JP2011242475A - Laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a wire grid polarization plate by using a base material which is excellent in terms of shock-resistance, cutting processing and adhesion with other components, and to mass-produce the wire grid polarization plate which is cut to desired size and shape, and which can be assembled with an apparatus using polarized light, easily and with good reliability at a low cost by processing the wire grid polarization plate with adhesive.SOLUTION: A laminate includes: a polarization plate having thin metallic wires arrayed at equal intervals on a substrate; an adhesive layer contacting with the polarization plate; and a separator film contacting with the adhesive layer. In the laminating direction, the laminate is cut from the polarization plate to at least the middle portion of the separator film, and the thickness of the polarization plate is ≥5 μm, a peeling force between the adhesive layer and the separator film is in the range of 10 to 1000 mN/25 mm, and an adhesive strength between the polarization plate and the adhesive layer is twice or more than twice as much as the peeling force between the adhesive layer and the separator film.

Description

  The present invention relates to a laminate that can be easily assembled in an apparatus using polarized light, and more particularly to a laminate having a wire grid polarizing plate processed with an adhesive.

  A wire grid formed by arranging conductor wires made of metal or the like in a lattice pattern at a specific pitch has a conductor pitch that is considerably smaller than the wavelength of incident light (for example, half or less). In contrast, almost all the light of the electric field vector component oscillating in parallel with the electric field vector is reflected and almost all the light of the electric field vector component perpendicular to the conductor line is transmitted.

  Compared with conventional dye-based polarizing plates, the wire grid polarizing plate is excellent in effective use of light because it can reflect and reuse light that does not transmit. Further, since it does not contain a volatile dye, it has many advantages such as excellent heat resistance and durability.

  With the recent development of photolithography technology, it has become possible to process a fine structure pattern having a pitch at the wavelength of light. Therefore, a wire grid polarizing plate in which a fine metal lattice is formed on a glass substrate is provided. It has been developed (Patent Document 1).

  Patent Document 2 discloses a transparent base material having a grid-like convex portion (also including a base substrate), a metal wire layer provided on a region including the grid-like convex portion of the base material, and a metal wire layer The wire grid polarizing plate which comprises the protective film which has an adhesive layer closely_contact | adhered to the front-end | tip part of this is disclosed.

Special table 2003-502708 gazette JP 2008-96677 A

  However, the wire grid polarizing plate formed on the above glass substrate is difficult to cut into the desired size and shape because it has low toughness and is easily chipped, there is no adhesive that can firmly fix the glass, In addition, since the specific gravity of glass is large, there are problems such as difficulty in bonding to parts used in combination with a polarizing plate and casing to be easily peeled off by vibration or the like even when fixed. Even in the case of a wire grid polarizing plate formed on a resin substrate, in the case of an adhesive layer that adheres closely to the tip of the metal wire layer, in the case of an adhesive having a low peel force, the interlayer can be easily separated. When peeled off or laterally displaced, there was a problem that fine metal wires were deformed and the performance was greatly reduced.

  In addition, when an adhesive with a high peel strength is selected, the adhesive gradually penetrates to the deep part of the metal wire layer, and there is a problem that the performance greatly fluctuates with time, and not only the effect as a protective film cannot be exhibited. When the wire grid polarizing plate is cut and used, if the cutting process is incorporated into the manufacturing process of the wire grid polarizing plate and transported after the cutting, the polarization axis is separated for each piece (small piece) of the cut wire grid polarizing plate. As a result, there is a problem that handling becomes difficult. On the other hand, in the case of cutting after transportation, a cutting step must be provided separately after transportation, and there is a problem that the production of the wire grid polarizer piece becomes very inefficient.

  Therefore, in the present invention, in a laminate having a wire grid polarizing plate, an adhesive layer and a separator film, an apparatus that maintains the appearance of the piece after cutting the wire grid polarizing plate and after separating the separator film and uses polarized light The purpose is to enable easy assembly (excellent handling).

  The laminate of the present invention is a laminate having a polarizing plate having fine metal wires arranged at equal intervals on a substrate, an adhesive layer in contact with the polarizing plate, and a separator film in contact with the adhesive layer, In the laminating direction, it is cut from the polarizing plate to at least the middle part of the separator film, the thickness of the polarizing plate is 5 μm or more, the peeling force between the pressure-sensitive adhesive layer and the separator film is 10 to 1000 mN / 25 mm, The adhesive force between the adhesive layer and the pressure-sensitive adhesive layer is at least twice the peel strength between the pressure-sensitive adhesive layer and the separator film.

  In the laminate of the present invention, it is preferable that the thickness of the separator film is 5 μm to 200 μm, and the depth of the separator film is 5 μm or more.

  The laminate of the present invention preferably further comprises a carrier film in contact with the polarizing plate and / or the separator film.

  In the laminate of the present invention, it is preferable that the carrier film is provided in contact with the separator film and is cut from the polarizing plate to at least an intermediate portion of the separator film in the lamination direction.

  In the laminate of the present invention, the adhesive force between the separator film and the carrier film is preferably less than twice the peel force between the adhesive layer and the separator film.

  In the laminate of the present invention, it is preferable that the carrier film is provided in contact with the polarizing plate and is cut from the separator film to at least a part of the carrier film in the lamination direction.

  In the laminate of the present invention, the adhesive force between the polarizing plate and the carrier film is preferably less than twice the peeling force between the adhesive layer and the separator film.

  In the laminate of the present invention, the thickness of the carrier film is preferably 5 μm to 200 μm, and the cut depth of the carrier film is preferably 5 μm or more.

  In the laminate of the present invention, the acid value of the pressure-sensitive adhesive layer is preferably 5.0 mgKOH / g or less.

  The laminated body of the present invention has a good appearance after cutting the wire grid polarizing plate into small pieces and after separating the separator film, and can be easily assembled to an apparatus using polarized light (excellent handleability). Demonstrate the effect.

It is a figure which shows the example of a structure and cutting process of a laminated body.

  Hereinafter, embodiments of the present invention will be described in detail.

  The laminate of the present invention is a laminate having a polarizing plate having fine metal wires arranged at equal intervals on a substrate, an adhesive layer in contact with the polarizing plate, and a separator film in contact with the adhesive layer. In the laminating direction, the polarizing plate is cut from the polarizing plate to at least a middle portion of the separator film, the polarizing plate has a thickness of 5 μm or more, and the peeling force between the pressure-sensitive adhesive layer and the separator film is 10 to 1000 mN. / 25 mm, and the adhesive force between the polarizing plate and the pressure-sensitive adhesive layer is at least twice the peeling force between the pressure-sensitive adhesive layer and the separator film.

  When the polarizing plate of the present invention is cut into a plurality of small pieces from a large-area original fabric, a method of cutting all layers among the polarizing plate, the adhesive layer and the separator film constituting the laminate, or cutting the separator film Without cutting, it is possible to select a method in which only the polarizing plate and the pressure-sensitive adhesive layer are cut and a plurality of small pieces are held on the separator film with a large area. Since the cut pieces are completely separated by the previous method, there is an advantage that they can be stored for a long time until the polarizing plate is used. By making the thickness of the separator film 4 μm or more, the adhesive layer is not altered. Can protect. In the later method, since the cut pieces are held on the separator film in a fixed position and orientation, there is an advantage that handling of individual pieces can be minimized. In addition, by making the thickness of the separator film 4 μm or more, the pressure-sensitive adhesive layer can be protected without deteriorating, more preferably 5 μm without completely cutting the separator film using a separator film having a thickness exceeding 5 μm. By cutting to the above depth, according to the width | variety of the cutting line of a separator film, an adhesive layer can be hold | maintained with isolate | separating at a fixed space | interval in the boundary part of a small piece. Thereby, even if it keeps for a long time until it uses a polarizing plate, the problem that an adhesive layer recombines in the boundary part of small pieces can be avoided.

