate; polyarylate; amorphous polyolefin; norbornene resin; plastic sheeting such as tri acetyl cellulose or epoxy resin.
In these plastic sheetings; particularly as the transparency of optical defect inspectability excellence, the film of optical isotropy, can the illustration poly 4-methylpene-1, each film such as polymethylmethacrylate, polystyrene, polycarbonate, polyethylene terephthalate, polyethersulfone, polyarylate, amorphous polyolefin, norbornene resin, tri acetyl cellulose or epoxy resin.
For these plastic sheetings,, can perhaps be pre-formed organic film or inorganic thin film in advance at surface conditioning agents such as its surface coated organosilicons in order to keep the releasable of appropriateness.In addition,, also can carry out chemical treatments such as saponification processing, perhaps carry out physical treatments such as corona treatment on the surface of plastic sheeting based on same purpose.
In addition, in order to regulate the fissility of releasable film, also can make above-mentioned plastic sheeting contain lubricant, surface modifier.As aforementioned lubricants, as long as, its kind, addition are just had no particular limits bringing dysgenic scope can not for inspectability, the fissility of the optical defect of liquid crystal material layer.As the object lesson of lubricant, can list fine silicon dioxide, fine aluminium oxide etc., as the index of its addition, the haze value of releasable substrate is generally below 50%, be preferably below 30%.If addition is very few, then can't confirm additive effect, on the other hand, if too much, so the inspectability variation of optical defect then is not preferred.
In addition, as required, can also contain other known various adjuvants, for example anti blocking agent, antioxidant, antistatic agent, thermal stabilizer, resistance to impact modifying agent etc.
Peeling force about the releasable film, even releasable film by the same material manufacturing, also can be owing to manufacture method, surface state, change with the wetting state of the bonding agent that uses etc., can not decide without exception, wish and the peeling force at the interface of bonding agent (peel off, measure under the peeling rate 30cm/ minute, room temperature for 180 °) 0.38~12N/m normally, be preferably 0.38~8.0N/m.When peeling force is lower than this value, after the liquid crystal material layer on the orientation substrate and releasable film is bonding, when peeling off orientation substrate, peeling force is crossed low and is found the perk of releasable film, can't obtain the good state of peeling off at desirable interface, the liquid crystal material layer becomes insufficient to the transfer printing of releasable substrate; In addition, when peeling force is too high, when peeling off the releasable film, produce the destruction of liquid crystal material layer or peeling off etc., so not preferred with the interface of desirable layer.
In addition, the thickness of releasable film also influences fissility sometimes, and hope is 16~100 μ m, is preferably 25~80 μ m especially.If thickness is blocked up, pick-up point instability then, fissility possible deviation; On the other hand,, then can't guarantee the physical strength of film, may produce problem such as tear during fabrication if thin excessively.
For the liquid crystal material layer that forms on the orientation substrate being transferred on above-mentioned such releasable film, after preferably giving the liquid crystal material laminar surface with optically isotropic curing type crylic acid resin bonding agent, by for example rayed make its reaction solidify (crosslinked) bonding after, peel off orientation substrate, easily transfer printing.
The curing type crylic acid resin bonding agent that uses, for example as the light-cured type acrylic-based adhesives, can use known material, particularly can the illustration polyester acrylate, various acrylic compounds oligomer such as epoxy acrylate, urethane acrylate, polyether acrylate, organic silicon acrylic ester or (methyl) acrylic monomer etc. separately, the potpourri of their potpourri or they and various reactive diluents.
In addition, these bonding agents can also add various particulates etc., surface modifier in the scope of not damaging its characteristic.
As aforementioned particulate, can the illustration refractive index different particulates with the compound that constitutes bonding agent, do not damage the transparency and be used to improve antistatic property electrically conductive microparticle, be used to improve the particulate of abrasion performance etc., more specifically, can list fine silicon dioxide, fine aluminium oxide, ITO (tin indium oxide) particulate, silver-colored particulate, various synthetic resin particulates etc.
