JP2018151627A - 位相差フィルム及びその製造方法、円偏光板並びに画像表示装置 - Google Patents
位相差フィルム及びその製造方法、円偏光板並びに画像表示装置 Download PDFInfo
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Abstract
Description
本発明の位相差フィルムは、押出成形などによって連続的に得られる長尺状の樹脂フィルムを斜め方向に延伸して得られるため、長尺状(無限長状)の形態を有しており、通常、ロール体の形態で保存・運搬される。
(式中、nxはフィルムの遅相軸方向の屈折率、ny進相軸方向の屈折率、dはフィルムの厚みを示す)。
本発明の位相差フィルムは、前記光学特性を有する延伸樹脂フィルムであればよい。樹脂フィルムを構成する樹脂の種類は特に限定されず、例えば、オレフィン系樹脂、スチレン系樹脂、アクリル系樹脂、ポリエステル樹脂、ポリカーボネート樹脂、ポリアミド樹脂などが挙げられる。これらの樹脂は、単独で又は二種以上組み合わせて使用できる。これらのうち、スチレン系樹脂、ポリエステル樹脂、ポリカーボネート樹脂が好ましく、フルオレン骨格を有するポリエステル樹脂(フルオレン含有ポリエステル樹脂)を含むのが特に好ましい。
フルオレン骨格を有するポリエステル樹脂(フルオレン含有ポリエステル樹脂)は、ジオール成分及びジカルボン酸成分の少なくとも一方の成分がフルオレン骨格を含んでいればよい。
フルオレン含有ポリエステル樹脂を構成するジオール成分がフルオレン骨格を含む場合、ジオール成分は、例えば、重合成分として、下記式(1)で表されるフルオレンジオールを含んでいてもよい。
フルオレン含有ポリエステル樹脂を構成する重合成分である他のジオール成分には、脂肪族ジオール、ポリアルキレングリコール、脂環族ジオール、複素脂環族ジオール、芳香族ジオールなどが含まれる。
フルオレン含有ポリエステル樹脂を構成するジカルボン酸成分がフルオレン骨格を含む場合、ジカルボン酸成分は、例えば、重合成分として、下記式(2−1)及び/又は(2−2)で表されるフルオレンジカルボン酸を含んでいてもよい。
フルオレン含有ポリエステル樹脂を構成する重合成分である他のジカルボン酸成分には、脂肪族ジカルボン酸、脂環族ジカルボン酸、芳香族ジカルボン酸などが含まれる。
前記フルオレン含有ポリエステル樹脂は、フルオレン骨格を有していればよいが、フルオレン骨格に加えて、脂肪族炭化水素環、脂環族炭化水素環及び複素脂環族炭化水素環、特に脂肪族炭化水素環及び脂環族炭化水素環を有するポリエステル樹脂が好ましい。
フルオレン含有ポリエステル樹脂の製造方法は、原料としてのジオール成分とジカルボン酸成分とを反応させればよく、慣用の方法、例えば、エステル交換法や直接重合法などの溶融重合法;溶液重合法;界面重合法などで調製でき、溶融重合法が好ましい。なお、反応は、重合方法に応じて、溶媒の存在下又は非存在下で行ってもよい。
本発明の位相差フィルムは、本発明の効果を妨げない限り、種々の添加剤を添加してもよい。添加剤としては、例えば、可塑剤、難燃剤、安定剤、帯電防止剤、充填剤、発泡剤、消泡剤、滑剤、離型剤、易滑性付与剤が挙げられ、可塑剤としては、エステル類、フタル酸系化合物、エポキシ化合物、スルホンアミド類などが挙げられ、難燃剤としては、無機系難燃剤、有機系難燃剤、コロイド難燃物質などが挙げられ、安定剤としては、酸化防止剤、紫外線吸収剤、熱安定剤などが挙げられ、充填剤としては、酸化物系無機充填剤、非酸化物系無機充填剤、金属粉末などが挙げられ、離型剤としては、天然ワックス類、合成ワックス類、直鎖脂肪酸又はその金属塩、酸アミド類などが挙げられ、易滑性付与剤としては、シリカ、酸化チタン、炭酸カルシウム、クレー、マイカ、カオリンなどの無機微粒子;(メタ)アクリル系樹脂、スチレン系樹脂(架橋ポリスチレン樹脂など)などの有機微粒子などが挙げられる。これらの添加剤は、単独で又は2種以上組み合わせて使用してもよい。
本発明の位相差フィルムの製造方法は、樹脂フィルムを斜め方向に延伸する斜め延伸工程を含む。
斜め延伸工程において、樹脂フィルムを斜め方向に延伸する方法としては、例えば、同時二軸式の斜め延伸法、湾曲式の斜め延伸法などが挙げられる。
[式中、Rは、前記延伸倍率であり、tは、延伸ゾーンである湾曲部を通過するのに要した時間(分)である]。
本発明の位相差フィルムの製造方法は、前記斜め延伸工程の前工程として、前記斜め延伸工程に供される樹脂フィルムの製膜工程をさらに有していてもよい。
本発明の位相差フィルムは、1/4波長位相差フィルムとして、偏光子(偏光板)とそのまま貼り合せることで円偏光板を形成できる。偏光子としては、通常、ポリビニルアルコール(PVA)フィルムが使用される。
示差走査熱量計(セイコーインスツル(株)製「DSC 6220」)を用いて、JIS K 7121に準拠して、ガラス転移温度Tgを測定した。
測厚計((株)ミツトヨ製「マイクロメーター」)により測定した。なお、平均厚みは、フィルムの長手方向に対して、チャック間を等間隔に3点測定し、その平均値を算出した。