  By setting the peeling force between the adhesive and the separator film to 10 mN / 25 mm or more, it is possible to prevent this interface from peeling off, turning over, or entering bubbles when cutting into small pieces. For example, a Thomson blade is used. A small piece of polarizing plate cut into a desired size and shape can be manufactured by such an inexpensive processing method suitable for mass production. In addition, by setting the peeling force between the adhesive and the separator film to 1000 mN / 25 mm or less, there is little deformation of the thin metal wire of the polarizing plate in the step of separating the separator film from the separator film when the polarizing plate is assembled and used in equipment. The quality deterioration of the polarizing plate in this process can be prevented. In the process of separating the polarizing plate from the separator film when the polarizing plate is assembled and used by making the adhesive force between the polarizing plate and the adhesive more than twice the peeling force between the adhesive and the separator film, The problem that the part between a board and an adhesive will isolate | separate can be prevented.

  As described above, the laminate processed with the pressure-sensitive adhesive of the present invention has an extremely fine and precise structure in which the size and arrangement pitch of the elements exhibiting the polarization function are the wavelength level of light, and it is inexpensive and large-scale. By a processing method suitable for production, it can be processed into small pieces cut into a desired size and shape without degrading the quality of the polarizing plate. In addition, the small piece has the advantage that it can be stored for a long time until it is used, and the advantage that it can be handled easily by human hands, and the quality of the polarizing plate deteriorates even in the process of separating it from the separator film when it is assembled in a device. And can be easily assembled in equipment using polarized light.

  In the laminate of the present invention, the polarizing plate (A) composed of fine metal wires arranged at equal intervals on the base material was formed on the base material, the resin film formed on the base material, and the resin film. A wire grid polarizing plate including a fine metal wire is preferable.

(About the base material)
The substrate is not particularly limited as long as it is transparent and flexible, and has a uniform thickness, and examples thereof include a plastic film, a thin glass material, and an organic-inorganic hybrid substrate. Among these, a plastic film is preferable from the viewpoint of impact resistance, bending workability, cutting workability, adhesion to a resin film layer and other parts, and cost. Examples of plastic film materials include, for example, polyethylene (PE) resin, polypropylene resin (PP), cross-linked polyethylene resin, polyvinyl chloride resin, cycloolefin (COP) resin, cycloolefin copolymer (COC) resin, polystyrene (PST). Resin, polyethylene terephthalate resin (PET), polybutylene terephthalate resin (PBT), polyethylene naphthalate (PEN) resin, polyarylate (PAR) resin, polycarbonate (PC) resin, polyamide resin (PA), polyimide (PI) resin, Polyetherimide (PEI) resin, polyphenylene ether resin, modified polyphenylene ether resin, polyethersulfone (PES) resin, polysulfone resin, polyetherketone resin, polyacetal Fat (POM), polymethyl methacrylate resins, such as cellulose triacetate (TAC) resin is preferred in view of price and performance. PET, COP, COC, TAC, and PC are particularly preferable in terms of price, workability, strength, and heat resistance.

  The thickness of the substrate is preferably 5 μm or more. This is a process of cutting a polarizing plate into a desired size and shape by being manufactured using a substrate having a thickness of 5 μm or more, and a process of separating from a separator film when the polarizing plate is assembled and used in equipment. This is because there is little deformation of the fine metal wire on the polarizing plate, so that deterioration of the quality of the polarizing plate in these steps can be prevented. Furthermore, in order to give the polarizing plate sufficient strength and minimize the influence of dents or the like, the thickness of the base material is more preferably 8 μm or more. Furthermore, in order to produce a wire grid polarizing plate by an inexpensive roll-to-roll process taking advantage of the film-like substrate, the thickness is more preferably 10 μm or more. Although there is no upper limit in particular in the thickness of a base material, it is preferable that it is 5 mm or less from the point of being able to process cheaply and efficiently even if it uses comparatively simple cutting processing equipment, and 3 mm from the surface of the transparency of a base material. In order to produce a wire grid polarizing plate by an inexpensive roll-to-roll process taking advantage of the film-like substrate, the thickness is preferably 1 mm or less, more preferably 0. It is 5 mm or less, More preferably, it is 0.2 mm or less.

  The base material is preferably subjected to a treatment for improving the adhesion to the resin film. For example, the surface to be bonded (front surface) is chemically bonded to the resin film or is used for physical bonding such as infiltration. It is preferable to perform easy adhesion coating, primer treatment, corona treatment, plasma treatment, high energy ray irradiation treatment, surface roughening treatment, porous treatment and the like. The surface to which the resin film is not adhered (back surface) may be untreated, but it is also preferable to apply an antireflection treatment.

  When an adhesive layer is provided on the back side, it is preferable that the adhesive force between the back surface of the polarizing plate and the adhesive is at least twice the peeling force between the adhesive and the separator film, as described later. Chemical bonding treatment similar to the front surface, easy adhesion coating for physical bonding such as penetration, primer treatment, corona treatment, plasma treatment, high energy ray irradiation treatment, surface roughening treatment, porous treatment, etc. It is preferable to apply. By doing in this way, the problem which isolate | separates in the part between a polarizing plate and an adhesive can be prevented at the process of isolate | separating from a separator film, when using a polarizing plate assembled | attached to an apparatus.

  Depending on the purpose, the substrate should contain a plasticizer, antioxidant, ultraviolet absorber, dye, pigment, flame retardant, gas barrier function material, adhesive, etc. Is also preferable.

(About resin film)
On the substrate, the surface has a regular uneven structure with a height in the range of 0.01 μm to 20 μm and a pitch in at least one direction in the range of 0.01 μm to 20 μm, and a thickness of 0. It is preferable that a resin film made of a molded product of a photocurable resin in a range of 01 μm to 3 μm is formed. Moreover, a thin metal wire can be formed on the uneven structure of the resin film.

  As a characteristic of a polarizing plate composed of fine metal wires arranged at equal intervals on a substrate, sufficient polarization performance can be obtained when the pitch of the fine metal wires is not more than a quarter of the wavelength of the target light. It is known that the polarization performance improves as the value of becomes smaller. For the purpose of stabilizing the polarization performance and improving the extinction ratio, it is more preferable to reduce the pitch. In order to have a polarization characteristic in the visible region, the pitch is preferably 150 nm or less, and in order to have a polarization characteristic up to a short wavelength light in the vicinity of 400 nm, it is preferably 120 nm or less, and a polarization characteristic up to the ultraviolet region. In order to have this, it is preferable that it is about 10 nm.

  The height of the uneven structure on the surface of the resin film is sufficient for the purpose of forming a layer containing air around the fine metal wires to improve the optical performance, and to keep the fine metal wires constant and firm. For the purpose of providing a rugged structure, the pitch is preferably in the range of 0.5 to 2.0 times, more preferably in the range of 1.0 to 2.0 times the pitch of the uneven structure.

  There is no restriction | limiting in the cross-sectional shape of the uneven structure of the surface of a resin film. These cross-sectional shapes may be trapezoidal, rectangular, square, prismatic, sinusoidal, such as semicircular. Here, the sinusoidal shape means that it has a curved portion formed by repetition of a concave portion and a convex portion. The curved portion only needs to be a curved curve. For example, a shape having a constriction in the convex portion is included in the sine wave shape. Further, in order to make it easier for the dielectric to cover the convex portions of the resin film and at least a part of the side surfaces thereof, it is preferable that the ends, vertices, and valleys of the shape have a curved shape with a gentle curvature.