In addition, as aforementioned surfaces modifier, so long as it is good with the compatibility of bonding agent, can not influence the curable of bonding agent, the optical property after the curing, just there is no particular limitation, can use organic metal class surfactant, the reactive surfactants etc. such as water soluble surfactant active, oil soluble surfactant, high molecular surfactant, fluorine class surfactant, organosilicon of ionic, nonionic.
There is no particular limitation for the curing of these curing type crylic acid resin bonding agents, can illustration for example be heating and curing, the normal temperature cure of oxidation-reduction class, be sick of curing, ultraviolet ray, electron beam isoreactivity actinic radiation-curable etc.Preferred curing is to use the photocuring method of ultraviolet ray, electron beam isoreactivity ray.The preferred light solidification method is because produce heat or produce fewly, so the influence of the liquid crystal material layer that orientation is fixed is few.Can add various known photoreaction initiator, irradiation is reacted from the light of light sources such as metal halide lamp, high-pressure mercury-vapor lamp, Cooper-Hewitt lamp, xenon lamp, arc lamp, laser, synchrotron radiation light source.Exposure as per unit area (1 square centimeter) in cumulative exposure, is generally 1~2000mJ, is preferably the scope of 10~1000mJ.But absorption region and the visibly different situation of wave spectrum of light source or the situation of the absorption energy that reactive compounds self has optical source wavelength etc. in photoreaction initiator are not limited to this.In these cases, also can adopt suitable photosensitizer or the different methods such as photoreaction initiator mixing use more than 2 kinds of absorbing wavelength.Under electronic beam solidified situation, accelerating potential is generally 10kV~200kV, is preferably 50kV~100kV.
As the thermal response initiating agent; can use for example diacyl peroxide such as benzoyl peroxide, lauroyl peroxide class; peroxidating ketone, ketal peroxide class, dialkyl peroxide class, peroxyesters and azos such as azoisobutyronitrile, AMBN two classes etc., use amount can be 0.1~10 weight % of resin.
In addition, when it is solidified, as photoreaction initiator, can illustration for example benzoin ether, benzoin ethylether, benzyl methyl ketal, hydroxy phenyl ketone, 1,1-dichloroacetophenone, thioxanthene ketone or and with the benzophenone of amine etc.Their use amount also can be 0.1~10 weight % of resin.
In the present invention, be formed for protecting the protective seam on surface on the liquid crystal material layer, this protective seam is made of the curing acrylic resin bed.This protective seam can be to have a curing type acrylate resin layer itself that optically isotropic photo-curable acrylate etc. constitutes by aforementioned, also can constitute as the bonding transparent thin-film of bonding agent with the curing type acryl resin.Any curing acrylic resin bed all is by acrylic compounds oligomer or monomer in the surface coated curable, and it is solidified to form.
The curable acrylate that uses, can use as acrylic-based adhesives, the agent of curable plastic-coated or the hard paint of plastics and known material, can illustration for example various acrylic compounds oligomer such as polyester acrylate, epoxy acrylate, urethane acrylate, polyether acrylate, organic silicon acrylic ester or monomer etc. are independent, the potpourri of their potpourri or they and various reactive diluents.
In addition, these bonding agents also can add various particulates etc., surface modifier in the scope of not damaging its characteristic.
As aforementioned particulate, can the illustration refractive index different particulates with the compound that constitutes bonding agent, do not damage the transparency and be used to improve antistatic property electrically conductive microparticle, be used to improve the particulate of abrasion performance etc., more specifically, can list fine silicon dioxide, fine aluminium oxide, ITO (tin indium oxide) particulate, silver-colored particulate, various synthetic resin particulates etc.
