JP2019028133A - Method for manufacturing laminate and method for manufacturing composite polarizing plate - Google Patents

Abstract

To provide a method for manufacturing a laminate by which degradation in the product performance of a laminate can be suppressed and a conveyance failure of a laminate can be suppressed in the process of manufacturing a laminate, and a method for manufacturing a composite polarizing plate using the above laminate.SOLUTION: The method for manufacturing a laminate includes: a step (a) of preparing a first laminate part including a first substrate layer, a first alignment layer and a first retardation layer in this order, and a second laminate part including a second substrate layer, a second alignment layer and a second retardation layer in this order; a step (b1) of removing a first end part at both ends in a width direction of the first laminate part; and a step (c) of bonding the first retardation layer side of the first laminate part after the first end part is removed to the second retardation layer side of the second laminate part via an adhesive layer.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a laminate manufacturing method and a composite polarizing plate manufacturing method.

  Organic EL display devices using organic light-emitting diodes (OLEDs) are not only lighter and thinner than liquid crystal display devices, but also have high image quality such as a wide viewing angle, fast response speed, and high contrast. Since it can be realized, it is used in various fields such as smartphones, televisions, and digital cameras. In an organic EL display device, it is known to improve antireflection performance by using a circularly polarizing plate or the like in order to suppress a decrease in visibility due to reflection of external light.

  Patent Documents 1 and 2 describe a structure in which an alignment layer and a retardation layer are laminated as an optical film such as a circularly polarizing plate applied to an image display panel of an organic EL display device or a liquid crystal display device.

Japanese Patent Laid-Open No. 2015-21975 Japanese Patent Laid-Open No. 2015-21976

  The optical film is usually produced by processing while continuously unwinding and transporting a long film. Film defects that occur during film transport may affect product performance as an optical film or cause film transport failure.

  The present invention suppresses a decrease in product performance of a laminated body during the production of the laminated body, and a laminated body manufacturing method capable of suppressing poor conveyance of the laminated body, and a composite polarizing plate using the laminated body It aims at providing the manufacturing method of this.

This invention provides the manufacturing method of the laminated body shown below, and the manufacturing method of a composite polarizing plate.
[1] A first laminated portion including a first base material layer, a first alignment layer, and a first retardation layer in this order, and a second base material layer, a second alignment layer, and a second retardation layer in this order. A step (a) of preparing two stacked portions;
A step (b1) of removing first ends which are both ends in the width direction of the first stacked portion;
The step (c) of bonding the first retardation layer side of the first laminated portion after removal of the first end portion and the second retardation layer side of the second laminated portion via an adhesive layer. And a method for producing a laminate.

  [2] Further, after the step (a) and before the step (c), the method includes a step (b2) of removing second end portions that are both ends in the width direction of the second stacked portion. The manufacturing method of the laminated body as described in [1].

[3] A step (d) of preparing the laminate manufactured by the method for manufacturing a laminate according to [1] or [2];
By peeling the first release layer including the first base material layer or the second base material layer included in the laminate, the laminate is laminated other than the first release layer and the first release layer. A step (e) of separating into a retardation layer;
Preparing a polarizing layer (f);
The polarizing layer and the laminated retardation layer are pasted so that the polarizing layer is disposed on the exposed surface side of the laminated retardation layer exposed by peeling off the first release layer in the step (e). A method of producing a composite polarizing plate, comprising the step of combining (g).

[4] In the step (g), the polarizing layer and the laminated retardation layer are bonded via a polarizing layer adhesive layer,
The production of the composite polarizing plate according to [3], wherein the polarizing layer adhesive layer is provided on the polarizing layer prepared in the step (f) or on the exposed surface side of the laminated retardation layer. Method.

  [5] In the cross section in the width direction of the laminated retardation layer bonded to the polarizing layer obtained in the step (g), the positions in the width direction of both ends of the polarizing layer adhesive layer are the polarizing layer. Of the outermost end of the laminated retardation layer bonded to the polarizing layer and the position of the outermost end of the laminated retardation layer bonded to the polarizing layer, or inward of these positions [4 ] The manufacturing method of the composite polarizing plate of description.

[6] The first release layer includes
[I] including the first base material layer and the first alignment layer included in the laminate,
[Ii] The first base material layer included in the laminate.
[Iii] including the second base material layer and the second alignment layer included in the laminate, and
[Iv] The second base material layer included in the laminate.
The manufacturing method of the composite polarizing plate in any one of [3]-[5] which is any of these.

[7] Further, after the step (g), the method includes a step (j) of peeling the second release layer included in the laminated retardation layer bonded to the polarizing layer,
In the case where the first release layer is the [i] or [ii], the second release layer includes the second base material layer and the second base layer included in the stacked retardation layer bonded to the polarizing layer. It is the second base material layer that includes two orientation layers or is included in the laminated retardation layer bonded to the polarizing layer,
In the case where the first release layer is the [iii] or [iv], the second release layer includes the first base material layer and the first base layer included in the laminated retardation layer bonded to the polarizing layer. The manufacturing method of the composite polarizing plate as described in [6] which is a said 1st base material layer contained in the said lamination | stacking phase difference layer bonded to the said polarizing layer including 1 orientation layer.

  [8] Furthermore, the process (k) which forms the adhesive layer for composite polarizing plates in the surface exposed by peeling a 2nd peeling layer from the said laminated phase difference layer bonded by the said polarizing layer in process (j) (k). The manufacturing method of the composite polarizing plate as described in [7] which has.

  According to the method for manufacturing a laminate of the present invention, it is possible to suppress deterioration in product performance of the laminate and suppress poor conveyance of the laminate when the laminate is manufactured.

(A)-(D) are schematic sectional drawings which show typically an example of each manufacturing process in the manufacturing method of the laminated body of this invention. (A)-(E) are schematic sectional drawings which show typically the other example of each manufacturing process in the manufacturing method of the laminated body of this invention. It is a schematic sectional drawing which shows typically an example of the composite polarizing plate manufactured with the manufacturing method of the composite polarizing plate of this invention.