  The thinner the resin film, the more (a) the light absorption in the resin film can be suppressed, and the transmittance is improved. (B) The amount of volatile residual components in the resin film can be reduced, and contamination by bleed or the like can be prevented. (C) The curl generated by the curing shrinkage of the photocurable resin is reduced, and the flatness of the polarizing plate composed of fine metal wires arranged at equal intervals on the substrate is improved. (D) The flexibility of the resin film is improved, and the occurrence of cracks when the wire grid polarizer is deformed or cut can be suppressed. (E) A favorable effect such as improved followability to stress stress generated between layers of the resin base material and the fine metal wires due to changes in temperature and humidity and increased reliability is recognized. On the other hand, when trying to manufacture a transfer product with a thin resin film using conventional technology, (f) micro foreign matter mixed in the photo-curable resin or micro foreign matter floating around the production equipment When the toner enters the transfer surface, the frequency of occurrence of lens-like defects around the foreign matter increases. (G) It is difficult to uniformly coat the photocurable resin on the resin base material due to defects such as smears and liquid repellency, and the frequency of occurrence of transfer defects increases. (H) The photocurable resin is susceptible to oxygen inhibition, and there is a problem in that the yield decreases, such as the frequency of occurrence of transfer defects due to remaining unreacted components remaining. As will be described later, the laminate of the present invention can be produced in the range of 0.01 μm to 3 μm in thickness of the resin film by optimizing the composition of the photocurable resin, optimizing the reaction conditions, and the transfer process.

  The laminate shown in the present embodiment is flexible because it is formed on a resin base material, but the resin film supporting the fine metal wires has an extremely thin thickness of 3 μm or less, so that the laminate is equally spaced on the base material. The deterioration in quality is small when the polarizing plate made of fine metal wires arranged in the shape is deformed or cut. For example, when a bending stress with a bending radius of 20 mm is applied, the resin film and the fine metal wires are not broken or broken, and the optical performance is not affected, so that the thickness of the resin film is 3 μm or less. In order to withstand bending stress with a bending radius of 5 mm, the thickness is preferably 1 μm or less, and more preferably 0.5 μm or less.

  Thus, the laminate of the present invention is resistant to stresses such as bending, vibration, and stress during cutting. Especially when cutting, since the cracks and folds of the resin film do not spread around the cutting line, it can be cut into arbitrary shapes and several millimeters of small pieces and arranged on the substrate at equal intervals It is also preferable in terms of downsizing and mass productivity of an apparatus equipped with a polarizing plate made of a thin metal wire.

  Moreover, it was confirmed that the laminate has high reliability with respect to changes in temperature and humidity because the thickness of the resin film can be reduced. Generally, when the specific surface area of a material increases, the reliability tends to decrease. However, in the case of a polarizing plate made of fine metal wires arranged at equal intervals on a base material, the resin substrate is obtained by reducing the thickness. As a result of improving the followability to the stress stress generated between the layers of the metal and the thin metal wires, it is estimated that the reliability has increased.

  In order to reduce the thickness of the resin film and reduce the occurrence of transfer defects, the viscosity of the photo-curing resin to be used is low, the release property from the stamper is good, and the adhesion to the resin substrate is good. Is required.

  The photocurable resin contains one or more monomers containing 3 or more acrylic groups and / or methacrylic groups in one molecule in a range of 20 to 60% by weight, and is bonded by a photocuring reaction. Thus, it is preferable that the composition satisfies 98% by weight or more and the viscosity at 25 ° C. is 10 mPa · s or less at the same time. Furthermore, the monomer which is an N-vinyl compound is contained in a range of 5 to 40% by weight, and a silicon compound containing an acrylic group and / or a methacryl group is contained in a range of 0.1 to 10% by weight. More preferably, another monomer is blended for the purpose of adjusting viscosity and adjusting various physical properties of the cured product. The blending ratio of the photopolymerization initiator to the photocurable resin composition is preferably in the range of 0.1 to 5.0% by weight. The photocurable resin composition is preferably one in which foreign substances (particles) are removed by a technique such as filtration. In the case of filtration, it is preferable to use a filter having a minimum particle diameter of 1 μm or less that can be captured, and more preferably 0.5 μm or less in order to improve the yield when the resin film is thinned. For any minimum particle size, the filter capture efficiency is preferably 99.9% or more.

  In the photocurable resin composition, other conventional additives such as flow regulators, leveling agents, organic and inorganic dyes and pigments, extenders, plasticizers, and the like as long as they do not impair the original purpose. Lubricants, reinforcing agents, antioxidants, anti-yellowing agents, UV absorbers, bluing agents, anti-settling agents, antifoaming agents, antiwear agents, friction reducers, antistatic agents, antifogging agents, etc. Can be included.

  The resin film is preferably formed by an optical nanoimprint technique in a roll process. For example, the photocurable resin composition is poured into a mold having a concavo-convex structure that is an inverted shape of the uneven structure on the surface of the resin film, and is molded by photocuring. As a method of pouring the photocurable resin composition into the mold, the photocurable resin composition is applied to the base material in the form of a thin film, and then brought into contact with the mold and filled between the uneven structure of the mold and the base material. Alternatively, after the photocurable resin composition is applied to the surface of the mold in a thin film shape, the mold is brought into contact with the base material so as to be filled between the concavo-convex structure of the mold and the base material.

  The method for applying the photocurable resin composition is not particularly limited. For example, a roll coater method, a (micro) gravure coater method, an air doctor coater method, a blade coater method, a knife coater method, a rod coater method, a curtain ( Flow) coater method, kiss coater method, bead coater method, cast coater method, rotary screen method, dip coating method, slot orifice coater method, barcode method, spray coating method, spin coating method, extrusion coater, fountain coater method, etc. It is done.

  In any method, it is important that air bubbles are not mixed in the uneven structure of the mold and that the thickness unevenness of the photocurable resin composition held between the mold and the substrate is reduced.

  It is preferable that the temperature of the mold is constantly adjusted in the range of 25 ° C to 100 ° C. When the temperature of the mold is 25 ° C. or higher, the fluidity of the photocurable resin is improved, the adhesive force between the resin film and the base material is improved, and the mold release property after the resin film is cured. Is preferable because it has the effect of improving. Moreover, since the temperature of a mold is 100 degrees C or less, since there is little thermal deformation of a base material, it is preferable. The range of 30 ° C to 80 ° C is more preferable, the range of 35 ° C to 70 ° C is more preferable, and the range of 40 ° C to 65 ° C is particularly preferable.

  The thickness of the resin film can be adjusted by the filling amount of the photocurable resin composition into the mold and the pressure for pressing the substrate and the mold.

  The degree of cleanliness around the transfer equipment is preferably class 10000 or more, more preferably class 1000 or more, further preferably class 100 or more, and particularly preferably class 10 or more.

(Dielectric layer)
In order to improve the adhesion between the resin film and the fine metal wire, the dielectric layer may be provided so as to cover the convex part of the resin film surface and at least a part of the side surface part before forming the fine metal wire. preferable. The dielectric constituting the dielectric layer is preferably substantially transparent in the band of light using the wire grid polarizing plate, and is preferably a material having a strong adhesive force with the metal constituting the resin film and the fine metal wire. For example, silicon (Si) oxide, nitride, halide, carbide alone or a composite thereof, aluminum (Al), chromium (Cr), yttrium (Y), zirconia (Zr), tantalum (Ta), Metal oxides such as titanium (Ti), barium (Ba), indium (In), tin (Sn), zinc (Zn), magnesium (Mg), calcium (Ca), cerium (Ce), copper (Cu) , Nitrides, halides, carbides or composites thereof (dielectrics in which other elements, simple substances, or compounds are mixed in a dielectric substance) can be used. The thickness of the dielectric layer is preferably 0.1 nm or more in order to improve the adhesion to the metal, and preferably 30 nm or less in order to increase productivity. The dielectric layer also has the effect of suppressing the release of volatile components from the resin film during the formation of fine metal wires, but if the thickness of the resin film is 3 μm or less, the amount of volatile components is small, so the thickness of the dielectric layer is less than 5 nm. Even if there is, sufficient effect can be exhibited. The thickness of the dielectric layer is more preferably 4 nm or less, and further preferably 3 nm or less.

  The method for coating the dielectric layer on the resin film is appropriately selected depending on the material constituting the dielectric layer. For example, a physical vapor deposition method such as a sputtering method or a vacuum vapor deposition method can be suitably used. The sputtering method is preferable from the viewpoint of adhesion strength.