In addition, as aforementioned surfaces modifier, so long as it is good with the compatibility of bonding agent, can not influence the curable of bonding agent, the optical property after the curing, just there is no particular limitation, can use organic metal class surfactant, the reactive surfactants etc. such as water soluble surfactant active, oil soluble surfactant, high molecular surfactant, fluorine class surfactant, organosilicon of ionic, nonionic.
There is no particular limitation for the curing of these curable acrylate, and the curing of the curing type crylic acid resin bonding agent that can use when making the foregoing liquid crystal material layer transfer to the releasable substrate is similarly carried out.
According to above method, obtain the laminate film that liquid crystal material layer/curing acrylic resin bed that releasable film/curing acrylic resin bed/orientation is fixing forms with this sequential cascade.Wherein, the thickness of this curing acrylic resin bed all is respectively 0.1~50 μ m, is preferably 0.5~20 μ m, more preferably 1~10 μ m.If thickness is thinner than this, the protection effect deficiency of the liquid crystal material layer in the environmental test then, if blocked up in addition, then the curing of curing acrylic resin bed is time-consuming, so the products thickness thickening is not preferred.
In addition, in the present invention,, also can between liquid crystal material layer and other layer, form release layer by using the releasable film that has been pre-formed the release layer that to peel off from this film surface at the releasable film surface.By forming release layer, the stress barrier effect of the appearance change of the liquid crystal material layer of film when obtaining being used to suppress to make, during environmental test (for example ripple etc.).In addition, wherein there is no particular limitation as release layer, and the hyaline layer of preferred optical isotropy can list for example polymkeric substance of acrylic compounds, methacrylic, NC Nitroncellulose class, epoxy compounds etc. and their potpourri.Thickness as release layer, be below the above 40 μ m of 0.3 μ m, be preferably below the above 10 μ m of 0.5 μ m, glass transition temperature (Tg) is more than 20 ℃, be preferably the hyaline layer of the optical isotropy more than 50 ℃, as long as the optical characteristics of not obvious infringement liquid crystal material layer just is not particularly limited for material.Thickness and glass transition temperature be outside this scope the time, its effect deficiency, and goods are blocked up etc., so not preferred.
In addition, that aforementioned release layer can adopt that the interpolation of crosslinked composition causes is partial cross-linked, add plastifier, add lubricant waits and controls rerum natura.
In addition; also there is no particular limitation to the formation method of release layer; can list methods such as for example employing is coated with, extrudes and on releasable films such as tygon, polypropylene, polyethylene terephthalate, be pre-formed the material that becomes release layer with above-mentioned thickness; with this layer driving fit, peel off the transfer printing of releasable film etc. by bonding agent bond layer, protective clear layer then.
In ensuing operation, the laminate film that the liquid crystal material layer/curing acrylic resin bed that releasable film/curing acrylic resin bed/orientation is fixing that as above obtains is formed with this sequential cascade is given the bonding agent that is used to fit on the liquid crystal display cells etc. in end article.Because production efficiency is good, so on long laminate film, give bonding agent continuously usually.There is no particular limitation as the method that gives bonding agent continuously, can list: behind direct coating adhesive on the curing acrylic resin aspect of laminate film, and the method for applying diffusion barrier; The method that the curing acrylic resin bed of the adhesive phase that forms on long diffusion barrier in advance and laminate film is fitted continuously etc.Usually, in order to ensure with the fissility of bonding agent, use as diffusion barrier and to have carried out the plastic sheetings such as polyethylene terephthalate that organosilicon is handled.
So, obtain the laminate film that liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier that releasable film/curing acrylic resin bed/orientation is fixing forms with this sequential cascade.
Then, the laminate film hemisect that the liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier that releasable film/curing acrylic resin bed/orientation is fixing that as above obtains is formed with this sequential cascade.
As the method for hemisect, can list following 2 kinds of methods.
<method A〉carry out hemisect so that the releasable film method of being cut fully at least.
<method B〉carry out hemisect so that the diffusion barrier method of being cut fully at least.
