JP2009109994A - 偏光板、光学フィルムおよび画像表示装置 - Google Patents
偏光板、光学フィルムおよび画像表示装置 Download PDFInfo
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- JP2009109994A JP2009109994A JP2008257462A JP2008257462A JP2009109994A JP 2009109994 A JP2009109994 A JP 2009109994A JP 2008257462 A JP2008257462 A JP 2008257462A JP 2008257462 A JP2008257462 A JP 2008257462A JP 2009109994 A JP2009109994 A JP 2009109994A
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- polarizing plate
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- adhesive
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Landscapes
- Polarising Elements (AREA)
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Abstract
【解決手段】偏光子の少なくとも片面に、接着剤層、透明保護フィルムおよび光学補償層をこの順で有する偏光板であって、前記光学補償層は、nx≒ny>nz(但し、面内屈折率が最大となる方向をX軸、X軸に垂直な方向をY軸、厚さ方向をZ軸とし、それぞれの軸方向の屈折率をnx、ny、nzとする)の関係を満足し、かつ、前記透明保護フィルムはラクトン環構造を有する(メタ)アクリル系樹脂を含有することを特徴とする偏光板。
【選択図】図1
Description
前記光学補償層は、nx≒ny>nz(但し、面内屈折率が最大となる方向をX軸、X軸に垂直な方向をY軸、厚さ方向をZ軸とし、それぞれの軸方向の屈折率をnx、ny、nzとする)の関係を満足し、かつ、
前記透明保護フィルムはラクトン環構造を有する(メタ)アクリル系樹脂を含有することを特徴とする偏光板、に関する。
本発明の製造方法に用いられるポリイミド溶液としては、本発明の効果が得られる限りにおいて任意の適切な溶液が採用され得る。当該溶液は、ポリイミドの粉末またはペレットを溶剤に溶解させたものでもよく、ポリイミド合成過程で得られる反応溶液をそのまま用いてもよい。本発明においては、ポリイミド粉末を溶剤に溶解させたものが好ましく用いられる。欠点や輝点などの光学的欠陥の少ないポリイミド層が得られるからである。
上記表面改質処理としては、任意の適切な方法が採用され得る。例えば、表面改質処理は、乾式処理でもよく、湿式処理でもよい。乾式処理の具体例としては、コロナ処理やグロー放電処理などの放電処理、火炎処理、オゾン処理、UVオゾン処理、紫外線処理や電子線処理などの電離活性線処理等が挙げられる。なかでも、本発明においては、UVオゾン処理、コロナ処理および/またはプラズマ処理が好ましく用いられる。連続生産が可能で、経済性および作業性に優れるからである。
透明保護フィルムの波長590nmにおける屈折率nx、ny、nzを、平行ニコル回転法を原理とする自動複屈折測定装置(王子計測機器株式会社製,自動複屈折計KOBRA21ADH)により計測し、面内位相差Re、厚み方向位相差Rthを算出した。
JIS Z0208の透湿度試験(カップ法)に準じて、温度40℃、湿度92%RHの雰囲気中、面積1m2の試料を24時間に通過する水蒸気のg数を測定した値である。
調製した接着剤水溶液(常温:23℃)を、レオメーター(RSI‐HS,HAAKE社製)により測定した。
アルミナコロイド水溶液を粒度分布計(日機装社製,ナノトラックUPA150)により、動的光散乱法(光相関法)で測定した。
2,2′−ビス(3,4−ジカルボキシフェニル)−ヘキサフルオロプロパン二無水物はクラリアントジャパン株式会社製のものを用い、2,2−ビス(トリフルオロメチル)−4,4’−ジアミノビフェニルは和歌山精化工業株式会社製のものを用いた。それ以外の化学薬品はすべて和光純薬工業株式会社から購入したものをそのまま用いた。
1H−NMR装置[日本電子株式会社製 製品名「LA400」]を用い、11ppm付近のポリアミック酸NH由来のピーク積分強度をX、7.0〜8.5ppmのポリアミック酸およびポリイミドの芳香環由来のピーク積分強度をYとし、式:A(%)=((Y−6X)/Y)×100により求めた。
ゲル・パーミエーション・クロマトグラフ(GPC)法よりポリエチレンオキサイドを標準試料として算出した。具体的には、以下の装置、器具および測定条件により測定した。
・サンプル:試料を溶離液に溶解して0.1重量%の溶液を調整した。
・前処理:8時間静置し、0.45μmのメンブレンフィルターでろ過した。
・分析装置:東ソー製「HLC−8020GPC」
・カラム:東ソー製 GMHXL+GMHXL+G2500HXL
・カラムサイズ:各7.8mmφ×30cm(計90cm)
・溶離液:ジメチルホルムアミド(10mMの臭化リチウムと10mMのリン酸を加えメスアップして1Lのジメチルホルムアミド溶液としたもの)
・流量:0.8ml/min.