(Metal fine wire)
There is no restriction | limiting in particular as a metal which comprises a metal fine wire, For example, it is comprised with silver (Ag), gold | metal | money (Au), copper (Cu), tungsten (W), aluminum (Al), or those alloys. It is preferable. Among these, from the viewpoint of cost and durability, it is more preferable to be made of aluminum or an alloy thereof. Further, from the viewpoint of improving the extinction ratio, it is preferable to use tungsten or an alloy thereof.

  There is no particular limitation on the method for forming the fine metal wire on the resin film, preferably on the dielectric layer formed so as to cover at least a part of the convex part of the resin film and the side surface part in advance, for example, A vacuum deposition method, a sputtering method, a physical vapor deposition method such as an ion plating method is preferred, and among them, a method in which a metal can be selectively laminated on a convex portion selectively or on one side of the convex portion is preferred, For example, a vacuum vapor deposition method can be mentioned, and an oblique vapor deposition method under vacuum is preferable from the viewpoint of manufacturing cost and productivity. The oblique vapor deposition method is a method in which a vapor deposition source deposits and laminates metal while having an incident angle α with respect to the normal line of the base material in a plane perpendicular to the extending direction of the grid-shaped convex portions. . The preferable range of the incident angle α is determined from the cross-sectional shape of the lattice-shaped convex portion and the metal thin wire to be produced. In general, the incident angle α is preferably 5 ° to 40 °, more preferably 10 ° to 30 °. Further, it is preferable to gradually reduce or increase the incident angle α while taking into consideration the projection effect of the metal laminated during the vapor deposition in order to control the cross-sectional shape such as the height of the thin metal wire. In addition, from such a manufacturing method, the extending directions of the grid-like convex portions and the fine metal wires are equal.

  The amount of metal vapor deposition for achieving the shape of the fine metal wires is determined by the shape of the grid-shaped convex portions, but generally the average vapor deposition thickness is about 50 nm to 150 nm. The average thickness here refers to the thickness of the deposited material on the assumption that the material is deposited on the smooth glass substrate from the direction perpendicular to the glass surface, and is used as a measure of the metal deposition amount.

  From the viewpoint of optical characteristics, the metal laminated on the bottom of the concave portion of the concave and convex lattice is removed by etching as necessary. The etching method is not particularly limited as long as it can remove a necessary amount of metal without adversely affecting the base material and the dielectric layer, but from the viewpoint of productivity and equipment cost, a method of immersing in an aqueous solution of acid or alkali Is preferred.

  The width of the fine metal wire is the maximum width observed from the normal direction of the polarizing plate surface composed of fine metal wires arranged at equal intervals on the substrate, and is arranged at equal intervals on the optical characteristics and the substrate. From the viewpoint of the structural strength of the polarizing plate made of a fine metal wire, the range is preferably 0.2 to 0.6 times the pitch of the uneven structure on the surface of the resin film. In addition, the height of the fine metal wire is determined by considering the optical properties of the polarizing plate, the structural strength of the polarizing plate composed of the fine metal wires arranged at equal intervals on the substrate, and the adhesion between the fine metal wire and the uneven structure. The range of 20 nm to 220 nm is preferable, and the range of 50 nm to 200 nm is more preferable.

  The polarizing plate is also preferably covered with a protective thin film for the purpose of preventing contamination and cleaning. The protective film is not particularly limited, and examples thereof include a method in which a fine metal wire is surface-coated with a resin or the like, and a method in which another resin film is bonded to the surface of the fine metal wire with an adhesive or an adhesive. The material of the protective film is preferably a material that is less corrosive to fine metal wires, and preferably has an acid value of 5.0 mgKOH / g or less. In order to obtain a highly reliable polarizing plate, it is more preferably 3.0 mgKOH / g or less, and further preferably 2.0 mgKOH / g or less. In addition, a material having a low refractive index, a low reflectance, and a low absorptance in the wavelength band to be used is preferable. It is also preferable to form a dielectric thin film or a moth-eye structure on the surface of the protective film for the purpose of controlling the reflectance of incident light.

(Adhesive layer)
As described above, the polarizing plate made of fine metal wires arranged at equal intervals on the base material of the present invention has a surface on the metal fine wire side and a surface on the base material side, and is provided with a coating layer for protecting the fine metal wires. In some cases, the surface of the coating layer is provided instead of the surface of the fine metal wire. The pressure-sensitive adhesive layer is formed so as to contact at least one surface selected from these three types of surfaces. The adhesive force between the polarizing plate and the pressure-sensitive adhesive is preferably at least twice the peeling force between the pressure-sensitive adhesive and the separator film, as will be described later. Further, even when the peeling force between the pressure-sensitive adhesive and the separator film is set to 200 mN / 25 mm or less, the pressure-sensitive adhesive force between the polarizing plate and the pressure-sensitive adhesive is sufficient to exhibit sufficient adhesion to the adherend. It is preferably 500 mN / 25 mm or more, and more preferably 1000 mN / 25 mm or more. By using a material having such a high adhesive force, the polarizing plate made of fine metal wires arranged at equal intervals on the substrate and the adherend can be stably bonded. As a material having a strong adhesive force, a material having an adhesive force to glass of 1500 mN / 25 mm or more, preferably 5000 mN / 25 mm or more may be used. The thickness of the pressure-sensitive adhesive layer is usually 200 μm or less, desirably 1 to 50 μm. The thickness is equal to or less than the thickness of the adherend.

  The pressure-sensitive adhesive layer is formed using a material containing as little acid as possible. This makes it possible to suppress the deterioration of the metal thin wire constituting the polarizing plate made of the fine metal wires arranged at equal intervals on the base material in a high temperature and high humidity environment, the layer protecting the fine metal wire, and the base material. . As a material containing as little acid as possible, it is preferable to use a material having an acid value of 5.0 mgKOH / g or less. If the acid strength is less than or equal to this numerical value, as will be described in the following examples, the polarizing plate composed of fine metal wires arranged at equal intervals on the substrate is deteriorated by the acid contained in the adhesive layer, the degree of polarization Can be suppressed.

  Specific materials for the pressure-sensitive adhesive layer include resins such as acrylic resins, silicon resins, urethane resins, polyester resins, and epoxy resins as long as the acid strength is within a range of 5.0 mgKOH / g or less. Can be used. In consideration of heat resistance, an adhesive mainly composed of a silicon-based resin (hereinafter referred to as “silicon-based adhesive”) is preferable. In consideration of transparency, adhesive strength, cost, etc., an adhesive mainly composed of an acrylic resin (hereinafter referred to as “acrylic adhesive”) is preferable, and further, in the resin structure of the adhesive It is more preferable to have a hydroxyl group from the viewpoint of suppressing a decrease in polarization characteristics.

  When the adhesive layer is formed so as to be in contact with the fine metal wire, it may be provided so as to cover at least a part of the fine metal wire, but in order to effectively suppress the corrosion of the fine metal wire, It is preferable to form the pressure-sensitive adhesive layer so as to cover a larger portion, thereby improving the corrosion resistance of the fine metal wires.

  Moreover, an additive can be used for an adhesive layer according to the request | requirement of function addition. Additives are refractive index modifiers, tackifiers, fillers, pigments, diluents, etc., such as UV absorbers, antioxidants, light stabilizers, antistatic agents, etc. that improve the stability of adhesives. Can be mentioned. The pressure-sensitive adhesive layer containing the additive is also referred to as a pressure-sensitive adhesive layer, and the use of the additive is not limited as long as the acid value is in the range of 5.0 mgKOH / g or less. For example, by using a refractive index adjusting agent in the pressure-sensitive adhesive layer, it is possible to prevent a decrease in transmittance due to a difference in refractive index at the interface of the polarizer that is a laminate. Moreover, the possibility of coloring yellow by excessive ultraviolet irradiation can be reduced by adding an ultraviolet absorber to the pressure-sensitive adhesive layer.

(Separator film)
A separator film is used in order to protect said adhesive layer. The peel strength between the separator film and the pressure-sensitive adhesive layer is preferably in the range of 10 to 1000 mN / 25 mm, more preferably 20 mN / 25 mm or more in order to prevent the interlayer from being turned during the cutting process, and 50 mN / 25 mm or more is more preferable. Further, in the work of separating the polarizing plate from the separator film when used in an apparatus, not only does not lower the quality of the polarizing plate but also it is preferably 800 mN / 25 mm or less in order to increase the working speed, and 500 mN / More preferably, it is 25 mm or less.