Wherein, under the situation of method A, if the releasable film is cut fully at least, and diffusion barrier is not cut fully at least and is residual, for the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase part of other curing acrylic resin bed/orientation, can cut also and can not cut.The state of wishing is to have only the releasable film by hemisect, and other parts are not cut.
In addition, under the situation of method B, if diffusion barrier is cut fully at least, and the releasable film at least not exclusively is cut and is residual, for the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase part of other curing acrylic resin bed/orientation, can cut also and can not cut.In addition, wherein, even for the fixing liquid crystal material layer/curing acrylic resin bed of curing acrylic resin bed/orientation/adhesive phase part may not be cut, also can only peel off the releasable film, these layers must be torn when the strip operation of releasable film.The state of wishing is to have only the releasable film not to be cut, and other parts are cut fully.
There is no particular limitation to peel off the method for releasable film, when being the situation of method A, if in the hemisect of releasable film part stick glass paper tape etc. and peel off, then can easily only peel off the releasable film.In addition, when being method B, catching by the diffusion barrier of hemisect part and directly peel off, then can easily only peel off the releasable film.
In addition, the releasable film is easier to be peeled off to making, and the method that improves operating efficiency describes.
For the laminate film of liquid crystal material layer/curing acrylic resin bed/bond layer/diffusion barrier that releasable film/curing acrylic resin bed/orientation is fixing with the length of this sequential cascade formation; after peeling off the releasable film continuously, the temporary transient replacing is attached on the better long diaphragm of fissility.So, become the laminate film of liquid crystal material layer/curing acrylic resin bed/bond layer/diffusion barrier that diaphragm/curing acrylic resin bed/orientation is fixing with the length of this sequential cascade formation.Wherein, diaphragm play prevent after processing time damage curing acrylic resin surface or the effect of adhering to discarded object.
Then, the laminate film of the length that this replacing is pasted is cut into given size, carries out above-mentioned hemisect with the sheet material that obtains.That is, the method as hemisect can list following 2 kinds of methods.
<method C〉carry out hemisect so that the diaphragm method of being cut fully at least.
<method D〉carry out hemisect so that the diffusion barrier method of being cut fully at least.
Wherein, under the situation of method C, if diaphragm is cut fully at least, and diffusion barrier is not cut and residual at least fully; for the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase part of other curing acrylic resin bed/orientation, can cut also and can not cut.The state of wishing is to have only diaphragm by hemisect, and other parts are not cut.
In addition; under the situation of method D, if diffusion barrier is cut fully at least, and diaphragm is not cut and residual at least fully; for the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase part of other curing acrylic resin bed/orientation, can cut also and can not cut.In addition, wherein, even for the fixing liquid crystal material layer/curing acrylic resin bed of curing acrylic resin bed/orientation/adhesive phase part may not be cut, also can only peel off diaphragm, these layers must be torn when the strip operation of diaphragm.The state of wishing is to have only diaphragm not to be cut, and other parts are cut fully.
There is no particular limitation to peel off the method for diaphragm, when being the situation of method C, if in the hemisect of diaphragm part stick glass paper tape etc. and peel off, then can easily only peel off diaphragm.In addition, when being method D, catching by the diffusion barrier of hemisect part and directly peel off, then can easily only peel off diaphragm.
Wherein, there is no particular limitation as the diaphragm that uses, the normally used film of can illustration using as phase-contrast film, polaroid of diaphragm.Can list for example co-extrusion film of tygon and vinyl-vinyl acetate copolymer, to tygon base material, polyethylene terephthalate base material or polyolefin substrate has been given film of acrylic compounds or synthetic rubber class bonding agent etc.Usually, the peeling force of the former co-extrusion film is little, so more preferably.Hope is generally 0.2~12N/m as the peeling force of diaphragm (peel off, measure under the peeling rate 30cm/ minute, room temperature for 180 °), is preferably 0.38~8.0N/m.When peeling force was lower than this value, diaphragm may be stripped from handling the way, and in addition, if too high, then before peeling off diaphragm, the possibility of peeling off between bonding agent/diffusion barrier increases, so not preferred.