<Method for producing laminate>
The method for producing a laminate of the present invention is a method for producing a laminate that can be suitably used for optical applications such as a composite polarizing plate described later, and includes a first substrate layer, a first alignment layer, and a first layer. A step (a) of preparing a first stacked unit including the retardation layer in this order, a second stacked unit including the second base material layer, the second alignment layer, and the second retardation layer in this order; A step (b1) of removing the first end that is both ends in the width direction of the first portion, the first retardation layer side of the first stacked portion after the removal of the first end, and the second retardation of the second stacked portion (C) which bonds the layer side through an adhesive layer. Moreover, you may have the process (b2) of removing the 2nd edge part which is the both ends of the width direction of a 2nd lamination | stacking part after the process (a) and before the process (c).

  According to said manufacturing method, while manufacturing the laminated body, it can suppress that the product performance of a laminated body falls, and can suppress the conveyance defect of a laminated body. Specifically, when transporting the laminated body, the width direction end of the first alignment layer or the second alignment layer, or the width direction end of the first retardation layer or the second retardation layer is adjacent. It is possible to suppress a phenomenon called “floating” that is lifted off from the layer. Thereby, the conveyance failure of a laminated body can be suppressed and it can suppress that the product performance of a laminated body falls.

  The cause of “floating” that occurs when the laminate is transported is estimated as follows. In other words, if there are deformed parts such as undulations and warping at both ends in the width direction of the first and second stacks, the flow during transport of the stack deteriorates and wrinkles occur at both ends in the width direction of the stack. It is easy to cause troubles such as. It is considered that the above-described floating occurs at the end portion in the width direction of the first or second alignment layer or the end portion in the width direction of the first or second retardation layer due to such a problem. In the manufacturing method of the laminated body of this invention, the process (b1) which removes at least the width direction both ends of a 1st laminated part is provided, and generation | occurrence | production of an above-described float is suppressed by removing the deformation | transformation part in a 1st laminated part. And the deterioration of the flow at the time of conveyance of a laminated body and generation | occurrence | production of the wrinkle to the width direction both ends of a laminated body are suppressed, and it suppresses that the product performance of a laminated body falls.

  Hereinafter, a preferred embodiment of a method for producing a laminate according to the present invention will be described with reference to the drawings.

[First Embodiment (Manufacturing Method of Laminate 50)]
Drawing 1 (A)-(D) is an outline sectional view showing typically each manufacturing process in a manufacturing method of a layered product of this embodiment. In the figure, W represents the width direction. In the manufacturing method of the laminated body 50 of this embodiment, first, as shown to FIG. 1 (A), the 1st laminated part which contains the 1st base material layer 11, the 1st orientation layer 12, and the 1st phase difference layer 13 in this order. 10 and a second laminated portion 20 including a second base material layer 21, a second alignment layer 22, and a second retardation layer 23 in this order as shown in FIG. 1B (step (a)). . The 1st lamination | stacking part 10 and the 2nd lamination | stacking part 20 are elongate film-like objects, The process mentioned later is performed, conveying the 1st lamination | stacking part 10 and the 2nd lamination | stacking part 20 continuously. The following width direction means the direction orthogonal to the length direction of a film-like thing.

Next, about the 1st lamination | stacking part 10 shown to FIG. 1 (A), the width direction both ends are cut | disconnected by the dotted line X1, and the 1st edge part 14 outside a width direction is removed from the dotted line X1 (process (b1)). ). Thereby, as shown in FIG. 1 (C), the first laminated portion having the first base layer 11b ₁ , the first alignment layer 12b ₁ and the first retardation layer 13b ₁ after the first end portion 14 is removed. 10b ₁ (hereinafter, also referred to as “first stacked portion 10b ₁ ”) is obtained. Thereafter, as shown in FIG. 1 (D), the first retardation layer 13b ₁ side of the first laminated portion 10b ₁ and the second retardation layer 23 side of the second laminated portion 20 are connected to the adhesive layer 30. Then, the laminated body 50 is obtained (step (c)).

  In the first stacked unit 10, the lengths in the width direction of the first base material layer 11, the first alignment layer 12, and the first retardation layer 13 may be the same or different from each other. For example, the first laminated unit 10 has the longest length in the width direction of the first base material layer 11, and the lengths in the width direction of the first alignment layer 12 and the first retardation layer 13 are the first base material layer 11. As shown in FIG. 1 (A), the first laminated portion 10 has a length in the width direction of the first base material layer 11 and the first alignment layer. 12 and the first retardation layer 13 may be shortened in this order. In this case, in the cross section in the width direction of the first stacked unit 10, both ends of the layer having a relatively short length in the width direction are located inside the width direction of both ends of the layer having a relatively long length in the width direction. Is preferred.

  Also in the second stacked unit 20, the lengths in the width direction of the second base material layer 21, the second alignment layer 22, and the second retardation layer 23 may be the same as in the first stacked unit 10. , May be different from each other. For example, in the second stacked unit 20, the length in the width direction of the second base material layer 21 is the longest, and the length in the width direction of the second alignment layer 22 and the second retardation layer 23 is the second base material layer 21. The length in the width direction of the second stacked portion 20 may be the second base material layer 21 and the second alignment layer as shown in FIG. 1B. 22 and the second retardation layer 23 may be shortened in this order. In this case, in the cross section in the width direction of the second stacked unit 20, both ends of the layer having a relatively short length in the width direction are located inside the width direction of both ends of the layer having a relatively long length in the width direction. Is preferred.

  The position of the dotted line X1 in FIG. 1 (A) indicates that when there are deformed portions such as undulations and warping at both ends in the width direction of the first laminated portion 10, all of the deformed portions are outside of the dotted line X1 in the width direction. It is preferable to determine that it is included. For example, when the first alignment layer and the first retardation layer are a coating film formed on the first base material layer, the deformed portion in the first laminated portion 10 is a deformed portion existing in the first base material layer 11. Can also cause. Therefore, the position of the dotted line X1 is preferably determined so that all of the deformed portion formed in the first base material layer is included in the first end portion 14, and the first alignment layer 12 formed on the deformed portion. In addition, the end portion of the first retardation layer 13 is also preferably removed as the first end portion 14.