  As a kind of separator film, it does not specifically limit but a well-known separator film (release sheet, release liner) is used suitably. Examples of the constituent material of the separator film include plastic films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester films, porous materials such as paper, cloth, and nonwoven fabric, nets, foamed sheets, metal foils, and laminates thereof. Although an appropriate thin leaf body etc. can be mention | raise | lifted, a plastic film is used suitably from the point which is excellent in surface smoothness. The plastic film is not particularly limited as long as it can protect the pressure-sensitive adhesive layer. For example, a polyethylene film, a polypropylene film, a polybutene film, a polybutadiene film, a polymethylpentene film, a polyvinyl chloride film, and a vinyl chloride co-polymer are used. Examples thereof include a polymer film, a polyethylene terephthalate film, a polybutylene terephthalate film, a polyurethane film, and an ethylene-vinyl acetate copolymer film. Of these, a polyethylene terephthalate film is preferred.

  The thickness of the separator film is preferably 3 μm or more, more preferably 10 μm or more, and even more preferably in the range of 20 μm to 100 μm in order to ensure the handleability of small pieces of the polarizing plate and the storage stability until use.

  For the separator film, if necessary, release and antifouling treatment with a silicone, fluorine, long chain alkyl or fatty acid amide release agent, silica powder, etc., coating type, kneading type, vapor deposition An antistatic treatment such as a mold can also be performed. In particular, the release property from the pressure-sensitive adhesive layer can be adjusted by appropriately performing a release treatment such as silicone treatment, long-chain alkyl treatment, or fluorine treatment on the surface of the separator film.

(Carrier film)
The carrier film is a laminated body for the purpose of holding the laminated body or protecting the laminated body when cutting the laminated body including the wire grid polarizing plate, the pressure-sensitive adhesive layer, and the separator film into small pieces. It is an adhesive film used by laminating. The carrier film can be bonded so as to be in contact with the separator film of the laminate, or can be bonded so as to be in contact with the wire grid polarizing plate of the laminate. For example, when half-cutting a laminate including a wire grid polarizing plate, the opposite side of the cut side comes into contact with a work table for cutting, etc. If the force is excessive, etc., it will cause frequent damage to the wire grid plate, which will deteriorate the polarization characteristics due to the falling of the wire grid, etc., so provide a carrier film on the side opposite to the side to cut Is desirable. In addition, in the laminated body in the order of the polarizing plate, the adhesive layer, and the separator film, by providing a carrier film on the side close to the bottom surface of the laminated body, the inside of the container in which the laminated body is put in the case of shaking during transportation Damage to the wire grid due to the force at the time of collision between the bottom of the product and the product can be suppressed. Furthermore, by wrapping a laminate composed of the polarizing plate, the adhesive layer, the separator film, and the carrier film with a protective film, contamination due to transportation can be suppressed.

  When bonding the carrier film so as to be in contact with the separator film of the laminate, the adhesive force between the carrier film and the separator film should be less than twice the peel force between the adhesive layer of the laminate and the separator film. It becomes possible to remove from the carrier film without separating the pressure-sensitive adhesive layer and the separator film after being cut into small pieces. The adhesive force between the carrier film and the separator film is less than 10 mN / 25 mm for the purpose of preventing separation between the carrier film and the separator film at the time of cutting, and less than 1 times the peeling force between the adhesive layer of the laminate and the separator film. It is more preferable in terms of workability when removing the laminate from the carrier film.

  Moreover, the adhesive force between a carrier film and a separator film can also be made into 2 times or more of the peeling force between the adhesive layer of a laminated body, and a separator film. In this case, the laminate can be held on the carrier film until the polarizing plate with the adhesive is bonded to the adherend, and the separator film remains on the carrier film and is separated between the adhesive layer and the separator film. Therefore, there is an advantage that the pressure-sensitive adhesive layer can be exposed at once, and an advantage that small pieces of the separator film can be prevented from being scattered during the bonding operation. The adhesive force between the carrier film and the separator film is more preferably 3 times or more and more preferably 5 times or more the peeling force between the adhesive layer of the laminate and the separator film.

  When the carrier film is bonded so as to be in contact with the wire grid polarizer of the laminate, the adhesive force between the carrier film and the wire grid polarizer is less than twice the peel force between the adhesive layer of the laminate and the separator film. By doing so, it becomes possible to remove from the carrier film without separating the pressure-sensitive adhesive layer and the separator film after being cut into small pieces. The adhesive force between the carrier film and the wire grid polarizing plate is within 10 mN / 25 mm for the purpose of preventing separation between the carrier film and the wire grid polarizing plate at the time of cutting. It is more preferable from the surface of workability | operativity at the time of removing a laminated body from a carrier film that it is less than 1 time.

  The type of carrier film is not particularly limited, and a known adhesive film is appropriately used. Examples of the material constituting the carrier film include plastic films such as polyethylene, polypropylene, polyethylene terephthalate, and polyester films, porous materials such as paper, cloth, and nonwoven fabric, nets, foamed sheets, metal foils, and laminates thereof. Although an appropriate thin leaf body etc. can be mention | raise | lifted, a plastic film is used suitably from the point which is excellent in surface smoothness. The plastic film is not particularly limited as long as it can form an adhesive surface. For example, polyethylene film, polypropylene film, polybutene film, polybutadiene film, polymethylpentene film, polyvinyl chloride film, vinyl chloride Examples thereof include a polymer film, a polyethylene terephthalate film, a polybutylene terephthalate film, a polyurethane film, and an ethylene-vinyl acetate copolymer film. Of these, a polyethylene terephthalate film is preferred. As a specific material for forming the adhesive surface, there is no particular limitation and conventionally known materials can be used, but when the adhesive surface is used so as to be in contact with the fine metal wires of the wire grid polarizer, A material having an acid strength of 5.0 mgKOH / g or less is preferable. Within this range, resins such as acrylic resins, silicon resins, urethane resins, polyester resins, and epoxy resins can be used. In consideration of heat resistance, an adhesive mainly composed of a silicon-based resin (hereinafter referred to as “silicon-based adhesive”) is preferable. In consideration of transparency, adhesive strength, cost, etc., an adhesive mainly composed of an acrylic resin (hereinafter referred to as “acrylic adhesive”) is preferable, and further, in the resin structure of the adhesive It is more preferable to have a hydroxyl group from the viewpoint of suppressing a decrease in polarization characteristics. Moreover, an additive can be used for the material which forms an adhesive surface according to the request | requirement of function addition. Additives are refractive index modifiers, tackifiers, fillers, pigments, diluents, etc., such as UV absorbers, antioxidants, light stabilizers, antistatic agents, etc. that improve the stability of adhesives. Can be mentioned. The pressure-sensitive adhesive layer containing the additive is also referred to as a pressure-sensitive adhesive layer, and the use of the additive is not limited as long as the acid value is in the range of 5.0 mgKOH / g or less. For example, by using a refractive index adjusting agent in the pressure-sensitive adhesive layer, it is possible to prevent a decrease in transmittance due to a difference in refractive index at the interface of the polarizer that is a laminate. Moreover, the possibility of coloring yellow by excessive ultraviolet irradiation can be reduced by adding an ultraviolet absorber to the pressure-sensitive adhesive layer.

  As necessary, the carrier film base material may be an antistatic treatment such as a coating type, a kneading type, or a vapor deposition type, a dyeing treatment, an easy printing treatment, a silicone type, a fluorine type, a long chain alkyl type or Release with a fatty acid amide-based release agent, silica powder, etc., and antifouling treatment can also be performed.

