JP2014222283A - Transfer body for optical film, optical film, image display device, manufacturing method of transfer body for optical film, and manufacturing method of optical film - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an optical film having lamination of a linear polarization plate and a 1/4 wavelength plate, where the 1/4 wavelength plate is a laminate of a 1/2 wavelength phase difference layer and a 1/4 wavelength phase difference layer, and to manufacture the optical film stably with high reliability while effectively avoiding the repelling between an oriented film and a phase difference layer and insufficiency of adhesion force when sequentially laminating the layers, and effectively avoiding damage to the optical film to reduce the entire thickness.SOLUTION: A transfer layer (16) has an oriented film 22 for a 1/4 wavelength phase difference layer, a 1/4 wavelength phase difference layer 18, an adhesive layer 20, a 1/2 wavelength phase difference layer 19, and an oriented film 23 for a 1/2 wavelength phase difference layer provided from a support substrate side, where the 1/2 wavelength phase difference layer 19 and 1/4 wavelength phase difference layer 18 are adhered with each other by the adhesive layer 20.

Description

  The present invention is an optical film formed by laminating a linearly polarizing plate and a quarter-wave plate, and an optical film comprising a quarter-wave plate composed of a half-wave retardation layer and a quarter-wave retardation layer. Related to film.

  Conventionally, regarding an image display device, a method has been proposed in which an optical film made of a circularly polarizing plate is arranged on the panel surface (viewer side surface) of an image display panel, and reflection of extraneous light is reduced by this optical film. Here, this optical film is composed of a laminate of a linear polarizing plate and a quarter-wave plate, and converts external light directed to the panel surface of the image display panel into linearly-polarized light by the linear polarizing plate, followed by a quarter-wave plate. Convert to circularly polarized light. Here, the extraneous light by the circularly polarized light is reflected by the surface of the image display panel or the like, but the rotation direction of the polarization plane is reversed during the reflection. As a result, contrary to the arrival time, this reflected light is converted into linearly polarized light in the direction shielded by the linear polarizing plate by the quarter wavelength plate, and then shielded by the subsequent linear polarizing plate. Outgoing emission is significantly suppressed.

  With regard to this optical film, Patent Document 1 and the like include a 1/2 wavelength phase difference layer that imparts a phase difference of ½ wavelength to transmitted light, and a 1 / wavelength that imparts a phase difference of ¼ wavelength to transmitted light. A method has been proposed in which a quarter-wave plate is formed by laminating four-wavelength retardation layers to use a liquid crystal material having a positive dispersion characteristic so that the quarter-wave plate functions with a reverse dispersion characteristic. Here, the reverse dispersion characteristic is a wavelength dispersion characteristic in which the phase difference in transmitted light is smaller as the wavelength is shorter.

  By the way, this kind of ½ wavelength retardation layer and ¼ wavelength retardation layer are prepared by solidifying (curing) the liquid crystal material in a state where the liquid crystal material is oriented by the orientation regulating force of the orientation film. be able to. In addition, the alignment film can be created by transferring the fine uneven shape created in the shaping mold by, for example, a shaping process using the shaping mold, or by a so-called photo-alignment technique. can do. Thereby, for example, as shown in FIG. 12, on the transparent substrate 2 made of TAC (triacetyl cellulose) or the like, the alignment film 3 related to the 1/2 wavelength retardation layer, the 1/2 wavelength retardation layer 4, 1/4. A quarter-wave plate 7 having a laminated structure of a half-wave retardation layer and a quarter-wave retardation layer is formed by sequentially forming an alignment film 5 and a quarter-wave retardation layer 6 according to the wavelength retardation layer. Can be created.

  However, in this way, the alignment film 3 related to the ½ wavelength retardation layer, the ½ wavelength retardation layer 4, the alignment film 5 related to the ¼ wavelength retardation layer, and the ¼ wavelength retardation layer 6 in this order. When the alignment film 5 is prepared, the coating liquid for the alignment film 5 is repelled on the surface of the half-wavelength retardation layer 4 and cannot be stably applied. In some cases, it is difficult to ensure sufficient adhesion strength between the alignment film 5 and the half-wave retardation layer 4. Accordingly, in this case, there is a problem that this type of optical film cannot be produced due to stability and high reliability.

  Moreover, when the quarter wave plate 7 produced in this way is laminated with a linearly polarizing plate to form an antireflection film using a circularly polarizing plate, there is also a problem that the entire thickness is increased. In addition, about the problem that this whole thickness is thick, the thickness can be made thin by the part of the base material 2 by applying the so-called transfer method and omitting the base material 2. Here, in the transfer method, for example, when a desired layer is formed on a base material, the layer is not directly formed on the base material, but can be peeled once on a releasable support. After forming the transfer body by laminating the layers, the layer formed on the support is finally placed on the base material (transfer base material) on which the layer is to be laminated according to the process, demand, etc. In this method, a desired layer is formed on the substrate by bonding and laminating, and then peeling and removing the support. In this optical film example, this type of optical film is applied by applying a transfer method by setting the substrate to be transferred to a linear polarizing plate and transferring the laminate according to the quarter-wave plate to the substrate to be transferred. Can be created.