  The position of the dotted line X1 that defines the region of the first end portion 14 is, for example, a region that is usually 0.5 cm or more inward in the width direction from the end portion of the first stacked portion 10 that is located on the outermost side in the width direction. It is preferably an area of 0 cm or more, more preferably an area of 1.5 cm or more, and usually an area of 20 cm or less, preferably an area of 15 cm or less, and an area of 10 cm or less. Is more preferable. The distance from the end of the first stacked unit 10 located on the outermost side in the width direction to the position of the dotted line X1 may be the same at both ends in the width direction of the first stacked unit 10 or may be different from each other.

As described above, the first end portion 14 may include only a part of the layers of the first stacked portion 10 as long as the first end portion 14 includes the deformed portions at both ends in the width direction of the first stacked portion 10. The first end portion 14 may not include the end portions of all the layers (the first base material layer 11, the first alignment layer 12, and the first retardation layer 13) constituting the first stacked portion 10. . However, in general, in a laminate in which a plurality of layers are laminated, the adhesion between the layers tends to be unstable at the end portions thereof, and therefore, in the first laminated portion 10, between the layers at both end portions in the width direction. The adhesive strength of the steel becomes unstable, and the above-described floating tends to occur. Therefore, first end portion 14 preferably includes all of the layers constituting the first laminated portion, the first laminated portion 10b ₁ obtained after removal of the first end portion 14, shown in FIG. 1 (C) as such, it is preferable that the first base layer 11b _1, the length of the first alignment layer 12b ₁ and the first width direction of the retardation layer 13b ₁ are the same. The layers included in the first end portion 14 removed from both ends in the width direction of the first stacked unit 10 may be the same as each other or different from each other.

The adhesive layer 30 for bonding the first retardation layer 13b ₁ side of the first laminated portion 10b ₁ after the removal of the first end portion 14 to the second retardation layer 23 side of the second laminated portion 20 is the first layer. By applying an adhesive or pressure-sensitive adhesive forming the adhesive layer 30 to one or both of the retardation layer 13b ₁ and the second retardation layer 23, or by transferring the adhesive layer 30 formed on a support film or the like Can be formed. The adhesive layer 30 is preferably formed so as not to protrude from both ends in the width direction of the first laminated portion 10b ₁ and the second laminate section 20, both widthwise end portions of the adhesive layer 30, the first laminated portion 10b ₁ It is preferable that it is the same as the outermost side in the width direction and the outermost side in the width direction of the second stacked portion 20, or is located inward in the width direction. The adhesive layer 30, by forming so as not to protrude from both ends in the width direction of the first laminated portion 10b ₁ and the second laminated portion 20, during transport of the stack 50, the adhesive layer from the both widthwise end portions of the stack 50 It is possible to prevent the adhesive or pressure-sensitive adhesive forming 30 from protruding and contaminating the conveyance path.

  Since the laminated body 50 obtained as described above has the deformed portions at both ends in the width direction of the first laminated portion 10 removed, deformation at both ends in the width direction of the laminated body 50 is suppressed. When the body 50 is transported, it is possible to suppress the floating of the layer forming the stacked body 50. In the present embodiment, it is possible to suppress the occurrence of floating in the layer forming the stacked body 50, particularly when undulation or warpage is generated at both ends in the width direction of the first stacked unit 10.

[Second Embodiment (Manufacturing Method of Laminate 51)]
2A to 2E are schematic cross-sectional views schematically showing each manufacturing process in the method for manufacturing a laminate according to this embodiment. In the figure, W represents the width direction. In the present embodiment, a method for manufacturing the stacked body 51 shown in FIG. The manufacturing method of the stacked body 51 of the present embodiment includes the step (b2) of removing the second end portions 24 (FIG. 2B) that are both ends of the second stacked portion 20 in the width direction. This is different from the embodiment. Below, the same code | symbol is attached | subjected about the same member as what was demonstrated in 1st Embodiment, and the description is abbreviate | omitted.

In the manufacturing method of the laminated body 51 of this embodiment, the 1st laminated part 10 and the 2nd laminated part 20 are prepared similarly to 1st Embodiment (FIG. 1 (A) and (B)) (process (a 2 (A) and 2 (B)), both ends in the width direction of the first laminated portion 10 are cut by a dotted line X1, and the first end portion 14 is removed (step (b1)), and FIG. first obtain a laminated portion 10b ₁ shown). Next, in the present embodiment, with respect to the second stacked unit 20 shown in FIG. 2B, both ends in the width direction are cut by a dotted line X2, and the second end 24 outside the width direction from the dotted line X2 is removed. (Step (b2)). Thereby, as shown in FIG. 2D, the second laminated portion having the second base layer 21b ₂ , the second alignment layer 22b ₂ and the second retardation layer 23b ₂ after the second end portion 24 is removed. 20b ₂ (hereinafter sometimes referred to as “second stacked portion 20b ₂ ”) is obtained. Thereafter, as shown in FIG. 2E, the first retardation layer 13b ₁ side of the first stacked portion 10b ₁ and the second retardation layer 23b ₂ side of the second stacked portion 20b ₂ are connected to the adhesive layer 30. (Step (c)) to obtain a laminate 51.

  The position of the dotted line X2 in FIG. 2B is that when there are deformed portions such as undulations and warping at both ends in the width direction of the second stacked portion 20, all of the deformed portions are outside of the dotted line X2 in the width direction. It is preferred to determine that they are included. For example, when the second alignment layer and the second retardation layer are coating films formed on the second base material layer, the deformed portion in the second laminated portion 20 is a deformed portion existing in the second base material layer 21. Can also cause. Therefore, the position of the dotted line X2 is preferably determined so that all the deformed portions formed in the second base material layer are included in the second end portion 24, and the second alignment layer formed on the deformed portions. 22 and the end portions of the second retardation layer 23 are also preferably removed as the second end portions 24.