(Cutting)
The laminated body of the present invention including the wire grid polarizing plate, the pressure-sensitive adhesive layer, the separator film, and, if necessary, the carrier film can be arbitrarily sized from a large-area original fabric using a conventionally known cutting processing technique. Can be cut into small pieces. As a specific cutting technique, for example, an ultra-thin blade that is devised so as not to cut deeper than the thickness of the protective layer, a punching blade whose height is adjusted, or a Thomson blade can be used. Moreover, it can be set as a desired shape by various methods, such as a rotary blade which has V shape, U shape, and a rectangle, a slice cutter, a laser cutter. An example of the structure and cutting process of a typical laminate is shown in FIG.

  (Laminate Example 1) is an example in which (A) a wire grid polarizing plate, (B) an adhesive layer, (C) a separator film, and (D) a carrier film are laminated in this order, and further protected on a wire grid polarizing plate. A film can be covered or a carrier film can be omitted.

  The cutting line (1) is cut from the wire grid polarizing plate to the middle part of the separator film in the laminating direction, thereby cutting the wire grid polarizing plate and the adhesive layer without cutting completely below the separator film. This is an example that remains integrated. By performing such a cutting process, if the BCs are separated, there is an advantage that the surface of the adhesive can be exposed at once. When the thickness of the separator film exceeds 5 μm, the cutting line (1) can be cut to a depth of 5 μm or more without completely cutting the separator film. In the examples described later, the separator film had a thickness of 38 μm and a depth of 5 μm. By performing such processing, it is possible to prevent a defect that the adhesive layer on the cutting line is re-adhered.

  The cutting line (2) cuts from the wire grid polarizing plate to the middle part of the carrier film in the laminating direction, thereby completely cutting from the wire grid polarizing plate to the separator film, without cutting the carrier film completely. This is an example that remains integrated. In the examples described later, the carrier film has a thickness of 50 μm and a depth of 5 μm. By performing such a cutting process, by appropriately selecting the peeling force between the BCs and the adhesive force between the CDs, the BCs are separated while holding C on D, and the surface of the adhesive is exposed at once. Either the usage method or the usage method of removing from the carrier film between CDs without separating between BCs can be selected.

  The cutting line (3) is an example in which all the layers of the laminated body example 1 are cut.

  (Laminated body example 2) is laminated in the same order as (Laminated body example 1), but the substrate-side surface of the wire grid polarizer is in contact with the adhesive layer. Furthermore, a protective film can be put on the wire grid polarizer, or a carrier film can be omitted. The processing features and advantages of the cutting lines (4), (5), and (6) correspond to the processing features and advantages of the cutting lines (1), (2), and (3) of (Laminate Example 1). Yes.

  (Laminated body example 3) is an example in which (C) a separator film, (B) an adhesive layer, (A) a wire grid polarizer, and (D) a carrier film are laminated in this order. The cutting line (7) is cut from the separator film to the middle part of the carrier film in the laminating direction to completely cut from the separator film to the wire grid polarizer, and the carrier film is integrated without being cut completely. It is an example that is left as it is. In the examples described later, the carrier film had a thickness of 50 μm and a depth of 5 μm. The cutting line (8) is an example in which all the layers of the laminated body example 3 are cut.

  (Laminated body example 4) is laminated in the same order as (laminated body example 3), but the base-side surface of the wire grid polarizer is an example in contact with the carrier film. The cutting line (9) is an example in which the part from the separator film to the wire grid polarizing plate is completely cut, and the carrier film is left without being cut completely. The cutting line (10) is an example in which all the layers of the laminated body example 4 are cut.

  Next, examples performed for clarifying the present invention will be described, but the present invention is not limited to these examples.

  First, the measurement method of the measured value in an Example is demonstrated.

<Adhesive strength and peel strength>
The adhesive strength between the adhesive layer and the wire grid polarizer, the peel strength between the adhesive layer and the separator film, and the adhesive strength of the carrier film were evaluated using a tensile tester. After bonding these test pieces, they were cut out to a width of 25 mm, left in a room at 25 ° C. and 50% RH for about 24 hours, and then measured under the conditions of a peeling rate of 1000 mm / min and a peeling angle of 90 °.

<Thickness>
It measured using the contact-type thickness meter (Digimatic indicator ID-C112CX by Mitutoyo Corporation).

<Cutting depth>
Measurement was performed using a shape measurement laser microscope (VK9700, manufactured by Keyence Corporation).

<Acid value>
The pressure-sensitive adhesive of the pressure-sensitive adhesive layer and the pressure-sensitive adhesive on the pressure-sensitive adhesive surface of the carrier film were evaluated. 3.0 g of the adhesive was added to 100 mL of N, N-dimethylformamide and stirred overnight to dissolve. A few drops of the phenolphthalein solution described in JIS-K-8001 or 0.1 g of thymol blue in 50 ml of ethanol (95), and made up to 100 ml with water was added. For the sample solution in which the adhesive was dissolved, the acid value was measured by performing neutralization titration with stirring using a 0.1 mol / l potassium hydroxide (KOH) ethanol solution described in JIS-K-0070. did. The KOH solution is calculated from the concentration obtained by the above titration and the KOH concentration calculated from the amount actually dissolved by performing neutralization titration using 0.1 mol / l hydrochloric acid with a known factor. What obtained the ratio (factor) of the density | concentration to be used was used. In the case of using phenolphthalein, the end point of the titration was the end point where a light red color continued for 30 seconds. Some adhesives turn pale yellow when dissolved in DMF. In this case, determination of the end point due to discoloration of phenolphthalein is difficult, so thymol blue was used. When thymol blue was used, the end point was a point where yellowish green continued for 30 seconds. Further, when a UV absorber or the like is included in the pressure-sensitive adhesive, thymol blue was used because it may become pale yellow due to dissolution in DMF. The end point was determined by taking the point where dark yellow continued for 30 seconds as the end point, and the acid value was calculated using the following equation.
A = B × f × 5.661 / S
A: Acid value (mgKOH / g)
B: Amount of 0.1 mol / l KOH ethanol solution used for titration (ml)
f: 0.1 mol / l KOH ethanol solution factor S: mass of adhesive (g)

<Optical characteristics>
The optical characteristics were evaluated with a spectrophotometer (V-7100 manufactured by JASCO Corporation). Here, the transmitted light intensity in a parallel Nicols state and a crossed Nicols state with respect to linearly polarized light was measured, and the degree of polarization and the light transmittance were calculated from the following equations. The measurement wavelength was 550 nm.
Polarization degree = [(Imax−Imin) / (Imax + Imin)] × 100%
Light transmittance = [(Imax + Imin) / 2] × 100%
Imax is the transmitted light intensity at the time of parallel Nicols, and Imin is the transmitted light intensity at the time of crossed Nicols.

  Next, a method for manufacturing the wire grid polarizer used in this example will be described below.

Example 1
(Manufacture of wire grid polarizer 1)
Trimethylolpropane triacrylate is 32% by mass as a monomer that is a trifunctional or higher acrylate compound, N-vinyl-2-pyrrolidone is 32% by mass as a monomer that is an N-vinyl compound, and other monomers. As a photopolymerization initiator, 33% by mass of 1,9-nonanediol diacrylate, 2% by mass of 2,4,6-trimethylbenzoyl-diphenyl-phosphine oxide, and 1% by mass of silicon diacrylate were filtered. Then, the photocurable resin 1 was prepared. This viscosity was 7.9 mPa · s.

  By applying the photo-curing resin continuously on a roll-shaped TAC resin film having a thickness of 80 μm, a width of 250 mm, and a length of 200 m, and then curing it with ultraviolet rays while making contact with a roll stamper having a fine lattice pattern on the surface, The grid pattern was transferred continuously. When the cross section of this transfer film was observed with an electron microscope, the shape of the fine lattice pattern was an accurate reversal of the roll stamper, and it was confirmed that the line and space structure had a pitch of 140 nm and a height of 150 nm. . The thickness of the resin film was 0.3 μm.

  A silicon nitride thin film was formed on the transfer surface side of the transfer film by a continuous film forming apparatus. Subsequently, the wire grid polarizing plate 1 was manufactured by forming the thin aluminum wire on the silicon nitride thin film.