  However, even when the transfer method is applied in this way, the alignment film 3 related to the ½ wavelength retardation layer, the ½ wavelength retardation layer 4, and the alignment film related to the ¼ wavelength retardation layer sequentially. As described above for the case where the 5, 1/4 wavelength retardation layer 6 is laminated, there is a problem that this type of optical film cannot be formed stably and with high reliability due to repelling and insufficient adhesion. In the case of the transfer method, the transfer layer is damaged during the manufacturing process, and as a result, the optical properties of the optical film may be deteriorated.

JP-A-10-68816 JP 2000-284126 A

  The present invention has been made in view of such a situation, and regarding an optical film by a circularly polarizing plate constituting a quarter-wave plate by laminating a half-wave retardation layer and a quarter-wave retardation layer, An object of the present invention is to make it possible to produce it stably and with high reliability, and to effectively avoid scratches and reduce the overall thickness.

  The present inventor has intensively studied to solve the above problems, and separately creates and laminates a 1/2 wavelength retardation layer and a 1/4 wavelength retardation layer, and further functions as an alignment film as a protective layer. Thus, the idea of applying the transfer method was reached and the present invention was conceived.

(1) A transfer body for an optical film comprising a support substrate and a transfer layer,
The transfer layer is
From the support substrate side,
An alignment film for a quarter wavelength retardation layer according to a quarter wavelength retardation layer;
A quarter-wave retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation-regulating force of the quarter-wave retardation layer alignment layer and that imparts a quarter-wave phase difference to transmitted light; ,
An adhesive layer;
A ½ wavelength retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation regulating force of the alignment film for the ½ wavelength retardation layer, and that imparts a retardation of ½ wavelength to transmitted light;
An alignment film for the ½ wavelength retardation layer is provided,
The 1/2 wavelength retardation layer and the 1/4 wavelength retardation layer were bonded together by the adhesive layer.

  According to (1), a ½ wavelength retardation layer and a ¼ wavelength retardation layer can be separately formed, and in the case of sequentially stacking an alignment film and a retardation layer, there is insufficient repelling and adhesion. It is possible to produce a transfer body for an optical film stably and with high reliability, and as a result, it is possible to produce an optical film with stability and high reliability using this optical film transfer body. Can do. In addition, since the alignment film for 1/2 wavelength retardation layer and the alignment film for 1/4 wavelength retardation layer can function as a protective layer for the transfer layer, the entire thickness can be reduced by the transfer method. Layer damage can be effectively avoided.

(2) a substrate made of a transparent film;
An optical functional layer of a linearly polarizing plate that functions as a linearly polarizing plate;
A quarter wave plate is laminated,
The quarter-wave plate was formed by the transfer layer of the optical film transfer body described in (1).

  According to (2), an optical film can be produced stably and with high reliability using the optical film transfer body of (1). Furthermore, it is possible to effectively avoid scratches and reduce the overall thickness.

(3) a substrate made of a transparent film;
An optical functional layer of a linearly polarizing plate that functions as a linearly polarizing plate;
A quarter wave plate is laminated,
The quarter-wave plate is
An alignment film for a quarter wavelength retardation layer according to a quarter wavelength retardation layer;
A quarter-wave retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation-regulating force of the quarter-wave retardation layer alignment layer and that imparts a quarter-wave phase difference to transmitted light; ,
An adhesive layer;
A ½ wavelength retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation regulating force of the alignment film for the ½ wavelength retardation layer, and that imparts a retardation of ½ wavelength to transmitted light;
An alignment film for the ½ wavelength retardation layer is provided,
The 1/2 wavelength retardation layer and the 1/4 wavelength retardation layer were bonded together by the adhesive layer.

  According to (3), a half-wave retardation layer and a quarter-wave retardation layer can be separately formed, and in the case of sequentially laminating an alignment film and a retardation layer, there is insufficient adhesion and adhesion. It is possible to produce a transfer body for an optical film stably and with high reliability, and as a result, it is possible to produce an optical film with stability and high reliability using this optical film transfer body. Can do. In addition, since the alignment film for 1/2 wavelength retardation layer and the alignment film for 1/4 wavelength retardation layer can function as a protective layer for the transfer layer, the entire thickness can be reduced by the transfer method. Layer damage can be effectively avoided.

  (4) An image display device in which the optical film according to (2) or (3) is disposed on a panel surface of an image display panel.

  According to (4), it is an optical film produced with stability and high reliability, and further, it is possible to provide an image display device using an optical film that effectively avoids scratches and reduces the overall thickness. it can.

(5) An alignment film creating step for a 1/2 wavelength retardation layer for creating an alignment film for a 1/2 wavelength retardation layer according to a 1/2 wavelength retardation layer on a first substrate;
A ½ wavelength retardation layer is formed that imparts a phase difference of ½ wavelength to transmitted light by the alignment of the liquid crystal material by the alignment regulating force of the alignment film for the ½ wavelength retardation layer. A retardation layer creating process;
An alignment film creating step for a quarter wavelength retardation layer for creating an alignment film for a quarter wavelength retardation layer according to a quarter wavelength retardation layer on a second substrate;
A quarter wavelength retardation layer is formed that imparts a phase difference corresponding to a quarter wavelength to transmitted light by the orientation of the liquid crystal material by the orientation regulating force of the alignment layer for the quarter wavelength retardation layer. A retardation layer creating process;
A bonding step of bonding the half-wave retardation layer and the quarter-wave retardation layer together with an adhesive layer.

