JP2009008860A - 偏光板の製造方法、偏光板、光学フィルムおよび画像表示装置 - Google Patents
偏光板の製造方法、偏光板、光学フィルムおよび画像表示装置 Download PDFInfo
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- JP2009008860A JP2009008860A JP2007169533A JP2007169533A JP2009008860A JP 2009008860 A JP2009008860 A JP 2009008860A JP 2007169533 A JP2007169533 A JP 2007169533A JP 2007169533 A JP2007169533 A JP 2007169533A JP 2009008860 A JP2009008860 A JP 2009008860A
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Abstract
【解決手段】 偏光子の少なくとも一方の面に、接着剤層を介して透明保護フィルムが設けられている偏光板の製造方法であって、偏光子の接着剤層が設けられる面に活性化処理を施す工程、偏光子の前記接着剤層を形成する面および/または透明保護フィルムの前記接着剤層を形成する面に、接着剤を塗工する工程、偏光子と透明保護フィルムとを、前記接着剤を介して貼り合わせる工程、を有する。
【選択図】 なし
Description
偏光子の接着剤層が設けられる面に活性化処理を施す工程、
偏光子の前記接着剤層を形成する面および/または透明保護フィルムの前記接着剤層を形成する面に、接着剤を塗工する工程、
偏光子と透明保護フィルムとを、前記接着剤を介して貼り合わせる工程、を有することを特徴とする偏光板の製造方法、に関する。
前記活性化処理によって、偏光子の表面は親水化処理が施されており、かつ、
前記接着剤層は水系接着剤により形成し、
前記貼り合わせ工程の後に、乾燥工程により接着剤層を形成することができる。
前記活性化処理によって、偏光子の表面は活性処理が施されており、かつ、
前記接着剤層はラジカル硬化型接着剤により形成し、
前記貼り合わせ工程の後に、硬化工程により接着剤層を形成することができる。
平均重合度2400、ケン化度99.9モル%、厚さ75μmのポリビニルアルコールフィルムを、30℃の温水中に60秒間浸漬して膨潤させた。次いで、3.2重量%(重量比:ヨウ素/ヨウ化カリウム=1/7)の30℃のヨウ素溶液中で30秒間染色しながら、3.3倍まで延伸した。次いで、30℃の3重量%のホウ酸、3重量%のヨウ化カリウム水溶液中に1分間浸漬しながら3.6倍まで延伸した。その後、60℃の4重量%のホウ酸、5重量%のヨウ化カリウム水溶液中に30秒間浸漬しながら総合延伸倍率が6倍まで延伸した。さらに、3重量%のヨウ化カリウム水溶液中に10秒間浸漬してヨウ素イオン含浸処理をした。その後、60℃のオーブンで4分間乾燥を行い、厚さ30μmの偏光子を得た。偏光子の水分率は12重量%であった。
水系接着剤A及び水系接着剤Bを用いて偏光板を作成する場合には、厚さ80μmのトリアセチルセルロースフィルムを用いた。電子線硬化型接着剤を用いて偏光板を作成する場合には、厚さ40μmのラクトン化ポリメタクリレート系フィルムを用いた。
アセトアセチル基を含有するポリビニルアルコール系樹脂(平均重合度:1200,ケン化度:98.5モル%,アセトアセチル基変性度:5モル%)100部に対し、メチロールメラミン20部を、30℃の温度条件下に、純水に溶解し、固形分濃度3.2重量%に調整した水溶液を調製した。これを水系接着剤Aとした。
ポリビニルアルコール系樹脂(平均重合度:1800,ケン化度:98.5モル%,アセトアセチル基変性度:0モル%)100部に対し、メチロールメラミン25部を、30℃の温度条件下に、純水に溶解し、固形分濃度3.5重量%に調整した水溶液を調製した。これを水系接着剤Bとした。
2−ヒドロキシ−3−フェノキシプロピルアクリレート(ナガセケムテックス株式会社製,DA−141)を用いた。
(偏光子の親水化処理)
コロナ照射機(春日電機社製,CT‐0212)によって、上記偏光子の両面を、それぞれ、放電量40W/m2/minでコロナ処理し、偏光子表面を親水化した。得られた偏光子の表面の対水接着角は31°であった。
上記透明保護フィルムの片側に、上記水系接着剤Aを、乾燥後の厚さが200nmとなるように塗工した。次いで、これを、上記偏光子の両面より、前記接着剤付き透明保護フィルムをロール機で貼り合わせた。その後、60℃で10分間乾燥して、偏光子の両側に透明保護フィルムを有する偏光板を得た。
実施例1において、偏光子の親水化処理にあたり、コロナ処理の放電量を80W/m2/minに変えたこと以外は、偏光子の親水化処理を行い、また当該得られた偏光子を用いたこと以外は、実施例1と同様にして偏光板を作成した。前記親水化処理により得られた偏光子の表面の対水接着角は28°であった。