As mentioned above, by peeling off releasable film or diaphragm, can obtain the optical thin film of liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier that curing acrylic resin bed/orientation is fixing with the sheet of this sequential cascade formation.The optical thin film of this sheet is being used as colorimetric compensation sheet, the viewing angle compensation of used for liquid crystal display element etc. when using, usually stacked with polaroid, the optical thin film that the stacked as required again liquid crystal material layer of being fixed by orientation forms, macromolecule oriented film etc. are as phase difference film.Wherein, in polaroid, the optical thin film that forms by the fixing liquid crystal material layer of orientation, macromolecule oriented film etc. stacked, also can be stacked by bonding agent, the bonding agent of known light transmission.As the optical laminate that so obtains, can illustration for example:
(1) polaroid/bonding agent, the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier of bond layer/curing acrylic resin bed/orientation
(2) polaroid/bonding agent, bond layer/macromolecule oriented film/bonding agent, the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier of bond layer/curing acrylic resin bed/orientation
(3) liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier of fixing of the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase/curing acrylic resin bed/orientation of polaroid/bonding agent, bond layer/curing acrylic resin bed/orientation etc.
Polaroid can use polarizing coating separately, based on improving purposes such as intensity, raising moisture-proof, raising thermotolerance, transparent protective seam etc. can be set on the one or both sides of polarizing coating.As transparent protective seam, can list directly or be laminated with the protective seam of transparent plastic films such as polyester, tri acetyl cellulose, the coating layer of resin, light-cured type resin beds such as acrylic compounds, epoxies etc. by bond layer.When the protective seam that these are transparent is overlayed on the two sides of polarizing coating, identical protective clear layer can be set on the two sides, and different protective clear layers can be set.
As aforementioned macromolecule oriented film, the unidirectional or two-way stretch phase-contrast film that can illustration forms by cellulose family, polycarbonate-based, polyarylate class, polysulfones, polyvinyl alcohol (PVA) (PVA) class, polyacrylic, polyester sulfone class, cyclic polyolefin hydro carbons etc.Wherein, from the homogeneity or the optical characteristics aspect of property easy to manufacture, film, the monodirectional tension film of cyclic polyolefin hydro carbons such as optimization polycarbonate class, norborene class.
The optical laminate that optical thin film that will have the fixing liquid crystal material layer of orientation that so obtains and polaroid are fitted, according to the optical parametric of liquid crystal material layer, can be used as compensating unit, ellipsoidal polarizing plate, the circular polarizing disk performance function of various liquid crystal indicators.
Promptly, constitute the liquid crystal material layer of optical laminate, for example to row orientations, the fixing liquid crystal material layer of twisted nematic orientation owing to play function as phase difference film, STN type, TN type, OCB type, HAN type etc. see through or the compensating plate of reflection-type liquid-crystal display device uses so can be used as the optical laminate of component parts with this liquid crystal material layer.
In addition, phase differential when the fixing liquid crystal material layer of row hydridization orientation utilizes from top view, can be used as phase-contrast film, the use of wavelength sheet, and the asymmetry that produces of the direction (inclination of the molecular axis of film thickness direction) of utilizing phase difference value, parts etc. are improved at the visual angle that also can be used for TN type liquid crystal indicator.
In addition, the liquid crystal material layer with 1/4 wavelength sheet function can be used as the liquid crystal indicator of circular polarizing disk, reflection-type, the uses such as anti-reflection filter of EL display device by making up with polaroid.
In addition, the liquid crystal material layer that constitutes this duplexer is so long as with cholesteric orientation, the fixing liquid crystal material layer of smectic type orientation, just can be used to improve polarisation reflective film that brightness uses, reflection-type chromatic filter, utilized the various anti-counterfeiting elements that come from the catoptrical look variation that the visual angle of selecting reflected energy causes, decorating film etc.