  According to (5), the ½ wavelength retardation layer and the ¼ wavelength retardation layer can be individually prepared, and the repelling and the adhesive strength are insufficient when the alignment film and the retardation layer are sequentially laminated. It is possible to produce a transfer body for an optical film stably and with high reliability, and as a result, it is possible to produce an optical film with stability and high reliability using this optical film transfer body. Can do. In addition, since the alignment film for 1/2 wavelength retardation layer and the alignment film for 1/4 wavelength retardation layer can function as a protective layer for the transfer layer, the entire thickness can be reduced by the transfer method. Layer damage can be effectively avoided.

(6) In (5),
Further, the first substrate is peeled from the alignment film for 1/2 wavelength retardation layer, and the alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength A peeling step of the first base material forming a laminate of the retardation layer, the quarter-wave retardation layer, and the second base material is provided.

  According to (6), the 1st base material and the 1st orientation film can be exfoliated beforehand, and the transfer object for optical films can be provided to the manufacturing process of an optical film.

(7) An optical film manufacturing method using an optical film transfer body manufactured by the optical film transfer body manufacturing method according to (5),
The first substrate is peeled from the alignment film for 1/2 wavelength retardation layer, and the alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength position A phase difference layer, an alignment film for a quarter wavelength phase difference layer, a first substrate peeling step for forming a laminate of a second substrate,
Alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength retardation layer, 1/4 wavelength retardation layer alignment film, laminate of second substrate And a step of bonding to the linear polarizing plate to be bonded to the linear polarizing plate.

  According to (7), an optical film can be produced stably and with high reliability. Furthermore, it is possible to effectively avoid scratches and reduce the overall thickness.

  (8) In (7), it has a peeling process of the 2nd substrate which peels the 2nd substrate from the layered product stuck to the linearly polarizing plate by the bonding process to the linearly polarizing plate. .

  According to (8), it is possible to provide an optical film in a form that functions as a circularly polarizing plate that is simply attached to an image display panel.

(9) An optical film manufacturing method using an optical film transfer body manufactured by the optical film transfer body manufacturing method according to (6),
Alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength retardation layer, 1/4 wavelength retardation layer alignment film, laminate of second substrate A step of bonding to a linear polarizing plate to be bonded to the linear polarizing plate is provided.

  According to (9), an optical film can be produced stably and with high reliability. Furthermore, it is possible to effectively avoid scratches and reduce the overall thickness.

  (10) In (9), the method includes a second base material peeling step of peeling the second base material from the laminate laminated to the linear polarizing plate by the sticking step to the linear polarizing plate. .

  According to (10), the optical film can be provided in a form that functions as a circularly polarizing plate, which is simply pasted on the image display panel.

  According to the present invention, the ½ wavelength phase difference layer and the ¼ wavelength phase difference layer can be separately formed, so that when the alignment film and the phase difference layer are sequentially laminated, the repelling property and the adhesion force are insufficient. Can be effectively avoided, and a transfer body for optical films and an optical film can be produced stably and with high reliability. Further, by applying the transfer method so that the alignment film functions as a protective layer, it is possible to effectively avoid scratches and reduce the overall thickness.

It is sectional drawing which shows the image display apparatus which concerns on 1st Embodiment of this invention. It is a figure where it uses for description of the optical film applied to the image display apparatus of FIG. It is sectional drawing which shows the transfer film which concerns on the optical film of FIG. It is a figure where it uses for description of the manufacturing process of the transfer film of FIG. It is a figure where it uses for description of the manufacturing process of the optical film by the transfer film of FIG. It is a figure where it uses for description of the process of the continuation of FIG. It is a figure where it uses for description of the manufacturing process of FIG. It is a figure with which it uses for description of the continuation of FIG. It is a figure where it uses for description of the transfer film which concerns on 2nd Embodiment of this invention. It is a figure where it uses for description of the transfer film which concerns on 3rd Embodiment of this invention. It is a figure where it uses for description of the transfer film by the example different from the example of FIG. It is a figure where it uses for description of the subject of this invention.

[First Embodiment]
[Optical film and image display device]
FIG. 1 is a diagram showing an image display apparatus according to the first embodiment of the present invention. In the image display device 11, an optical film 13 is disposed on the panel surface (viewer side surface) of the image display panel 12. Here, the image display panel 12 is an organic EL panel having a flexible sheet shape, for example, and displays a desired color image. The image display panel 12 is not limited to a sheet-shaped organic EL panel, and various image display panels such as a plate-shaped organic EL panel and a liquid crystal display panel can be widely applied.

  The optical film 13 is an optical film that suppresses reflection of extraneous light arriving at the image display panel 12 by the function of a circularly polarizing plate. For this reason, the optical film 13 is configured by laminating a linear polarizing plate 15 and a quarter-wave plate 16. The optical film 13 is peeled off a separator film (not shown) to expose the pressure-sensitive adhesive 14 with a pressure-sensitive adhesive, and is then attached and held on the panel surface of the image display panel 12 by the pressure-sensitive adhesive layer 14. Instead of the pressure-sensitive adhesive, the optical film 13 may be arranged by various adhesives such as an ultraviolet curable resin and an adhesive. The linear polarizing plate 15 and the quarter wavelength plate 16 are integrated with each other through the adhesive layer 17. Here, although various adhesives such as an ultraviolet curable resin, a thermosetting resin, and a pressure sensitive adhesive can be widely applied, the adhesive layer 17 is made of an ultraviolet curable resin from the viewpoint of reducing the overall thickness. In this case, it can be formed with a thickness of about 1 μm.