逆波長分散性フィルムの面内位相差R0(550)と位相差の波長分散特性R0(450)/R0(550)は、位相差計(大塚電子(株)製「RETS−100」)を用いて、波長450nm及び550nmで測定した。測定値はフィルム厚さ50μmに換算した値を示す。
位相差計(大塚電子(株)製「RETS−100」)を用いて、配向角を測定した。
(共重合ポリエステル樹脂の重合)
9,9−ビス(4−(2−ヒドロキシエトキシ)フェニル)フルオレン(大阪ガスケミカル(株)製)0.6モル、エチレングリコール(関東化学(株)製)2.4モル、1,4−シクロヘキサンジカルボン酸(日興リカ(株)製)1.0モルを反応槽に投入し、溶解させた後、エステル化触媒として、酢酸マンガン・4水和物(関東化学(株)製)0.05重量部及び酢酸カルシウム・1水和物(関東化学(株)製)0.1重量部を投入し、撹拌しながら常法に従って、230℃まで徐々に加熱し、エステル交換反応を行った。所定量のメタノールを系外に抜き出した後、重合触媒の酸化ゲルマニウム(関東化学(株)製)0.2重量部と着色防止剤のトリメチルリン酸(関東化学(株)製)0.2重量部を投入し、減圧しながら加熱し、270℃、0.13KPaに到達後、所定のトルクに達するまで撹拌を続けた。重合物は缶底より抜出し、水中をくぐらせたストランドを切断して樹脂ペレットを得た。得られた樹脂のガラス転移温度を測定した。
Tダイを装着した二軸押出装置(スクリュー径40mm、L/D=32)に、得られた樹脂ペレットを供給して、シリンダー温度260℃で、有効幅500mmのフィルムを押出してロールに巻き取った。厚さは150μmであった。
前記フィルムのロールを湾曲式のテンター式延伸装置を用いて、入口のフィルム幅143mm、出口のフィルム幅396mm(延伸倍率は3.9倍)、クリップの移動速度1.2m/分(延伸速度は209%/分)、延伸温度120℃、ガイドレールの湾曲部の角度θ45°で斜め延伸を行った。延伸後の得られたフィルムの位相差、配向角及び厚みを測定した。
延伸前のフィルムの厚みや延伸条件を変えた以外は実施例1と同様にして、逆波長分散フィルムを製造し、位相差、配向角及び厚みを測定した。
9,9−ビス(4−(2−ヒドロキシエトキシ)フェニル)フルオレン(大阪ガスケミカル(株)製)0.8モル、エチレングリコール(関東化学(株)製)2.2モル、トランス体比率が98モル%の1,4−シクロヘキサンジカルボン酸ジメチル1.0モルを用いる以外は実施例1と同様の方法で重合を行い、樹脂を調製した。さらに、延伸前のフィルムの厚みや延伸条件を変えた以外は実施例1と同様にして、逆波長分散フィルムを製造し、位相差、配向角及び厚みを測定した。
2…延伸ゾーン
3…巻取側
Claims (15)
- 長尺状の斜め延伸樹脂フィルムで形成され、長尺方向に対する遅相軸が40〜50°であり、波長550nmにおける面内位相差R0(550)が100〜160nmであり、波長450nmにおける面内位相差R0(450)と前記面内位相差R0(550)との比率R0(450)/R0(550)が0.8以上1未満である位相差フィルム。
- ロール体である請求項1記載の位相差フィルム。
- 延伸樹脂フィルムが延伸ポリエステル樹脂フィルムである請求項1又は2記載の位相差フィルム。
- 延伸ポリエステル樹脂フィルムがフルオレン骨格を有するフルオレン含有ポリエステル樹脂を含む請求項1〜3のいずれかに記載の位相差フィルム。
- フルオレン含有ポリエステル樹脂が脂環族炭化水素環をさらに有する請求項4記載の位相差フィルム。
- フルオレン含有ポリエステル樹脂のガラス転移温度が90〜145℃である請求項4又は5記載の位相差フィルム。
- 平均厚みが20〜100μmである請求項1〜6のいずれかに記載の位相差フィルム。
- 樹脂フィルムを斜め方向に延伸する斜め延伸工程を含む請求項1〜7のいずれかに記載の位相差フィルムの製造方法。
- テンター式横延伸装置のガイドレールを湾曲させて斜め方向に延伸する請求項8記載の製造方法。
- 延伸速度が200〜800%/分である請求項8又は9記載の製造方法。
- 延伸倍率が2〜5倍である請求項8〜10のいずれかに記載の製造方法。
- 押出成形又は溶液キャスト成形により樹脂フィルムを得る製膜工程をさらに含む請求項8〜11のいずれかに記載の製造方法。
- 請求項1〜7のいずれかに記載の位相差フィルムと偏光子とを積層した円偏光板。
- 請求項13記載の円偏光板を備えた画像表示装置。
- 有機ELディスプレイである請求項14記載の画像表示装置。
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JP7016976B1 (ja) | 2021-03-16 | 2022-02-07 | 大阪ガスケミカル株式会社 | 位相差フィルム |
WO2022196685A1 (ja) * | 2021-03-16 | 2022-09-22 | 大阪ガスケミカル株式会社 | 位相差フィルム |
JP2022142679A (ja) * | 2021-03-16 | 2022-09-30 | 大阪ガスケミカル株式会社 | 位相差フィルム |
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