  The position of the dotted line X2 that defines the region of the second end portion 24 is, for example, a region that is usually 0.5 cm or more inward in the width direction from the end portion located on the outermost side in the width direction of the second stacked portion 20. It is preferably an area of 0 cm or more, more preferably an area of 1.5 cm or more, and usually an area of 20 cm or less, preferably an area of 15 cm or less, and an area of 10 cm or less. Is more preferable. The distance from the end located on the outermost side in the width direction of the second stacked unit 20 to the position of the dotted line X2 may be the same at both ends of the second stacked unit 20 or may be different from each other.

The second end portion 24 may include only a part of the layer of the second stacked portion 20 as long as it includes a deformed portion at both ends in the width direction of the second stacked portion 20. 24 may not include the end portions of all the layers (second base material layer 21, second alignment layer 22, and second retardation layer 23) constituting the second stacked portion 20. However, in general, in a laminate in which a plurality of layers are laminated, the adhesion between the layers tends to be unstable at the end portions thereof, and therefore, in the second laminated portion 20, between the layers at both end portions in the width direction. The adhesive strength of the steel becomes unstable, and the above-described floating tends to occur. Therefore, it is preferable that the second end portion 24 includes all the layers constituting the second stacked portion, and the second stacked portion 20b ₂ obtained after removing the second end portion 24 is shown in FIG. as such, it is preferred length of the second substrate layer 21b _2, the second alignment layer 22b ₂ and the second width direction of the retardation layer 23b ₂ are the same. The layers included in the second end portion 24 removed from both ends in the width direction of the second stacked unit 20 may be the same as each other or different from each other. Further, the first laminated portion 10b ₁ after the first end portion 14 is removed, and the second laminated portion 20b ₂ after the second end portion 24 is removed, the length in the width direction may be the same as each other , May be different from each other.

In the present embodiment, the first retardation layer 13b ₁ side of the first laminated portion 10b ₁ after the first end portion 14 is removed and the second retardation layer of the second laminated portion 20b ₂ after the second end portion 24 is removed. 23b ₂ side is bonded through the adhesive layer 30. The adhesive layer 30 is formed on one or both of the first retardation layer 13b ₁ and the second retardation layer 23b ₂ by applying an adhesive or pressure-sensitive adhesive that forms the adhesive layer 30, or formed on a support film or the like. It can be formed by transferring the adhesive layer 30 or the like. Similar to the previous embodiment, also in this embodiment, the adhesive or pressure-sensitive adhesive forming the adhesive layer 30 protrudes from both ends of the laminated body 51 in the width direction when the laminated body 51 is transported, and the transport path is contaminated. to prevent, both widthwise end portions of the adhesive layer 30 is equal to the most widthwise outer most in the width direction outside, and the second laminate unit 20b ₂ of the first laminated portion 10b _1, the width direction inside than those Preferably it is located.

  In the laminated body 51 obtained as described above, the deformed portions at both widthwise end portions of the first laminated portion 10 and the second laminated portion 20 are removed, so that deformation of both widthwise end portions of the laminated body 51 is prevented. It is suppressed, and it is possible to suppress the floating of the layer forming the stacked body 51 when the stacked body 51 is transported. In the present embodiment, since both end portions in the width direction of the second stacked portion 20 are also removed in addition to the first stacked portion 10, it is possible to further suppress the occurrence of the above-mentioned floating as compared with the first embodiment. Can do.

<Method for producing composite polarizing plate>
The manufacturing method of the composite polarizing plate of this invention includes the process (d) which prepares the laminated body manufactured by the manufacturing method of the said laminated body, and the 1st base material layer or the 2nd base material layer contained in a laminated body. A step (e) of separating the laminate into a first retardation layer and a laminated retardation layer other than the first separation layer by separating the first release layer; and a step (f) of preparing a polarizing layer; The step of bonding the polarizing layer and the laminated retardation layer so that the polarizing layer is disposed on the exposed surface side of the laminated retardation layer exposed by peeling off the first release layer in the step (e) (g) And). The polarizing layer and the laminated retardation layer are preferably bonded via an adhesive layer for a polarizing layer.

  Hereinafter, a preferred embodiment of a method for producing a composite polarizing plate of the present invention will be described with reference to the drawings. In addition, the same code | symbol is attached | subjected about the same member as what was demonstrated in previous embodiment, and the description is abbreviate | omitted.

[Third Embodiment (Production Method of Composite Polarizing Plate 90)]
FIG. 3 is a schematic cross-sectional view schematically showing the composite polarizing plate of the present embodiment. The composite polarizing plate 90 of the present embodiment includes a polarizing layer 60, a polarizing layer adhesive layer 70, a first retardation layer 13 ′, an adhesive layer 30 ′, a second retardation layer 23 ′, a second alignment layer 22 ′, It has 2nd base material layer 21 'in this order. Note that the symbol “′” in the first retardation layer 13 ′ or the like indicates the corresponding layer (in the case of the first retardation layer 13 ′) in the stacked bodies 50 and 51 shown in FIGS. 1D and 2E. The first retardation layer 13b ₁ is a corresponding layer, and in the case of the second retardation layer 23 ′, the second retardation layer 23 or the second retardation layer 23b ₂ is a corresponding layer. Represents the layer to be used. The layer with the symbol “′” in the composite polarizing plate 90 is completely the same as the layer in the laminates 50 and 51 as long as it is derived from the corresponding layer in the laminates 50 and 51. For example, the shape etc. may not be completely the same as the layer in the laminated bodies 50 and 51 by cut | disconnecting the laminated bodies 50 and 51 to arbitrary magnitude | sizes. The same applies to the layers described below using the symbol “′”.