  The quarter wavelength plate 16 includes a quarter wavelength retardation layer 18 that imparts a phase difference of ¼ wavelength to transmitted light, and a ½ wavelength that imparts a phase difference of ½ wavelength to the transmitted light. It is comprised by the laminated body which bonded together the phase difference layer 19 with the contact bonding layer 20. FIG. Thereby, the optical film 13 sufficiently suppresses reflection of extraneous light in a wide wavelength band used for displaying a color image.

  The quarter-wave plate 16 is used for the production of the quarter-wave retardation layer 18 and the half-wave retardation layer 19. An alignment film 23 is provided on each of the image display panel 12 side and the linearly polarizing plate 15 side, whereby the optical film 13 is manufactured by applying a transfer method so that the entire thickness is reduced. The four-wavelength retardation layer 22 and the ½-wavelength retardation layer 23 function as protective layers to prevent the quarter-wave retardation layer 18 and the ½-wavelength retardation layer 19 from being damaged. .

  Accordingly, in the image display device 11, the ¼ wavelength phase difference layer 18, the ½ wavelength phase difference layer 19, and the linear polarizing plate 15 are sequentially arranged from the display screen side of the image display panel 12. In addition, as shown in FIG. 2, the slow axes (indicated by arrows respectively) of the ½ wavelength phase difference layer 19 and the ¼ wavelength phase difference layer 18 with respect to the transmission axis of the linearly polarizing plate 15 indicated by arrows. Are arranged so as to form angles of 15 degrees and 75 degrees counterclockwise, respectively.

  The quarter-wave retardation layer alignment film 22 and the half-wave retardation layer alignment film 23 are formed by forming a fine uneven shape on the surface, and 1 / The liquid crystal material according to the four-wavelength phase difference layer 18 and the half-wavelength phase difference layer 19 is aligned.

  In this embodiment, the quarter-wave retardation layer alignment film 22 and the half-wave retardation layer alignment film 23 are formed after the forming resin layer for forming a fine concavo-convex shape is formed. A fine concavo-convex shape is created and formed on the surface of this shaping resin layer by a shaping treatment. In this embodiment, an ultraviolet curable resin is applied to the shaping resin, and an acrylic ultraviolet curable resin is used. However, the present invention is not limited to this, and various resins used for the shaping process can be widely applied. it can.

  In addition, the fine uneven shape relating to the alignment film 23 for 1/2 wavelength retardation layer and the alignment film 22 for 1/4 wavelength retardation layer is formed by a line (line) uneven shape extending in one direction. The direction extending in one direction is formed so as to be at an angle of 15 degrees and 75 degrees counterclockwise with respect to the transmission axis of the linearly polarizing plate 15, respectively.

  The quarter-wave retardation layer 18 and the half-wave retardation layer 19 are made of a liquid crystal material that is solidified (cured) while maintaining refractive index anisotropy by the orientation regulating force of the corresponding orientation films 22 and 23. It is formed. Although the ¼ wavelength retardation layer 18 and the ½ wavelength retardation layer 19 can widely apply various liquid crystal materials applicable to this type of optical film, in this embodiment, the same material is used. Applied.

  More specifically, for example, the compounds represented by the following chemical formulas (1) to (13) are used for the quarter-wave retardation layer 18 and the half-wave retardation layer 19. That is, 4% of BASF Irgacure 184 or Irgacure 907 as an initiator is added to the following liquid crystal compound to the liquid crystal material, and the fluoric polymer that is a DIC MegaFac series is further added to the liquid crystal layer for the purpose of improving the coating property. Add about 0.1% to 0.5% depending on the thickness of the film, and use MIBK, cyclohexanone, or a mixed solvent of MIBK and cyclohexanone to dissolve to a solid concentration of 25% to prepare a coating solution. The substrate is coated with a die head to obtain a drying process for 3 minutes at a setting of 80 ° C., and is oriented and fixed by ultraviolet curing in a nitrogen atmosphere.

  Although various adhesives such as an ultraviolet curable resin, a thermosetting resin, and a pressure sensitive adhesive can be widely applied to the adhesive layer 20, an ultraviolet curable resin is applied from the viewpoint of reducing the overall thickness. In this case, it can be formed with a thickness of about 1 μm.

  The linearly polarizing plate 15 is provided with the optical functional layer 15B after the lower surface side of the base material 15A made of a transparent film such as TAC (triacetylcellulose) is saponified. In addition, 15 A of base materials replace with this, poly (meth) methyl acrylate, poly (meth) butyl acrylate, methyl (meth) acrylate- (meth) butyl acrylate copolymer, (meth) acrylate methyl- A resin such as an acrylic resin such as a styrene copolymer, a glass such as soda glass, potash glass, lead glass, or quartz glass can be used.

  The optical functional layer 15B is a part that bears an optical function as a linearly polarizing plate, and is produced, for example, by adsorbing and orienting iodine compound molecules on a film material made of polyvinyl alcohol (PVA).