・検出器:RI(示差屈折計)
・カラム温度: 40℃
・注入量:100μl
カールフィッシャー水分計[京都電子工業(株)製 製品名「MKA−610」]を用いて、150±1℃の加熱炉にサイズ10mm×30mmに切り出した偏光板を入れ、窒素ガス(200ml/分)を滴定セル溶液中にバブリングさせて測定した。
厚みが10μm未満の場合、薄膜用分光光度計[大塚電子(株)製 製品名「瞬間マルチ測光システム MCPD−2000」]を用いて測定した。厚みが10μm以上の場合、アンリツ製デジタルマイクロメーター「K−351C型」を使用して測定した。
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、0.3重量%(重量比:ヨウ素/ヨウ化カリウム=0.5/8)の30℃のヨウ素溶液中で1分間染色しながら、3.5倍まで延伸した。次いで、65℃の3重量%のホウ酸エステル水溶液中に10秒間浸漬しながら総合延伸倍率が6倍まで延伸した。その後、40℃のオーブンで3分間乾燥を行い、厚さ30μmの偏光子を得た。
以下に示すものを用いた。
透明保護フィルム1:前記一般式(1)中、R1は水素原子、R2およびR3はメチル基であるラクトン環構造を有する(メタ)アクリル系樹脂[共重合モノマーの重量比:メタクリル酸メチル/2−(ヒドロキシメチル)アクリル酸メチル=8/2;ラクトン環化率約100%]90重量部とアクリロニトリル−スチレン(AS)樹脂{トーヨーAS AS20,東洋スチレン(株)製}10重量部の混合物を押出成形し、縦2.0倍、横2.4倍に延伸した透明保護フィルム(厚さ40μm,Re=0nm,Rth=0nm)を用いた。
透明保護フィルム2:厚さ40μmのトリアセチルセルロースフィルム(富士フィルム(株)製,Re=1nm,Rth=50nm)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%,アセトアセチル化度:5モル%)100部に対し、メチロールメラミン50部を、30℃の温度条件下に、純水に溶解し、固形分濃度3.6%に調整した水溶液を調製した。前記水溶液100部に対し、アルミナコロイド水溶液(平均粒子径15nm,固形分濃度10%,正電荷)18部を加えて接着剤水溶液を調製した。接着剤水溶液の粘度は9.6mPa・sであった。接着剤水溶液のpHは、4−4.5の範囲であった。これを接着剤1とする。また、前記接着剤1において、アルミナコロイド水溶液を加えなかった接着剤水溶液を調製した。接着剤水溶液の粘度は7.0mPa・sであった。接着剤水溶液のpHは、4−4.5の範囲であった。これを接着剤2とする。
<ポリイミド1の合成>
機械式攪拌装置、ディーンスターク装置、窒素導入管、温度計および冷却管を取り付けた反応容器(500mL)内に2,2′−ビス(3,4−ジカルボキシフェニル)−ヘキサフルオロプロパン二無水物17.77g(40mmol)および2,2−ビス(トリフルオロメチル)−4,4’−ジアミノビフェニル12.81g(40mmol)を加えた。続いて、イソキノリン2.58g(20mmol)をm−クレゾール275.21gに溶解させた溶液を加え、23℃で1時間攪拌して(600rpm)均一な溶液を得た。次に、反応容器を、オイルバスを用いて反応容器内の温度が180±3℃になるように加温し、温度を保ちながら5時間攪拌して黄色溶液を得た。さらに3時間攪拌を行ったのち、加熱および攪拌を停止し、放冷して室温に戻すと、ポリマーがゲル状物となって析出した。
上記で得られたポリイミド(白色粉末)17.7重量部をメチルイソブチルケトン(沸点116℃)100重量部に溶解し、濃度15重量%のポリイミド溶液を調製した。このポリイミド溶液を、上記透明保護フィルム1の表面にロッドコータにより一方向に塗工した。次に、135±1℃の空気循環式恒温オーブン内で5分間乾燥して溶剤を蒸発させ、透明保護フィルム1上に厚み3.0μmのポリイミド層を形成して積層フィルムAを作製した。ポリイミド層はネガティブCプレートとして機能した。