(Manufacture of laminated body example 1A)
The surface of the fine metal wire of the wire grid polarizing plate 1 and the acrylic adhesive 1 (trade name “WT # 5402A”: manufactured by Sekisui Chemical Co., Ltd.) carried on an easily peelable PET separator film 1 having a thickness of 50 μm. Laminate Example 1A was manufactured by pasting together and subsequently laminating carrier film 1 (trade name “SS-PET50AS”: manufactured by Lintec Corporation) on the opposite surface of separator film 1. The pressure-sensitive adhesive 1 was dissolved in DMF, and the acid value was measured and found to be 0.8 mgKOH / g. Moreover, when the adhesive force (peeling force) between each layer was evaluated, between wire grid polarizing plate 1 and adhesive 1 is 3000 mN / 25 mm or more, and between adhesive 1 and separator film 1 is 140 mN / 25 mm, The distance between the separator film 1 and the carrier film 1 was 200 mN / 25 mm. The optical performance was also evaluated.

(Manufacture of laminated body example 1B)
The surface of the fine metal wire of the wire grid polarizing plate 1 and an acrylic adhesive 1 (trade name “WT # 5402A” manufactured by Sekisui Chemical Co., Ltd.) supported on an easily peelable PET separator film having a thickness of 50 μm are pasted. Then, the laminated body example 1B was manufactured by laminating the carrier film 2 (trade name “PET50PAT1”: manufactured by Lintec Corporation) on the opposite surface of the easily peelable PET separator film. When the adhesive force (peeling force) between the separator film 1 and the carrier film 2 was evaluated, it was 11000 mN / 25 mm. The optical performance was also evaluated.

(Cutting of laminated body examples 1A and 1B)
About the laminated body examples 1A and 1B, using a punching apparatus that can handle half-cutting, punching was performed in a lattice shape at a pitch of 10 mm in the vertical direction and a pitch of 10 mm in the horizontal direction, and cut into 10 mm square pieces. Processing was performed under three conditions corresponding to the cutting lines (1), (2), and (3), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 1.

(Manufacture and processing of laminate examples 2A and 2B)
The base surface of the wire grid polarizing plate 1 and an acrylic pressure-sensitive adhesive 1 (trade name “WT # 5402A” manufactured by Sekisui Chemical Co., Ltd.) carried on an easily peelable PET separator film 1 having a thickness of 50 μm are pasted. Laminate examples 2A and 2B were produced in the same manner as laminate example 1 except that they were combined. The adhesive force between the wire grid polarizer 1 and the adhesive 1 was 3000 mN / 25 mm or more. This was cut in three conditions corresponding to the cutting lines (4), (5), and (6) in the same manner as in the laminated body example 1. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 1.

(Manufacture and processing of laminate example 3A)
Acrylic pressure-sensitive adhesive 1 (trade name “WT # 5402A” manufactured by Sekisui Chemical Co., Ltd.) carried on an easily peelable PET separator film 1 having a thickness of 50 μm and a substrate surface of the wire grid polarizing plate 1 are attached. Subsequently, the surface of the fine metal wires of the wire grid polarizing plate 1 and the carrier film 3 (trade name “L-8020”: manufactured by Hitachi Chemical Co., Ltd.) were bonded together to produce a laminate example 3A. The pressure-sensitive adhesive on the adhesive surface of the carrier film 3 was dissolved in DMF, and the acid value was measured and found to be 1.2 mgKOH / g. Moreover, the adhesive force between the wire grid polarizing plate 1 and the carrier film 3 was 200 mN / 25 mm. The optical performance was also evaluated. This was cut in the same manner as in Laminate Example 1 under two conditions corresponding to the cutting lines (7) and (8), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 1.

(Manufacture and processing of laminate example 4A)
An acrylic pressure-sensitive adhesive 1 (trade name “WT # 5402A” manufactured by Sekisui Chemical Co., Ltd.) carried on an easily peelable PET separator film 1 having a thickness of 50 μm, and the surface of the fine metal wires of the wire grid polarizing plate 1 A laminated body example 4A was produced in the same manner as the laminated body example 3 except that the lamination was performed. The adhesive force between the wire grid polarizer 1 and the carrier film 3 was 150 mN / 25 mm. This was cut in the same manner as in Laminate Example 3 under two conditions corresponding to the cutting lines (9) and (10), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 1.

(Comparative Example 1)
(Manufacture of wire grid polarizer 2)
Similar to the wire grid polarizer 1, the photocurable resin 1 is applied onto a PET resin film substrate having a thickness of 3 μm, and is cured with ultraviolet rays while being in contact with a stamper having a fine grid pattern on the surface. The pattern was transcribed. When the cross section of this transfer film was observed with an electron microscope, the shape of the fine lattice pattern was an accurate reversal of the roll stamper, and it was confirmed that the line and space structure had a pitch of 140 nm and a height of 150 nm. . The thickness of the resin film was 0.3 μm.

  A silicon nitride thin film was formed on the transfer surface side of the transfer film using a film forming apparatus. Subsequently, the wire grid polarizing plate 2 was manufactured by forming a thin aluminum wire on the silicon nitride thin film.

(Manufacture of laminated body example 1C)
The surface of the fine metal wire of the wire grid polarizing plate 2 and the acrylic adhesive 1 (trade name “WT # 5402A”: manufactured by Sekisui Chemical Co., Ltd.) supported on the easily peelable PET separator film 1 having a thickness of 50 μm Lamination example 1C was manufactured by pasting together carrier film 1 (trade name “SS-PET50AS” manufactured by Lintec Corporation) on the opposite surface of separator film 1. When the adhesive force between the wire grid polarizing plate 2 and the adhesive 1 was evaluated, it was 3000 mN / 25 mm or more. The optical performance was also evaluated.

(Cutting of laminated body example 1C)
About the laminated body example 1C, using a punching apparatus that can handle half-cutting, it was punched in a lattice shape at a pitch of 10 mm in the vertical direction and at a pitch of 10 mm in the horizontal direction, and cut into 10 mm square pieces. Processing was performed under three conditions corresponding to the cutting lines (1), (2), and (3), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 2.

(Production and processing of laminated body example 3B)
Acrylic pressure-sensitive adhesive 1 (trade name “WT # 5402A” manufactured by Sekisui Chemical Co., Ltd.) carried on an easily peelable PET separator film 1 having a thickness of 50 μm and a substrate surface of the wire grid polarizer 2 are attached. Subsequently, the surface of the fine metal wires of the wire grid polarizing plate 1 and the carrier film 3 (trade name “L-8020” manufactured by Hitachi Chemical Co., Ltd.) were bonded together to produce a laminate example 3B. The adhesive force between the wire grid polarizer 1 and the carrier film 3 was 210 mN / 25 mm. The optical performance was also evaluated. This was cut in the same manner as in the laminated body example 3A under two conditions corresponding to the cutting lines (7) and (8), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 2.

(Comparative Example 2)
(Manufacture of laminated body example 1D)
The surface of the fine metal wire of the wire grid polarizing plate 1 and the acrylic adhesive 1 (trade name “WT # 5402A”: manufactured by Sekisui Chemical Co., Ltd.) carried on an easily peelable PET separator film 1 having a thickness of 50 μm. Pasted together. Next, the separator film 1 was peeled off and replaced with another separator film 2. Subsequently, the laminated body example 1D was manufactured by bonding the carrier film 1 (trade name “SS-PET50AS”: manufactured by Lintec Corporation) to the opposite surface of the separator film 2. When the adhesive force between the adhesive 1 and the separator film 2 was evaluated, it was 1240 mN / 25 mm, and the adhesive force between the separator film 2 and the carrier film 1 was 220 mN / 25 mm. The optical performance was also evaluated.

(Cutting of laminated body example 1D)
About the laminated body example 1D, using a punching apparatus that can handle half-cutting, it was punched in a lattice shape at a pitch of 10 mm in the vertical direction and a pitch of 10 mm in the horizontal direction, and cut into square pieces of 10 mm square. Processing was performed under three conditions corresponding to the cutting lines (1), (2), and (3), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 2.