  Thus, in the optical film 13, by configuring the quarter wavelength plate 16 with a laminate in which the quarter wavelength retardation layer 18 and the half wavelength retardation layer 19 are bonded by the adhesive layer 20, respectively. The ¼ wavelength phase difference layer 18 and the ½ wavelength phase difference layer 19 created by separate processes can be used, and thereby an alignment film and a phase difference layer are sequentially laminated. In this case, it can be created by effectively avoiding shortage of adhesion and insufficient adhesion, and as a result, it can be created with high stability and reliability.

    Further, the quarter-wave retardation layer alignment film 22 and the half-wave retardation layer alignment film 23 used for the production of the quarter-wave retardation layer 18 and the half-wave retardation layer 19 are respectively images. By providing the display panel 12 side and the linear polarizing plate 15 side, thereby producing the optical film 13 by applying a transfer method to reduce the overall thickness, the alignment film 22 for a quarter wavelength retardation layer, The alignment film 23 for the ½ wavelength retardation layer can function as a protective layer, and the ¼ wavelength retardation layer 18 and the ½ wavelength retardation layer 19 can be prevented from being damaged.

[Transcript]
In the optical film 13, the quarter-wave plate 16 and the linear polarizing plate 15 are integrated by the adhesive layer 17, and the transfer method is applied to a series of processes related to this integration. Thereby, in this embodiment, the substrate to be transferred is the linear polarizing plate 15, and the layers (transfer layers) used for transfer are the quarter-wave retardation layer alignment film 22 and the quarter-wave retardation layer 18. , An adhesive layer 20, a ½ wavelength phase difference layer 19, and a ½ wavelength phase difference layer alignment film 23.

  FIG. 3 is a diagram showing a configuration of a transfer film 21 which is this transfer body. The transfer film 21 is formed on the support base material 25, the quarter-wave retardation layer alignment film 22, the quarter-wave retardation layer 18, the adhesive layer 20, and the half-wave retardation layers 19, 1/2. A wavelength retardation layer alignment film 23 and a substrate 24 are provided.

  Here, the support base material 25 is a base material that is detachably supported after the transfer layer is detachably supported and the transfer layer is bonded and laminated on the transfer target substrate. In this embodiment, a PET (Polyethylene terephthalate) film, which is a transparent film material, is applied, whereby the transfer film 21 is configured to be able to inspect optical characteristics. The PET film is subjected to corona treatment as necessary, whereby the adhesion force is appropriately set. The support base material 25 may have a sheet shape as a whole. The support substrate 25 may be a resinous film material made of a resin such as a polyester resin such as polyethylene terephthalate, polybutylene terephthalate, or polyethylene aphthalate, or a polyolefin resin such as polypropylene or polymethylpentene.

  When the peelability from the transfer layer is insufficient, the support base material 25 is provided with a release layer that promotes peeling on the transfer layer side. Here, the release layer can be applied with a material having relatively high adhesion to the support substrate 25 (low peelability) and low adhesion to the transfer layer (high peelability). . In this embodiment, the lowermost layer of the transfer layer is an alignment film 22 for a quarter wavelength retardation layer made of an ultraviolet curable resin. Polymer compound), fluorine-based resin, melamine resin, epoxy resin, or a mixture of these resins and other resins (acrylic resin, cellulose-based resin, polyester resin, etc.) as appropriate.

  Incidentally, when the peelability by the release layer is insufficient, a release layer may be provided between the support substrate 25 and the release layer, and this release layer may be used to supplement the peelability by the release layer. . For the release layer, a material having relatively low adhesion to the support film (high peelability) and high adhesion to the release layer (low peelability) can be applied. More specifically, in this embodiment, the release layer includes an acrylic resin, a cellulose resin, a polyester resin, a urethane resin, a vinyl chloride-vinyl acetate copolymer, or a mixture of two or more selected from the above. Alternatively, a mixture of one or more selected from the above and other resins can be applied.

  The base material 24 is a base material that carries the transfer layer in a peelable manner and is used for peeling and removing as appropriate at the time of transfer or the like. In this embodiment, it is comprised similarly to the support body base material 25. FIG. Also in the base material 24, in order to appropriately set the adhesion between the lower-layer half-wave retardation layer alignment film 23, corona treatment is performed as necessary, and a release layer and a release layer are provided. Can be formed.

〔Manufacturing process〕
FIG. 4 is a diagram for explaining the manufacturing process of the transfer film 21. In this manufacturing process, the half-wave retardation layer alignment film 23 and the half-wave retardation layer 19 are formed on the substrate 24 (FIG. 4A). In addition, the quarter-wave retardation layer alignment film 22 and the quarter-wave retardation layer 18 are formed on the substrate 25 (FIG. 4B). In the manufacturing process, the optical characteristics of the ½ wavelength phase difference layer 19 and the ¼ wavelength phase difference layer 18 are inspected by transmitted light, respectively, and then the ½ wavelength phase difference layer 19 and ¼ wavelength are obtained by the adhesive layer 20. The phase difference layer 18 is bonded together, thereby creating the transfer film 21 (FIG. 4C). This optical characteristic includes the direction of the slow axis described above with reference to FIG. 2, the defect of the retardation layer, and the like.