  In the manufacturing method of the composite polarizing plate 90 shown in FIG. 3, first, the laminated body (for example, the laminated bodies 50 and 51 (FIG. 1D, FIG. 2E)) obtained by previous embodiment is prepared. (Step (d)). A laminated body is an elongate film-like thing, The process mentioned later is performed, conveying this laminated body continuously. Next, by peeling the first base material layer and the first alignment layer of the first laminated portion as the first peeling layer, the laminated body is divided into the first peeling layer and the laminated retardation layer other than the first peeling layer. (Step (e)).

  Subsequently, the polarizing layer 60 is prepared (step (f)). On the polarizing layer 60, the adhesive layer 70 for polarizing layers can be provided. The polarizing layer adhesive layer 70 may be provided on the polarizing layer 60 prepared in the step (f), but as the polarizing layer 60 prepared in the step (f), the polarizing layer provided with the polarizing layer adhesive layer 70 in advance. Layers may be used. The polarizing layer 60 and the first retardation layer 13 ′ of the laminated retardation layer are bonded via the polarizing layer adhesive layer 70 (step (g)) to obtain the composite polarizing plate 90. Thus, when the first release layer is the first base layer and the first alignment layer, the polarizing layer 60 is provided on the exposed surface side of the laminated retardation layer that is exposed by peeling the first release layer. .

  After the step (g), the second base material layer 21 ′ and the second alignment layer 22 ′ included in the laminated retardation layer may be peeled as the second peeling layer (step (j)). An adhesive layer for composite polarizing plate (not shown) may be formed on the second retardation layer 23 ′ that is the surface exposed by peeling the second release layer (step (k)). The composite polarizing adhesive layer can be used when bonding to a display panel such as an organic EL display device or a liquid crystal display device.

  The length in the width direction of the polarizing layer 60 may be the same as the length in the width direction of any layer other than the polarizing layer 60 constituting the composite polarizing plate 90, or may be different from any layer. . For example, the length of the polarizing layer 60 in the width direction may be shorter or longer than the length of the other layers in the width direction. Moreover, as shown in FIG. 3, the length in the width direction of each layer of the composite polarizing plate 90 may be the same.

  In the cross section in the width direction of the composite polarizing plate 90, the positions in the width direction of both ends of the polarizing layer adhesive layer 70 are the outermost position in the cross section in the width direction of the polarizing layer 60 and the cross section in the width direction of the laminated retardation layer. It is preferred that they are the same as the outermost positions or are located inside these positions. Thereby, when the composite polarizing plate 90 is transported, it is possible to prevent the polarizing layer adhesive layer 70 from protruding outward in the width direction and adhering onto the transport path, thereby contaminating the transport path.

  The manufacturing method of the composite polarizing plate of this embodiment may be changed like the modification shown below. Further, a composite polarizing plate may be manufactured by arbitrarily combining the above-described third embodiment and the following modifications.

(Modification 1 of 3rd Embodiment)
The first release layer described above includes the first base layer and the first alignment layer, but does not include the first alignment layer, that is, the first release layer is the first base layer. Good. In this case, since the first base material layer is peeled from the laminated body, the exposed surface of the laminated retardation layer becomes the first alignment layer 12 ′, and the first alignment layer 12 ′ is interposed via the polarizing layer adhesive layer 70. And the polarizing layer 60 are bonded together (step (g)) to obtain a composite polarizing plate.

(Modification 2 of the third embodiment)
The polarizing layer 60 described above has the polarizing layer adhesive layer 70 on the polarizing layer 60. The polarizing layer adhesive layer 70 is a laminated retardation layer that is exposed by peeling off the first peeling layer. It may be provided on the first retardation layer 13 ′. In this case, after peeling off the first release layer from the laminate (step (e)), a step of forming the polarizing layer adhesive layer 70 on the first retardation layer 13 ′ of the laminate retardation layer may be provided. . Also in this case, the polarizing layer adhesive layer 70 is the same as the outermost position in the cross section in the width direction of the polarizing layer 60 and the outermost position in the cross section in the width direction of the laminated retardation layer for the same reason as described above. It is preferable that it exists or is located inside these positions. In addition, the polarizing layer adhesive layer 70 may be provided on both the polarizing layer 60 and the first retardation layer 13 ′.

(Modification 3 of the third embodiment)
The second release layer described above includes the second substrate layer 21 ′ and the second alignment layer 22 ′, but does not include the second alignment layer 22 ′, that is, the second release layer is the second substrate layer 21. It may be '. In this case, only the second base material layer 21 ′ is peeled from the composite polarizing plate 90 (step (j)), and the second alignment layer 22 ′ is exposed, so that the composite polarizing adhesive is adhered onto the second alignment layer 22 ′. A layer can be formed (step (k)).

(Modification 4 of the third embodiment)
The first release layer described above includes the first base layer and the first alignment layer, but the first release layer may include the second base layer and the second alignment layer. It may be a base material layer. When the first release layer includes the second base material layer and the second alignment layer or is the second base material layer, the second retardation layer 23 ′ according to the layer included in the first release layer. Or 2nd orientation layer 22 'and the polarizing layer 60 can be bonded through the contact bonding layer 70 for polarizing layers (process (g)). In this case, the second release layer may include the first base layer and the first alignment layer, or may be the first base layer, and the first release layer may be a first base depending on the layer included in the second release layer. An adhesive layer for a composite polarizing layer can be formed on the retardation layer 13 ′ or the first alignment layer 12 ′ (step (k)).

  As mentioned above, although embodiment of this invention and its modification were demonstrated, this invention is not limited to these embodiment and its modification, For example, combining each process of the said embodiment and its modification. It can also be implemented. Hereafter, each process common in all embodiment and its modification is demonstrated in detail.

<Laminate>
As described above, the stacked body is manufactured using the first stacked portion 10 and the second stacked portion 20 and has the adhesive layer 30.