By the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier of releasable film/curing acrylic resin bed/orientation is implemented hemisect with the laminate film that this sequential cascade forms, then peel off the releasable film, can high efficiency ground make the optical thin film of the film that does not have supporting substrate.
Embodiment
Below, by embodiment and comparative example the present invention is carried out more specific description, but the present invention is not limited to this.
In addition, the liquid crystal liquid crystal property macromolecular compound that uses in the present embodiment is the liquid crystal liquid crystal property macromolecular compound (the mole % that respectively constitutes the unit of the numeric representation polymkeric substance of the bracket bottom right in the formula) that following formula is represented, this compound to the row orientation, is glassy state below liquid crystal transition temperature under mesomorphic state.Therefore, the orientation in the time of can be with liquid crystal is fixed, and the fixing film of this orientation is suitable as the phase-contrast film that liquid crystal indicator uses and uses.
<embodiment 1 〉
Use roll coater as the carrying out of the long film of polyimide of orientation substrate film on the face of friction treatment, the coating solution of coating fluid crystallinity macromolecular compound, dry then, heated 20 minutes down at 210 ℃, obtain the liquid crystal liquid crystal property macromolecule membrane of the length that the orientation of liquid crystal high molecular compound is fixing.Use another roll coater on the liquid crystal liquid crystal property polymeric membrane of the length that forms on this polyimide, be coated with commercially available ultraviolet hardening acrylic-based adhesives (UV-3400, East Asia synthetic (strain) makes), form bond layer.In addition, on bond layer, fit long unilateral stretching polyethylene terephthalate (PET) film as the releasable film, bonding agent is solidified, thereby obtain laminate film by orientation substrate film/polymer liquid crystal layer/length that curing acrylic resin bed 1/ releasable film forms.The laminate film of the length that the use roller will obtain obtains the laminate film by liquid crystal liquid crystal property macromolecule layer/length that curing acrylic resin bed 1/ releasable film constitutes at the interface peel of orientation substrate film and liquid crystal liquid crystal property macromolecule layer.Then, use roll coater on the liquid crystal liquid crystal property macromolecule layer of this laminate film, to be coated with ultraviolet hardening acrylic-based adhesives (UV-3400).And then, the PET film handled of organosilicon of on the bond layer of coating, having fitted long carrying out, bonding agent is solidified, thereby obtain handling the laminate film of PET film/curing acrylic resin bed 2/ liquid crystal liquid crystal property macromolecule layer/length that curing acrylic resin bed 1/ releasable film constitutes by organosilicon.
After using roller that the organosilicon processing PET film of this laminate film that obtains is peeled off continuously, the bonding agent of fitting and giving on long diffusion barrier in advance obtains the laminate film (A) by diffusion barrier/adhesive phase/curing acrylic resin bed 2/ liquid crystal liquid crystal property macromolecule layer/length that curing acrylic resin bed 1/ releasable film constitutes.
Then, the laminate film (A) of this length is cut into the sheet material of 10 A4 sizes.And then, use commercially available hemisection cutter (キ Application グ ヅ system society makes Ha one Off カ Star one RH24 that TEPRA uses), respectively with 1 angle (corner) portion's hemisect so that the releasable film be cut.On the releasable pellicular front of this hemisect, stick the glass paper tape and peel off, can easily peel off at the interface of releasable film and curing acrylic resin bed 1 for 10 as a result.
<embodiment 2 〉
The laminate film (A) of the length that embodiment 1 is obtained is cut into the sheet material of 10 A4 sizes.Then, use the commercially available hemisection cutting mill identical with embodiment 1, respectively with 1 bight hemisect so that diffusion barrier be cut.Catch the bight of this hemisect directly to peel off, can easily peel off at the interface of releasable film and curing acrylic resin bed 1 for 10 as a result.