  Thus, as described above with reference to FIG. 12, when an optical film is formed by sequentially laminating an alignment film and a retardation layer, the optical characteristics of the ½ wavelength retardation layer and the ¼ wavelength retardation layer are respectively set. Although it cannot be inspected, when the ½ wavelength retardation layer 19 and the ¼ wavelength retardation layer 18 are individually formed and integrated as in this embodiment, the ½ wavelength retardation layer 19 is integrated. The optical characteristics of the quarter-wave retardation layer 18 can be inspected. As a result, the quality can be improved and the optical film 13 can be produced stably.

  FIG. 5 is a diagram for explaining the manufacturing process of the optical film 13 that follows. In this manufacturing process, only the base material 24 is peeled from the transfer film 21 (FIG. 5A), and then attached to the linear polarizing plate 15 via the adhesive layer 17 (FIG. 5B), thereby supporting the manufacturing process. The optical film 13 is formed integrally with the body substrate 25 and the quarter-wave retardation layer alignment film 22 and with the half-wave retardation layer alignment film 23 left behind. In addition, you may make it provide the transfer film 21 to the manufacturing process of the optical film 13 by providing the process which peels the base material 24 in the manufacturing process of the transfer film 21, and the form which peeled the base material 24.

  Thus, the alignment film 23 for a half-wave retardation layer protects the underlying half-wave retardation layer 19 until the substrate 24 is peeled off and bonded to the linearly polarizing plate 15.

  Subsequently, as shown in FIG. 6, in this step, after the support base material 25 is peeled from the optical film 13 (FIG. 6A), the adhesive layer 14 and the separator film are arranged to have a desired size. The optical film 13 is produced by cutting. In the subsequent manufacturing process of the image display device 11, in the final process, the separator film is peeled to expose the adhesive layer 14, and the optical film 13 is attached to the panel surface of the image display panel 12 through the adhesive layer 14 (FIG. 6). (B)). In addition, you may perform the process which peels the support body base material 25 in the manufacturing process of an image display apparatus.

  As a result, the quarter-wave retardation layer alignment film 22 protects the upper quarter-wave retardation layer 18 after the substrate 25 is peeled off until it is bonded to the image display panel 12.

  FIG. 7 is a diagram showing the manufacturing process described above with reference to FIGS. 4 (A) and 4 (B). In FIG. 7, the structure in which the quarter-wave retardation layer alignment film 22 and the quarter-wave retardation layer 18 are formed on the base material 25 according to FIG. Show.

  In this manufacturing process, the base material 24 is pulled out from the supply reel 31, coated with a coating solution of an ultraviolet curable resin with a die 32, and then dried with a drying furnace 33. Note that the coating of the coating liquid is not limited to using a die, and various methods can be applied. In this manufacturing process, the roll plate 34 is a mold for molding in which the fine irregularities related to the alignment film 23 for the ½ wavelength retardation layer are formed on the peripheral side surface. In this manufacturing process, the base material 24 coated with an ultraviolet curable resin is pressed against a roll plate 34 by a pressure roller 35, and the ultraviolet curable resin is cured by irradiation with ultraviolet rays by an ultraviolet irradiation device 36 made of high-pressure mercury vapor. . Thus, in the manufacturing process, the uneven shape formed on the peripheral side surface of the roll plate 34 is transferred to the base material 24. Thereafter, the substrate 24 is peeled off together with the ultraviolet curable resin cured from the roll plate 34 by the peeling roller 37, and a coating liquid of a liquid crystal material is applied by the die 39. Then, after drying in the drying furnace 40, the liquid crystal material is cured by irradiating ultraviolet rays from the ultraviolet irradiating device 41, and taken up on the take-up reel 42. By this series of treatments, the half-wave retardation layer alignment film 23 and the half-wave retardation layer 19 are formed on the substrate 24.

  Further, in this manufacturing process, instead of the roll plate 34, a roll plate 44 used for the production of the alignment film 22 for the quarter wavelength retardation layer is arranged, and similarly, the base material 25 is pulled out from the supply reel 31, After coating the coating solution of the ultraviolet curable resin by 32, the coating liquid is dried by the drying furnace 33, and the quarter wavelength retardation layer alignment film 22 is formed by the roll plate 44. Further, after the liquid crystal material is applied and dried, the liquid crystal material is cured and wound on the take-up reel 52, whereby the quarter-wave retardation layer alignment film 22 is formed on the substrate 25. The quarter wavelength retardation layer 18 is formed.

  FIG. 8 is a diagram for explaining the bonding process of the quarter wavelength retardation layer 18 and the half wavelength retardation layer 19 (FIG. 4C). In this manufacturing process, the laminate of the base material 24, the ½ wavelength retardation layer alignment film 23, and the ½ wavelength retardation layer 19 is drawn out from the take-up reel 42, and the ultraviolet curing as an adhesive is performed by the die 55. After the application of the conductive resin, the laminate of the substrate 25, the quarter-wave retardation layer alignment film 22 and the quarter-wave retardation layer 18 which are dried by the drying furnace 56 and pulled out from the take-up reel 52, Laminate. Thereafter, the ultraviolet curable resin applied by irradiating the ultraviolet rays with the ultraviolet irradiation device 57 is cured, and then the substrate 24 is peeled off and taken up on the take-up reel 58.