上記積層フィルムA(透明保護フィルム1側)および透明保護フィルム2のそれぞれの片面に、上記接着剤1を乾燥後の接着剤層の厚みが80nmとなるように塗布したものを用意した。また、接着剤の塗布は、その調製から30分間後に23℃の温度条件下で行なった。次いで、23℃の温度条件下で偏光子の両面に、前記接着剤付きの積層フィルムAおよび透明保護フィルム2をロール機で貼り合せた後、55℃で6分間乾燥して偏光板を作成した。
<積層フィルムBの作成>
液晶材料(ディスコチック液晶)、具体的には重合性メソゲン化合物(BASF社製のLC242)および重合性カイラル剤(BASF社製のLC756)を、重合性メソゲン化合物/重合性カイラル剤の混合比(重量比)=11/88で混合した混合物を、シクロペンタノンに溶解し、さらに反応開始剤(チバスペシャルティケミカルズ社製のイルガキュア907、前記混合物に対して1重量%)を添加して、濃度30重量%の液晶材料溶液を調製した。配向基板としての上記透明保護フィルム1をラビング布にて配向処理した後、前記液晶材料溶液を、ワイヤーバーにて乾燥時の塗布厚みが7μmになるように塗布し、90℃で2分間一旦乾燥し、さらに130℃まで加熱した後に徐々に冷却した。塗布された液晶材料を均一な配向状態を保持しながら、80℃の環境下にて紫外線照射(10mW/cm2×1分間)して硬化して、透明保護フィルム1上に厚み7μmの液晶ド層を形成して積層フィルムBを作製した。液晶層はネガティブCプレートとして機能した。
実施例1の偏光板の作成において、積層フィルムAの代わりに、上記積層フィルム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1の偏光板の作成において、積層フィルムおよび接着剤の種類を表1に示すように変えたこと以外は実施例1と同様にして偏光板を作成した。
<積層フィルムCの作成>
前記一般式(5)で表されるポリイミド(但し、式中、X=50,Y=50である)をメチルイソブチルケトン(沸点116℃)に溶解し、濃度10重量%のポリイミド溶液を調製した。このポリイミド溶液を、上記透明保護フィルム1の表面にロッドコータにより一方向に塗工した。次に、120℃の空気循環式恒温オーブン内で10分間乾燥して溶剤を蒸発させ、透明保護フィルム1上に厚み2.5μmのポリイミド層を形成して積層フィルムCを作製した。ポリイミド層はネガティブCプレートとして機能した。
実施例1の偏光板の作成において、積層フィルムAの代わりに、上記積層フィルムC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1の偏光板の作成において、接着剤の種類を表1に示すように変え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1の偏光板の作成において、接着剤の種類を表1に示すように変え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1の偏光板の作成において、積層フィルムの種類、接着剤の種類を表1に示すように変えたこと以外は実施例1と同様にして偏光板を作成した。なお、積層フィルムの種類は積層フィルムA乃至Cにおいて、透明保護フィルム1の代わりに透明保護フィルム2を用いたものを積層フィルムA´乃至C´として表した。
得られた偏光板について下記評価を行った。結果を表2に示す。