(Manufacture and processing of laminated body example 3C)
Acrylic pressure-sensitive adhesive 1 (trade name “WT # 5402A” manufactured by Sekisui Chemical Co., Ltd.) carried on an easily peelable PET separator film 1 having a thickness of 50 μm and a substrate surface of the wire grid polarizer 2 are attached. Combined. Next, the separator film 1 was peeled off and replaced with another separator film 2. Subsequently, the surface of the fine metal wires of the wire grid polarizing plate 1 and the carrier film 3 (trade name “L-8020”: manufactured by Hitachi Chemical Co., Ltd.) were bonded together to produce a laminate example 3C. The optical performance was also evaluated. This was cut in the same manner as in the laminated body example 3A under two conditions corresponding to the cutting lines (7) and (8), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 2.

(Comparative Example 3)
(Manufacture of laminated body example 1E)
The surface of the fine metal wire of the wire grid polarizing plate 1 is bonded to the acrylic adhesive 2 (trade name “RA-600”: manufactured by Sumilon Co., Ltd.) supported on the 50 μm-thick easy-release PET separator film 3. Then, the laminated body example 1E was manufactured by pasting together the carrier film 1 (trade name “SS-PET50AS”: manufactured by Lintec Corporation) on the opposite surface of the separator film 3. The pressure-sensitive adhesive 2 was dissolved in DMF, and the acid value was measured and found to be 0.5 mgKOH / g. Moreover, when the adhesive force (peeling force) between each layer was evaluated, between the wire grid polarizing plate 1 and the adhesive 1 is 150 mN / 25 mm or more, and between the adhesive 2 and the separator film 3 is 140 mN / 25 mm, The distance between the separator film 3 and the carrier film 1 was 200 mN / 25 mm. The optical performance was also evaluated.

(Cutting of laminated body example 1E)
About the laminated body example 1E, using the punching apparatus which can respond to a half cut, it punched in the shape of a grid | lattice at 10 mm pitch in the vertical direction, and 10 mm pitch in the horizontal direction, and cut it into the 10 mm square small piece. Processing was performed under three conditions corresponding to the cutting lines (1), (2), and (3), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 2.

(Manufacture and processing of laminated body example 3D)
Acrylic pressure-sensitive adhesive 2 (trade name “RA-600”: manufactured by Sumilon Co., Ltd.) carried on an easily peelable PET separator film 3 having a thickness of 50 μm and the substrate surface of the wire grid polarizing plate 1 were bonded together. Subsequently, the surface of the fine metal wires of the wire grid polarizing plate 1 and the carrier film 3 (trade name “L-8020”: manufactured by Hitachi Chemical Co., Ltd.) were bonded together to produce a laminate example 3D. The optical performance was also evaluated. This was cut in the same manner as in Laminate Example 1 under two conditions corresponding to the cutting lines (7) and (8), respectively. About these, the optical performance and external appearance after a cutting | disconnection, the optical performance and external appearance after isolate | separating an adhesive layer and a separator film, and the handleability of the cut | disconnected product were evaluated. The results are shown in Table 2.

(Example 2)
With regard to the laminated body example 1A, a small piece processed under the condition of the cutting line (1) was attached to a glass plate and allowed to stand in a room at 25 ° C. and 50% RH for about 24 hours, and then the optical performance and appearance were evaluated. This was put into a temperature and humidity chamber (model: μ-2002, manufactured by Isuzu Seisakusho), the environment in the chamber was set to 85 ° C. and 85% RH, and the temperature and humidity test was performed for 500 hours. After the test, the optical performance and appearance were evaluated after being left for about 24 hours in a room at 25 ° C. and 50% RH. There was no significant change in optical performance or appearance.

(Example 3)
(Manufacture and processing of laminated body example 1F)
The surface of the fine metal wire of the wire grid polarizing plate 1 and the acrylic pressure-sensitive adhesive 3 (trade name “EW1500”, manufactured by ERI YEL TEXEL Co., Ltd.) supported on the easily peelable PET separator film 4 having a thickness of 50 μm are bonded together. Subsequently, the laminated body example 1F was manufactured by bonding the carrier film 1 (trade name “SS-PET50AS”: manufactured by Lintec Corporation) to the opposite surface of the separator film 4. The pressure-sensitive adhesive 1 was dissolved in DMF and the acid value was measured and found to be 6.0 mgKOH / g. Moreover, when the adhesive force (peeling force) between each layer was evaluated, between the wire grid polarizing plate 1 and the adhesive 3 is 3000 mN / 25 mm or more, and between the adhesive 1 and the separator film 4 is 120 mN / 25 mm, The distance between the separator film 4 and the carrier film 1 was 200 mN / 25 mm. The optical performance was also evaluated.

  The laminated body example 1F thus manufactured was punched into a 10 mm square square piece by punching in a lattice shape at a pitch of 10 mm in the vertical direction and a pitch of 10 mm in the horizontal direction using a punching apparatus that can handle half cut. It processed on the conditions corresponding to a cutting line (1).

(Constant temperature and humidity test of laminate example 1F)
With regard to the laminated body example 1F, a small piece processed under the condition of the cutting line (1) was attached to a glass plate and allowed to stand in a room at 25 ° C. and 50% RH for about 24 hours, and then the optical performance and appearance were evaluated. This was put into a temperature and humidity chamber (model: μ-2002, manufactured by Isuzu Seisakusho), the environment in the chamber was set to 85 ° C. and 85% RH, and the temperature and humidity test was performed for 500 hours. After the test, the optical performance and appearance were evaluated after being left for about 24 hours in a room at 25 ° C. and 50% RH. The degree of polarization after the test was 20% lower than that before the test. Further, the color of the sample after the test was more yellowish than that before the test.

  As mentioned above, about the laminated body example 1A-the laminated body example 1F, the laminated body example 2A, the laminated body example 2B, the laminated body example 3A-the laminated body example 3D, and the laminated body example 4A, respectively, adhesion | attachment of a wire grid polarizing plate, an adhesive layer, a separator film, and a carrier film Table 3 summarizes the peel force on the surface.

  The present invention is suitably used for a laminate having a wire grid polarizing plate processed with an adhesive.

Claims (9)

  A laminate having a polarizing plate having fine metal wires arranged at equal intervals on a substrate, a pressure-sensitive adhesive layer in contact with the polarizing plate, and a separator film in contact with the pressure-sensitive adhesive layer, in the stacking direction, It is cut from the polarizing plate to at least the middle part of the separator film, the thickness of the polarizing plate is 5 μm or more, the peeling force between the pressure-sensitive adhesive layer and the separator film is 10 to 1000 mN / 25 mm, and the polarization The laminated body characterized by the adhesive force between a board and the said adhesive layer being 2 times or more of the peeling force between the said adhesive layer and the said separator film.   2. The laminate according to claim 1, wherein the separator film has a thickness of 5 μm to 200 μm, and the cut depth of the separator film is 5 μm or more.   The laminate according to claim 1, further comprising a carrier film in contact with the polarizing plate and / or the separator film.   The laminate according to claim 3, wherein the carrier film is provided in contact with the separator film, and is cut from the polarizing plate to at least a middle portion of the separator film in the laminating direction.   The laminate according to claim 4, wherein the adhesive force between the separator film and the carrier film is less than twice the peel force between the adhesive layer and the separator film.   The laminate according to claim 3, wherein the carrier film is provided in contact with the polarizing plate, and is cut from the separator film to at least a middle portion of the carrier film in the laminating direction.   The laminate according to claim 6, wherein the adhesive force between the polarizing plate and the carrier film is less than twice the peel force between the adhesive layer and the separator film.   The laminate according to any one of claims 3 to 7, wherein a thickness of the carrier film is 5 µm to 200 µm, and a cut depth of the carrier film is 5 µm or more.   The laminate according to any one of claims 1 to 8, wherein an acid value of the pressure-sensitive adhesive layer is 5.0 mgKOH / g or less.

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