  According to the above configuration, in the transfer film and the optical film, the ½ wavelength retardation layer 19 and the ¼ wavelength retardation layer 18 are laminated by the adhesive layer 20, so that the ½ wavelength retardation layer 19, The quarter-wave retardation layer 18 can be individually created, and in this way, in the case of sequentially creating an alignment film and a retardation layer, the lack of adhesion can be effectively avoided, As a result, it can be created with stability and high reliability.

  Further, by arranging the alignment films 22 and 23 according to the ½ wavelength retardation layer 19 and the ¼ wavelength retardation layer 18 to function as a protective layer, the transfer method is applied to reduce the overall thickness. In this way, damage to the quarter-wave retardation layer 18 and the half-wave retardation layer 19 can be prevented.

[Second Embodiment]
FIG. 9 is a diagram showing a manufacturing process according to the second embodiment of the present invention in comparison with FIG. This manufacturing process includes a base material 24, a ½ wavelength retardation layer alignment film 23, a laminate of the ½ wavelength retardation layer 19, and a base material 25, a ¼ wavelength retardation layer alignment film 22, The manufacturing process according to FIG. 9 is applied to the manufacturing process of the laminated body of the ¼ wavelength retardation layer 18, and the ½ wavelength retardation layer alignment film 23 and the ¼ wavelength retardation layer alignment film 22 are applied. Is made of a photo-alignment film. This embodiment has the same configuration as that of the first embodiment except that the configuration related to the photo-alignment film is different. In FIG. 9, a reference numeral is given by an example in which the alignment film 23 for half-wave retardation layer is formed of a photo-alignment film.

  That is, in this embodiment, the base material 24 is pulled out from the supply reel 31, and the coating liquid related to the photo-alignment film is applied by the die 32. In the photo-alignment film, various materials such as a photodimerization type material and a photoisomerization reaction type photo-alignment material can be applied. In the coating method, various methods can be applied. In this step, the coating liquid is dried by the drying furnace 33, and then irradiated with linearly polarized ultraviolet rays in a predetermined polarization direction from the ultraviolet irradiation device 60, thereby forming the alignment film 23 for a ½ wavelength retardation layer. To do. Subsequently, in this step, after the liquid crystal material is applied by the die 39, the liquid crystal material is dried by the drying furnace 40, the liquid crystal material is cured by the ultraviolet irradiation by the ultraviolet irradiation device 41, and wound on the take-up reel 42. Similarly, a quarter-wave retardation layer alignment film 22 is formed.

  Even when the alignment film is formed by applying the photo-alignment technique as in this embodiment, the same effect as that of the first embodiment can be obtained.

[Third Embodiment]
By the way, like the embodiment described above, after the 1/2 wavelength retardation layer 19 and the 1/4 wavelength retardation layer 18 are laminated, the 1/2 wavelength retardation layer 19 is formed for lamination with the linearly polarizing plate 15. When peeling the base material 24 on the side, if the base material 25 on the quarter-wave retardation layer 18 side is peeled off, it is difficult to bond to the linear polarizing plate 15. Therefore, in this embodiment, when the substrate 25 on the ¼ wavelength retardation layer 19 side is peeled off by applying the treatment for reinforcing the adhesion to the substrate 25 on the ¼ wavelength retardation layer 18 side, The base material 25 on the quarter wavelength retardation layer 18 side is prevented from peeling off.

  Specifically, as shown in FIG. 10, an adhesion enhancement layer 25 </ b> A is formed on the surface of the support substrate 25. Here, the reinforcing layer 25 </ b> A is formed by corona treatment of the support base material 25.

  As shown in FIG. 11, instead of the reinforcing layer 25 </ b> A on the adhesion side on the substrate 25 side or in addition to the reinforcing layer 25 </ b> A, on the substrate 24 side on the 1/2 wavelength retardation layer 19 side, An adhesion reducing layer 24A may be provided. Note that a release layer applied to the transfer method can be applied to the reduction layer 24A. In the release layer, for example, silicon resin (organosilicon-based polymer compound), fluorine-based resin, melamine resin, epoxy resin, or other appropriate resin (acrylic resin, cellulose-based resin, polyester resin). Etc.) can be applied.

  In this embodiment, the same effect as that of the above-described embodiment can be obtained by providing the adhesion strengthening layer 25A and the adhesion reducing layer 24A on the substrate 25 side and the substrate 24 side. Further, in this case, when the base 24 on the 1/2 wavelength retardation layer 19 side is peeled off by the adhesion strengthening layer 25A and the adhesion reducing layer 24A, the base on the 1/4 wavelength retardation layer 18 side. 25 can be prevented from peeling off and can be more stably produced.

Other Embodiment
The specific configuration suitable for the implementation of the present invention has been described in detail above, but the present invention can be variously modified and further combined with the configuration of the above-described embodiment without departing from the spirit of the present invention. .

  That is, in the above-described embodiment, the case where an optical film is produced by continuous processing of a long film material has been described. However, the present invention is not limited to this, and can be widely applied to the case of producing by processing a single wafer. it can.