偏光板を、偏光子の吸収軸が長辺に対して45°となるように、160mm×90mmに切り出した。当該偏光板の積層フィルム面(光学補償層側)にアクリル系粘着剤層を貼り付けた。この粘着剤層付きの偏光板を、ガラス板の両面に、偏光板(偏光子)の吸収軸が直交するように貼り付けたものをサンプルとした。サンプルについて、加熱試験(80℃,100時間)、加湿試験(60℃,90%RH,100時間)を行った。試験後、目視での観察および輝度を測定した。
○:表示ムラがない、または部分的に表示ムラが見られる。
×:全面に表示ムラが見られる。
偏光板の端部において、偏光子と透明保護フィルムとの間にカッターの刃先を挿入した。当該挿入部において、偏光子と透明保護フィルムとを掴み、それぞれ反対方向に引っ張った。このとき、偏光子および/または透明保護フィルムが破断して剥離できなかった場合は、密着性が良好:「○」と判断した。一方、偏光子と透明保護フィルムとの間で一部または全部は剥離した場合は、密着性に乏しい:「×」と判断した。
偏光板を、偏光子の吸収軸方向に50mm、吸収軸に直交する方向に25mmになるように切り出してサンプルを調製した。当該サンプルを、60℃の温水に浸漬し、時間経過とともにサンプルの端部の剥がれ量(mm)を測定した。剥がれ量(mm)の測定は、ノギスにより行なった。5時間経過後の剥がれ量(mm)を表2に示す。
偏光板を1000mm×1000mmになるように切り出してサンプルを調製した。サンプルの偏光板を、蛍光灯下に置いた。サンプルの偏光板の光源側に別の偏光板を、それぞれの吸収軸が直行するように設置し、この状態で、光抜けする箇所(クニック欠陥)の個数をカウントした。
11 偏光子
12、12’ 接着剤層
13 積層フィルム
131、131’ 光学補償層
132、132’ 透明保護フィルム
20 液晶セル
21、21’ 基板
22 液晶層
30、30’ 位相差板
100 液晶パネル
Claims (9)
- 偏光子の少なくとも片面に、接着剤層、透明保護フィルムおよび光学補償層をこの順で有する偏光板であって、
前記光学補償層は、nx≒ny>nz(但し、面内屈折率が最大となる方向をX軸、X軸に垂直な方向をY軸、厚さ方向をZ軸とし、それぞれの軸方向の屈折率をnx、ny、nzとする)の関係を満足し、かつ、
前記透明保護フィルムはラクトン環構造を有する(メタ)アクリル系樹脂を含有することを特徴とする偏光板。 - 前記接着剤層は、ポリビニルアルコール系樹脂、架橋剤および平均粒子径が1〜100nmの金属化合物コロイドを含有してなる樹脂溶液であって、かつ、
金属化合物コロイドは、ポリビニルアルコール系樹脂100重量部に対して、200重量部以下の割合で配合されている偏光板用接着剤から形成されたものであることを特徴とする請求項1記載の偏光板。 - 金属化合物コロイドが、アルミナコロイド、シリカコロイド、ジルコニアコロイド、チタニアコロイドおよび酸化スズコロイドから選ばれるいずれか少なくとも1種であることを特徴とする請求項2記載の偏光板。
- 金属化合物コロイドが、正電荷を有することを特徴とする請求項2または3記載の偏光板。
- 金属化合物コロイドが、アルミナコロイドであることを特徴とする請求項4記載の偏光板。
- 前記光学補償層が、ポリイミド層であることを特徴とする請求項1〜5のいずれかに記載の偏光板。
- 前記光学補償層が、液晶材料により形成されていることを特徴とする請求項1〜6のいずれかに記載の偏光板。
- 請求項1〜7のいずれかに記載の偏光板が、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1〜7のいずれかに記載の偏光板または請求項8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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