[First Laminating Unit 10 and Second Laminating Unit 20]
As shown in FIG. 1A and the like, the first stacked unit 10 includes a first base layer 11, a first alignment layer 12, and a first retardation layer 13 stacked in this order, and the second stacked unit 20 As shown in FIG. 1B and the like, the second base material layer 21, the second alignment layer 22, and the second retardation layer 23 are laminated in this order.

(First base material layer 11 and second base material layer 21)
The 1st base material layer 11 and the 2nd base material layer 21 are the 1st alignment layer 12 and the 2nd alignment layer 22 which are formed on these base material layers, and the 1st phase contrast layer 13 and the 2nd phase contrast It functions as a support layer that supports the layer 23. It is preferable that the 1st base material layer 11 and the 2nd base material layer 21 are the films formed with the resin material.

  As the resin material, for example, a resin material excellent in transparency, mechanical strength, thermal stability, stretchability and the like is used. Specifically, polyolefin resins such as polyethylene and polypropylene; cyclic polyolefin resins such as norbornene polymers; polyester resins such as polyethylene terephthalate and polyethylene naphthalate; (meth) acrylic acid, poly (meth) methyl acrylate, etc. (Meth) acrylic acid resins; cellulose ester resins such as triacetyl cellulose, diacetyl cellulose and cellulose acetate propionate; vinyl alcohol resins such as polyvinyl alcohol and polyvinyl acetate; polycarbonate resins; polystyrene resins; Arylate resin; Polysulfone resin; Polyethersulfone resin; Polyamide resin; Polyimide resin; Polyether ketone resin; Polyphenylene sulfide resin; Ren'okishido resins, and mixtures thereof, may be mentioned copolymer and the like. Among these resins, it is preferable to use any of cyclic polyolefin-based resins, polyester-based resins, cellulose ester-based resins and (meth) acrylic acid-based resins, or a mixture thereof. The “(meth) acrylic acid” means “at least one of acrylic acid and methacrylic acid”.

  The 1st base material layer 11 and the 2nd base material layer 21 may be a single layer which mixed 1 type or 2 types or more of said resin, and may have a multilayer structure of two or more layers. When it has a multilayer structure, the resin which comprises each layer may be the same, and may differ. Moreover, the material which makes the 1st base material layer 11 and the 2nd base material layer 21 may be the same, may differ, and also may be the same or different also about a layer structure.

  Arbitrary additives may be added to the resin material forming the resin film. Examples of the additive include an ultraviolet absorber, an antioxidant, a lubricant, a plasticizer, a release agent, an anti-coloring agent, a flame retardant, a nucleating agent, an antistatic agent, a pigment, and a coloring agent.

  Although the thickness of the 1st base material layer 11 and the 2nd base material layer 21 is not specifically limited, Generally it is preferable that it is 1-500 micrometers from the point of workability | operativity, such as intensity | strength and handleability, and it is 1-300 micrometers. Is more preferable, and it is further more preferable that it is 5-200 micrometers.

  In order to improve the adhesion between the first substrate layer 11 and the first alignment layer and the adhesion between the second substrate layer and the second alignment layer, at least the first alignment layer of the first substrate layer is Corona treatment, plasma treatment, flame treatment, etc. may be performed on the surface on the side to be formed and on the surface on which at least the second alignment layer of the second base material layer is formed. Also good. Note that the layers included in the first release layer and the second release layer described in the previous embodiment are set by adjusting the relationship of adhesion between the layers forming the first stacked unit 10 and the second stacked unit 20. can do.

(First alignment layer 12 and second alignment layer 22)
The first alignment layer 12 and the second alignment layer 22 align the liquid crystal compounds contained in the first retardation layer 13 and the second retardation layer 23 formed on these alignment layers in a desired direction. Has regulatory power. Examples of the first alignment layer 12 and the second alignment layer 22 include an alignment polymer layer formed of an alignment polymer, a photo-alignment polymer layer formed of a photo-alignment polymer, and a concavo-convex pattern or a plurality of grooves (grooves) on the layer surface. The first alignment layer 12 and the second alignment layer 22 may be the same type of layer or different types of layers. The thickness of the first alignment layer and the second alignment layer is usually 10 to 500 nm, and preferably 10 to 200 nm.

  For the orientation polymer layer, a composition in which the orientation polymer is dissolved in a solvent is applied to the base material layer (first base material layer 11 or second base material layer 21), the solvent is removed, and rubbing treatment is performed as necessary. Can be formed. In this case, in the orientation polymer layer formed of the orientation polymer, the orientation regulating force can be arbitrarily adjusted depending on the surface state of the orientation polymer and the rubbing conditions.

  A photo-alignment polymer layer applies a composition containing a polymer or monomer having a photoreactive group and a solvent to a base material layer (first base material layer 11 or second base material layer 21), and irradiates polarized light. Can be formed. In this case, in the photo-alignable polymer layer, the alignment regulating force can be arbitrarily adjusted depending on the polarization irradiation conditions for the photo-alignable polymer.

  The groove alignment layer is an active method for forming a concavo-convex pattern by performing exposure, development, etc. through an exposure mask having a pattern-shaped slit on the photosensitive polyimide film surface, a plate-shaped master having grooves on the surface, and the like. A method of forming an uncured layer of energy beam curable resin, transferring the layer to a base material layer (first base material layer 11 or second base material layer 21), and curing the base material layer (first base layer) An uncured layer of an active energy ray-curable resin is formed on the material layer 11 or the second base material layer 21), and unevenness is formed and cured by pressing a roll-shaped master having unevenness on this layer. It can be formed by a method or the like.

(First retardation layer 13 and second retardation layer 23)
The first retardation layer 13 and the second retardation layer 23 are not particularly limited as long as they give a predetermined retardation to the light. For example, a half-wave plate, a quarter-wave plate, a positive C plate, What functions as a quarter wavelength plate etc. of reverse wavelength dispersion can be mentioned. The laminate of this embodiment is used as a composite polarizing plate in combination with a polarizer layer. As will be described later, in the case where the composite polarizing plate constitutes a circularly polarizing plate, the retardation layer is formed so that the circularly polarizing plate is obtained by a combination of the first retardation layer, the second retardation layer, and the polarizer layer. It is preferable to set the type and arrangement.