2, 15A, 24, 25 Base material 3, 23 Alignment film for 1/2 wavelength retardation layer (alignment film)
4, 19 1/2 wavelength retardation layer 5, 22 Alignment film for 1/4 wavelength retardation layer (alignment film)
6, 18 1/4 wavelength retardation layer 7, 16 1/4 wavelength plate 11, 71 Image display device 12 Image display panel 13, 73 Optical film 14 Adhesive layer 15 Linearly polarizing plate 15B Optical functional layer 17, 20 Adhesive layer 21 Transfer film 31 Supply reel 32, 39 Die 33, 40 Drying furnace 34, 44 Roll plate 35, 37 Roller 36, 41 Ultraviolet irradiation device 42 Take-up reel

Claims (10)

A transfer body for an optical film comprising a support substrate and a transfer layer,
The transfer layer is
From the support substrate side,
An alignment film for a quarter wavelength retardation layer according to a quarter wavelength retardation layer;
A quarter-wave retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation-regulating force of the quarter-wave retardation layer alignment layer and that imparts a quarter-wave phase difference to transmitted light; ,
An adhesive layer;
A ½ wavelength retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation regulating force of the alignment film for the ½ wavelength retardation layer, and that imparts a retardation of ½ wavelength to transmitted light;
An alignment film for the ½ wavelength retardation layer is provided,
The transfer member for an optical film, wherein the half-wave retardation layer and the quarter-wave retardation layer are bonded together by the adhesive layer. A substrate made of a transparent film;
An optical functional layer of a linearly polarizing plate that functions as a linearly polarizing plate;
A quarter wave plate is laminated,
The optical film in which the quarter-wave plate is formed by the transfer layer of the optical film transfer body according to claim 1. A substrate made of a transparent film;
An optical functional layer of a linearly polarizing plate that functions as a linearly polarizing plate;
A quarter wave plate is laminated,
The quarter-wave plate is
An alignment film for a quarter wavelength retardation layer according to a quarter wavelength retardation layer;
A quarter-wave retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation-regulating force of the quarter-wave retardation layer alignment layer and that imparts a quarter-wave phase difference to transmitted light; ,
An adhesive layer;
A ½ wavelength retardation layer that is formed of a liquid crystal material oriented in a desired direction by the orientation regulating force of the alignment film for the ½ wavelength retardation layer, and that imparts a retardation of ½ wavelength to transmitted light;
An alignment film for the ½ wavelength retardation layer is provided,
The optical film in which the half-wave retardation layer and the quarter-wave retardation layer are bonded together by the adhesive layer. The image display apparatus which has arrange | positioned the optical film of Claim 2 or Claim 3 on the panel surface of an image display panel. An alignment film creating step for a 1/2 wavelength retardation layer for creating an alignment film for a 1/2 wavelength retardation layer according to a 1/2 wavelength retardation layer on a first substrate;
A ½ wavelength retardation layer is formed that imparts a phase difference of ½ wavelength to transmitted light by the alignment of the liquid crystal material by the alignment regulating force of the alignment film for the ½ wavelength retardation layer. A retardation layer creating process;
An alignment film creating step for a quarter wavelength retardation layer for creating an alignment film for a quarter wavelength retardation layer according to a quarter wavelength retardation layer on a second substrate;
A quarter wavelength retardation layer is formed that imparts a phase difference corresponding to a quarter wavelength to transmitted light by the orientation of the liquid crystal material by the orientation regulating force of the alignment layer for the quarter wavelength retardation layer. A retardation layer creating process;
The manufacturing method of the transcription | transfer body for optical films provided with the bonding process which bonds together the said 1/2 wavelength phase difference layer and a 1/4 wavelength phase difference layer with a contact bonding layer. Further, the first substrate is peeled from the alignment film for 1/2 wavelength retardation layer, and the alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength The manufacturing method of the transcription | transfer body for optical films of Claim 5 provided with the peeling process of the 1st base material which forms the laminated body of retardation layer, the alignment film for 1/4 wavelength phase difference layers, and a 2nd base material. . An optical film manufacturing method using an optical film transfer body manufactured by the optical film transfer body manufacturing method according to claim 5,
The first substrate is peeled from the alignment film for 1/2 wavelength retardation layer, and the alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength position A phase difference layer, an alignment film for a quarter wavelength phase difference layer, a first substrate peeling step for forming a laminate of a second substrate,
Alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength retardation layer, 1/4 wavelength retardation layer alignment film, laminate of second substrate A process for producing an optical film, comprising: a step of bonding to a linear polarizing plate to be bonded to a linear polarizing plate. The optical film according to claim 7, further comprising a second base material peeling step for peeling the second base material from the laminate that is pasted to the linear polarizing plate in the step of sticking to the linear polarizing plate. Manufacturing process. An optical film manufacturing method using an optical film transfer body manufactured by the optical film transfer body manufacturing method according to claim 6,
Alignment film for 1/2 wavelength retardation layer, 1/2 wavelength retardation layer, adhesive layer, 1/4 wavelength retardation layer, 1/4 wavelength retardation layer alignment film, laminate of second substrate A process for producing an optical film comprising a step of bonding to a linearly polarizing plate to be bonded to a linearly polarizing plate. 10. The optical film according to claim 9, further comprising a second base material peeling step for peeling the second base material from the laminate bonded to the linear polarizing plate in the step of sticking to the linear polarizing plate. Manufacturing process.

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