実施例1において、偏光子の親水化処理にあたり、コロナ処理の放電量を240W/m2/minに変えたこと以外は、偏光子の親水化処理を行い、また当該得られた偏光子を用いたこと以外は、実施例1と同様にして偏光板を作成した。前記親水化処理により得られた偏光子の表面の対水接着角は30°であった。
実施例1において、水系接着剤Aの代わりに、水系接着剤Bを用いたこと以外は、実施例1と同様にして偏光板を作成した。
実施例2において、水系接着剤Aの代わりに、水系接着剤Bを用いたこと以外は、実施例2と同様にして偏光板を作成した。
実施例3において、水系接着剤Aの代わりに、水系接着剤Bを用いたこと以外は、実施例3と同様にして偏光板を作成した。
(偏光子のラジカル活性化処理)
コロナ照射機によって、上記偏光子の両面を、それぞれ、放電量240W/m2/minでコロナ処理し、偏光子表面を活性化した。
上記透明保護フィルムの片側に、上記電子線硬化型接着剤を、輪転機(回転速度500rpm)を用いて乾燥後の厚さ2μmとなるように塗工した。次いで、これを、上記偏光子の両面より、前記接着剤付き透明保護フィルムをロール機で貼り合わせた。貼り合わせた透明保護フィルム側(両側)から、岩崎電気製電子線照射装置EC110を用いて、電子線を照射して、偏光子の両側に透明保護フィルムを有する偏光板を得た。ライン速度は5m/min、加速電圧は110kV、照射線量は50kGyとした。
実施例1において、偏光子に親水化処理(コロナ処理)を施すことなく用いたこと以外は、実施例1と同様にして偏光板を作成した。前記偏光子の表面の対水接着角は55°であった。
実施例1において、偏光子に親水化処理(コロナ処理)を施すことなく、一方、透明保護フィルムは、放電量80W/m2/minでコロナ処理したものを用いたこと以外は、実施例1と同様にして偏光板を作成した。
実施例4において、偏光子に親水化処理(コロナ処理)を施すことなく用いたこと以外は、実施例4と同様にして偏光板を作成した。前記偏光子の表面の対水接着角は55°であった。
実施例4において、偏光子に親水化処理(コロナ処理)を施すことなく、一方、透明保護フィルムは、放電量80W/m2/minでコロナ処理したものを用いたこと以外は、実施例4と同様にして偏光板を作成した。
実施例7において、偏光子にコロナ処理を施すことなく用いたこと以外は、実施例7と同様にして偏光板を作成した。
実施例および比較例で得られた、偏光板について下記評価を行った。結果を表1に示す。
得られた偏光板を幅15mm、長さ100mmに切断して、サンプルとした。変角度ピール測定機により、サンプルの一端を剥離角度120°、剥離速度37.5mm/minで剥離して接着強度(N/25mm)を測定した。
Claims (11)
- 偏光子の少なくとも一方の面に、接着剤層を介して透明保護フィルムが設けられている偏光板の製造方法であって、
偏光子の接着剤層が設けられる面に活性化処理を施す工程、
偏光子の前記接着剤層を形成する面および/または透明保護フィルムの前記接着剤層を形成する面に、接着剤を塗工する工程、
偏光子と透明保護フィルムとを、前記接着剤を介して貼り合わせる工程、を有することを特徴とする偏光板の製造方法。 - 活性化処理が、コロナ処理、プラズマ処理、グロー処理およびオゾン処理から選ばれるいずれか少なくとも一つの処理であることを特徴とする請求項1記載の偏光板の製造方法。
- 偏光子がポリビニルアルコール系偏光子であることを特徴とする請求項1または2記載の偏光板の製造方法。
- 前記活性化処理によって、偏光子の表面は親水化処理が施されており、かつ、
前記接着剤層は水系接着剤により形成し、
前記貼り合わせ工程の後に、乾燥工程により接着剤層を形成することを特徴とする請求項1〜3のいずれかに記載の偏光板の製造方法。 - 偏光子の表面が、親水化処理によって、対水の接触角が、10〜50°になっていることを特徴とする請求項4記載の偏光板の製造方法。
- 水系接着剤が、ポリビニルアルコール系接着剤であることを特徴とする請求項4または5記載の偏光板の製造方法。
- 前記活性化処理によって、偏光子の表面は活性処理が施されており、かつ、
前記接着剤層はラジカル硬化型接着剤により形成し、
前記貼り合わせ工程の後に、硬化工程により接着剤層を形成することを特徴とする請求項1〜3のいずれかに記載の偏光板の製造方法。 - ラジカル硬化型接着剤が電子線硬化型接着剤であり、硬化工程が電子線硬化工程であることを特徴とする請求項7記載の偏光板の製造方法。
- 請求項1〜8のいずれかに記載の製造方法により得られた偏光板。
- 請求項9記載の偏光板が、少なくとも1枚積層されていることを特徴とする光学フィルム。
- 請求項9記載の偏光板または請求項10記載の光学フィルムが用いられていることを特徴とする画像表示装置。
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