  The first retardation layer 13 and the second retardation layer 23 can be formed using a known liquid crystal compound. The kind of liquid crystal compound is not particularly limited, and a rod-like liquid crystal compound, a disk-like liquid crystal compound, and a mixture thereof can be used. The liquid crystal compound may be a polymer liquid crystal compound, a polymerizable liquid crystal compound, or a mixture thereof.

  For example, when a polymerizable liquid crystal compound is used, a composition containing the polymerizable liquid crystal compound is applied on the alignment layer (the first alignment layer 12 or the second alignment layer 22) to form a coating film. The first retardation layer 13 and the second retardation layer 23 can be formed by curing the film.

[Adhesive layer 30]
The adhesive layer 30 can be formed of an adhesive, a pressure-sensitive adhesive, and a combination thereof, and is usually one layer, but may be two or more layers. When the adhesive layer 30 is composed of two or more layers, each layer may be formed of the same material, or may be formed of different materials.

  As an adhesive agent, it can form, for example, combining 1 type (s) or 2 or more types among a water-system adhesive agent, an active energy ray hardening-type adhesive agent, an adhesive, etc. Examples of the aqueous adhesive include an aqueous polyvinyl alcohol resin solution, an aqueous two-component urethane emulsion adhesive, and the like. The active energy ray-curable adhesive is an adhesive that is cured by irradiating active energy rays such as ultraviolet rays, for example, an adhesive containing a polymerizable compound and a photopolymerizable initiator, an adhesive containing a photoreactive resin, Examples thereof include those containing a binder resin and a photoreactive crosslinking agent. Examples of the polymerizable compound include photopolymerizable monomers such as a photocurable epoxy monomer, a photocurable acrylic monomer, and a photocurable urethane monomer, and oligomers derived from these monomers. As said photoinitiator, what contains the substance which generate | occur | produces active species, such as a neutral radical, an anion radical, and a cation radical, irradiating active energy rays, such as an ultraviolet-ray, can be mentioned.

  Examples of the pressure-sensitive adhesive include compositions in which an acrylic resin, a styrene resin, a silicone resin, or the like is used as a base polymer and a crosslinking agent such as an isocyanate compound, an epoxy compound, or an aziridine compound is added.

  The adhesive layer 30 is preferably formed using an active energy ray curable adhesive, and particularly preferably formed using an adhesive containing an ultraviolet curable epoxy monomer and a photocationic polymerization initiator. . In this case, when manufacturing the laminated body 50 (FIG. 1 (D)), after bonding the 1st laminated part 10b1 and the 2nd laminated part 20 through the said active energy ray hardening-type adhesive agent, The adhesive layer 30 may be formed by irradiating active energy rays and curing the active energy ray-curable adhesive.

<Composite polarizing plate>
As described above, the composite polarizing plate is manufactured using the laminate and the polarizing layer 60 and has the polarizing layer adhesive layer 70. Moreover, the composite polarizing plate may have an adhesive layer for composite polarizing plates.

  The composite polarizing plate can be used as a circularly polarizing plate. For example, by using this circularly polarizing plate in an organic EL display device, the antireflection performance in the organic EL display device can be improved. When the composite polarizing plate is used as a circularly polarizing plate, the layer structure of the composite polarizing plate is a structure in which a polarizing layer (linear polarizing layer), a half-wave plate, a quarter-wave plate are laminated in this order, or a polarizing layer ( Linear polarizing layer), 1/4 wavelength plate with reverse wavelength dispersion, and positive C plate are stacked in this order to set the type of retardation layer forming the first retardation layer and the second retardation layer. To do.

  For example, when the composite polarizing plate 90 shown in FIG. 3 is used as a circularly polarizing plate, the first retardation layer 13 ′ is a half-wave plate and the second retardation layer 23 ′ is a quarter-wave plate. Alternatively, the first retardation layer 13 ′ may be a reverse-dispersing quarter-wave plate, and the second retardation layer 23 ′ may be a positive C plate. When the polarizing layer 60 is provided on the second retardation layer 23 ′, the second retardation layer 23 ′ is a half-wave plate and the first retardation layer 13 ′ is a quarter-wave plate. Alternatively, the second retardation layer 23 ′ may be a reverse-dispersing quarter-wave plate, and the first retardation layer 13 ′ may be a positive C plate.

[Polarizing layer 60]
As the polarizing layer 60, a uniaxially stretched polyvinyl alcohol resin layer having a dichroic dye adsorbed and oriented can be used. As a polyvinyl alcohol-type resin which makes a polyvinyl alcohol-type resin layer, what saponified polyvinyl acetate type-resin can be used, for example, saponification degree is 80-100 mol% normally, 90-100 mol%. Is preferable, and it is more preferable that it is 94-100 mol%. Iodine or a dichroic organic dye can be used for the dichroic dye contained (adsorption orientation) in the polyvinyl alcohol-based resin layer.

  The polarizing layer 60 is a step of uniaxially stretching a polyvinyl alcohol-based resin layer, a step of dyeing the stretched polyvinyl alcohol-based resin layer with a dichroic dye, and adsorbing the dichroic dye, and the dichroic dye being adsorbed The polyvinyl alcohol resin layer can be manufactured through a step of treating with a boric acid aqueous solution, a step of washing with water after the treatment with a boric acid aqueous solution, and the like. The thickness of the obtained polarizing layer 60 is usually 2 to 60 μm.

  The polarizing layer 60 may have a protective film on one surface or both surfaces thereof. The protective film may be a simple protective film having no optical function, or may be a protective film having both optical functions such as a retardation film and a brightness enhancement film. The material of the protective film is not particularly limited. For example, a cyclic polyolefin resin film, a cellulose acetate resin film made of a resin such as triacetyl cellulose or diacetyl cellulose, polyethylene terephthalate, polyethylene naphthalate, poly Examples of the film known in the art include a polyester resin film, a polycarbonate resin film, a (meth) acrylic resin film, and a polypropylene resin film made of a resin such as butylene terephthalate. The thickness of the protective film is preferably thin because of the demand for thinning, and is usually 300 μm or less, preferably 200 μm or less, more preferably 50 μm or less, and usually 5 μm or more, and 20 μm or more. Preferably there is.