<embodiment 3 〉
Use the interface of roller at releasable film and curing acrylic resin bed 1; after the laminate film (A) of the length that embodiment 1 is obtained is peeled off continuously; long diaphragm (PAC-2-70G thereon fits; サ Application エ one change is ground society and is made), obtain laminate film (B) by diffusion barrier/adhesive phase/curing acrylic resin bed 2/ liquid crystal liquid crystal property macromolecule layer/length that curing acrylic resin bed 1/ diaphragm constitutes.
The laminate film (B) of this length is cut into the sheet material of 10 A4 sizes, uses the commercially available hemisection cutting mill identical with embodiment 1, respectively with 1 bight hemisect so that diaphragm be cut.On the protection face of this hemisect, stick the viscose paper band and peel off, can easily peel off at the interface of diaphragm and curing acrylic resin bed 1 for 10 as a result.
<embodiment 4 〉
The laminate film (B) of the length that embodiment 3 is obtained is cut into the sheet material of 10 A4 sizes.Then, use the commercially available hemisection cutting mill identical, so that diffusion barrier is cut, catch the bight of this hemisect directly to peel off the bight hemisect, can easily peel off at the interface of diaphragm and curing acrylic resin bed 1 for 10 as a result with embodiment 1.
<comparative example 1 〉
The laminate film (A) of the length that embodiment 1 is obtained is cut into the sheet material of 10 A4 sizes.Trial is sticked the glass paper tape and is only peeled off the releasable film on the releasable pellicular front in this bight, but 10 all only at the interface peel of adhesive phase and diffusion barrier.
<comparative example 2 〉
The laminate film (B) of the length that embodiment 3 is obtained is cut into the sheet material of 10 A4 sizes.Trial is sticked the glass paper tape and is only peeled off diaphragm on the protection face in this bight, the result can only peel off 5 diaphragm, remaining 5 interface peels at adhesive phase and diffusion barrier.
The evaluation result of embodiment 1~4 and comparative example 1~2 is aggregated in the table 1.
Table 1
The releasable film The hemisect position The disbonded test of releasable film or diaphragm
Embodiment 1 Unilateral stretching PET Cutting unilateral stretching PET Easily peel off unilateral stretching PET (in 10 10)
Embodiment 2 Unilateral stretching PET The cutting and separating film Easily peel off unilateral stretching PET (in 10 10)
Embodiment 3 PAC-2-70G Cutting PAC-2-70G Easily peel off PAC-2-70G (in 10 10)
Embodiment 4 PAC-2-70G The cutting and separating film Easily peel off PAC-2-70G (in 10 10)
Comparative example 1 Unilateral stretching PET Do not have Unstripped unilateral stretching PET (in 10 10)
Comparative example 2 PAC-2-70G Do not have A part is unusual interface peel (in 10 5)

Claims (5)

1. the manufacture method of an optical thin film, it is characterized in that: the laminate film with the sequential cascade of the fixing liquid crystal material layer/curing acrylic resin bed/adhesive phase/diffusion barrier of releasable film/curing acrylic resin bed/orientation is carried out hemisect, peel off the releasable film then.
2. the manufacture method of the described optical thin film of claim 1 is characterized in that: carry out hemisect so that at least the releasable film cut fully.
3. the manufacture method of the described optical thin film of claim 1 is characterized in that: carry out hemisect so that at least diffusion barrier cut fully.
4. the manufacture method of each described optical thin film of claim 1~3 is characterized in that: the fixing liquid crystal material layer of orientation is by forming at liquid crystal aligning under the temperature more than the liquid crystal tr pt, the high molecule liquid crystal material that becomes glassy state under the temperature below the liquid crystal tr pt.
5. the manufacture method of each described optical thin film of claim 1~3 is characterized in that: be orientated fixing liquid crystal material layer by the crosslinked layer that obtains of the liquid crystal material with reactive group of liquid crystal aligning is constituted.
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