[Adhesive layer 70 for polarizing layer]
The polarizing layer adhesive layer 70 can be formed of an adhesive, a pressure-sensitive adhesive, and a combination thereof. The polarizing layer adhesive layer 70 is usually one layer, but may be formed of two or more layers. When the polarizing layer adhesive layer 70 includes two or more layers, each layer may be formed of the same material or different materials.

  Examples of the adhesive and pressure-sensitive adhesive forming the polarizing layer adhesive layer 70 include the same adhesives and pressure-sensitive adhesives used for the adhesive layer 30. As the polarizing layer adhesive layer 70, an adhesive is preferably used.

[Adhesive layer for composite polarizing plate]
The adhesive layer for a composite polarizing plate can be formed with an adhesive, a pressure-sensitive adhesive, and a combination thereof. The adhesive layer for a composite polarizing plate is usually one layer, but may be formed of two or more layers. When the composite polarizing plate adhesive layer is composed of two or more layers, each layer may be formed of the same material or different materials.

  Examples of the adhesive and pressure-sensitive adhesive forming the composite polarizing plate adhesive layer are the same as those of the adhesive and pressure-sensitive adhesive used in the adhesive layer 30. An adhesive is preferably used as the adhesive layer for the composite polarizing plate.

DESCRIPTION OF SYMBOLS 10 1st laminated part, 10b ₁ 1st laminated part after 1st edge part removal, 11 1st base material layer, 11b ₁ 1st base material layer, 12 1st orientation layer, 12b ₁ 1st orientation layer, 13 1st 1 retardation layer, 13b ₁ 1st retardation layer, 13 '1st retardation layer, 14 1st edge part,
20 2nd lamination | stacking part, 20b ₂ 2nd lamination | stacking part after 2nd edge part removal, 21 2nd base material layer, 21b ₂ 2nd base material layer, 21 '2nd base material layer, 22 2nd orientation layer, 22b ₂ second alignment layer, 22 ′ second alignment layer, 23 second retardation layer, 23b ₂ second retardation layer, 23 ′ second retardation layer, 24 second end,
30 adhesive layer, 30 ′ adhesive layer, 50 laminate, 51 laminate, 60 polarizing layer, 70 polarizing layer adhesive layer, 90 composite polarizing plate,
W Width direction.

Claims (8)

The 1st lamination part containing the 1st base material layer, the 1st alignment layer, and the 1st phase contrast layer in this order, The 2nd lamination part containing the 2nd base material layer, the 2nd orientation layer, and the 2nd phase contrast layer in this order And (a) preparing
A step (b1) of removing first ends which are both ends in the width direction of the first stacked portion;
The step (c) of bonding the first retardation layer side of the first laminated portion after removal of the first end portion and the second retardation layer side of the second laminated portion via an adhesive layer. And a method for producing a laminate.   Furthermore, it has the process (b2) of removing the 2nd edge part which is the both ends of the width direction of a said 2nd lamination | stacking part after the said process (a) and before the said process (c). The manufacturing method of the laminated body as described in any one of. A step (d) of preparing the laminate manufactured by the method for manufacturing a laminate according to claim 1 or 2;
By peeling the first release layer including the first base material layer or the second base material layer included in the laminate, the laminate is laminated other than the first release layer and the first release layer. A step (e) of separating into a retardation layer;
Preparing a polarizing layer (f);
The polarizing layer and the laminated retardation layer are pasted so that the polarizing layer is disposed on the exposed surface side of the laminated retardation layer exposed by peeling off the first release layer in the step (e). A method of producing a composite polarizing plate, comprising the step of combining (g). In the step (g), the polarizing layer and the laminated retardation layer are bonded via a polarizing layer adhesive layer,
4. The composite polarizing plate according to claim 3, wherein the polarizing layer adhesive layer is provided on the polarizing layer prepared in the step (f) or on the exposed surface side of the laminated retardation layer. Method.   In the cross section in the width direction of the laminated retardation layer bonded to the polarizing layer obtained in the step (g), the positions in the width direction at both ends of the polarizing layer adhesive layer are the outermost sides of the polarizing layer. The same as the position of the edge part located in the outermost part of the lamination | stacking phase difference layer bonded to the edge part and the said polarizing layer, or it exists inside these positions. A method for producing a composite polarizing plate. The first release layer is
[I] including the first base material layer and the first alignment layer included in the laminate,
[Ii] The first base material layer included in the laminate.
[Iii] including the second base material layer and the second alignment layer included in the laminate, and
[Iv] The second base material layer included in the laminate.
The manufacturing method of the composite polarizing plate of any one of Claims 3-5 which is any one of these. Further, after the step (g), the method includes a step (j) of peeling the second release layer included in the laminated retardation layer bonded to the polarizing layer,
In the case where the first release layer is the [i] or [ii], the second release layer includes the second base material layer and the second base layer included in the stacked retardation layer bonded to the polarizing layer. It is the second base material layer that includes two orientation layers or is included in the laminated retardation layer bonded to the polarizing layer,
In the case where the first release layer is the [iii] or [iv], the second release layer includes the first base material layer and the first base layer included in the laminated retardation layer bonded to the polarizing layer. The manufacturing method of the composite polarizing plate of Claim 6 which is a said 1st base material layer containing the 1st orientation layer or being contained in the said laminated phase difference layer bonded by the said polarizing layer.   Furthermore, it has the process (k) which forms the adhesive layer for composite polarizing plates in the surface exposed by peeling a 2nd peeling layer from the said laminated phase difference layer bonded by the said polarizing layer in process (j). The manufacturing method of the composite polarizing plate of Claim 7.

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