JP2020030342A - 偏光子、偏光フィルム、光学フィルム、ならびに画像表示装置 - Google Patents
偏光子、偏光フィルム、光学フィルム、ならびに画像表示装置 Download PDFInfo
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- JP2020030342A JP2020030342A JP2018156269A JP2018156269A JP2020030342A JP 2020030342 A JP2020030342 A JP 2020030342A JP 2018156269 A JP2018156269 A JP 2018156269A JP 2018156269 A JP2018156269 A JP 2018156269A JP 2020030342 A JP2020030342 A JP 2020030342A
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Abstract
Description
耐久性向上層は、60℃における滴定試験において、塩基性成分を0.5当量添加してもpH上昇が3.0以内である化合物(A)を含有する硬化性組成物により形成される。
偏光子は、特に制限されず、各種のものを使用できる。偏光子としては、例えば、ポリビニルアルコール系フィルム、部分ホルマール化ポリビニルアルコール系フィルム、エチレン・酢酸ビニル共重合体系部分ケン化フィルムなどの親水性高分子フィルムに、ヨウ素や二色性染料などの二色性材料を吸着させて一軸延伸したもの、ポリビニルアルコールの脱水処理物やポリ塩化ビニルの脱塩酸処理物などポリエン系配向フィルムなどが挙げられる。これらのなかでもポリビニルアルコール系フィルムとヨウ素などの二色性物質からなる偏光子が好適である。これら偏光子の厚みは一般に1〜30μmである。
接着剤層の厚みは、0.01〜3.0μmであることが好ましい。接着剤層の厚みが薄過ぎる場合、接着剤層の凝集力が不足し、剥離力が低下するため好ましくない。接着剤層の厚みが厚すぎる場合、偏光フィルムの断面に応力をかけた際の剥離が起こりやすくなり、衝撃による剥がれ不良が発生するため好ましくない。接着剤層の厚みは、より好ましくは0.1〜2.5μm、最も好ましくは0.5〜1.5μmである。
本発明に係る偏光フィルムは、炭素−炭素二重結合および環状骨格を有する化合物(A)を含有する硬化性組成物により形成された耐久性向上層を少なくとも一方の表面に備える偏光子を備える。さらに本発明に係る偏光フィルムは、前記偏光子の少なくとも一方の面に透明保護フィルムが積層されたものであってもよい。また好ましくは耐久性向上層と透明保護フィルムとの間に、さらに接着剤層を備える。以下に、耐久性向上層と透明保護フィルムとの間に、さらに接着剤層を備える偏光フィルムを例に挙げて説明する。
偏光子の貼合面に化合物(A)を含有する硬化性組成物を塗布して耐久向上層を形成する第1塗布行程と、耐久性向上層を構成する硬化性組成物を硬化する硬化工程と、透明保護フィルムの貼合面に接着剤組成物を塗布する第2塗布行程と、偏光子の耐久性向上層形成面と透明保護フィルムの接着剤組成物塗布面とを貼り合わせる貼合行程と、偏光子面側または透明保護フィルム側から活性エネルギー線を照射して、接着剤組成物を硬化させることにより得られた接着剤層を介して、偏光子および透明保護フィルムを接着させる接着行程を含む偏光フィルムの製造方法、により製造可能である。なお、前記第1塗布行程の前に、偏光子の少なくとも一方の面に易接着層を形成する易接着層形成行程を追加し、偏光子の易接着層形成面に硬化性組成物を塗布する第1塗布行程を実施してもよい。さらに、前記易接着層形成行程の前に、偏光子の少なくとも一方の面に表面改質処理を行う処理工程を実施してもよい。
透明保護フィルムとしては、透明性、機械的強度、熱安定性、水分遮断性、等方性などに優れるものが好ましい。例えば、ポリエチレンテレフタレートやポリエチレンナフタレートなどのポリエステル系ポリマー、ジアセチルセルロースやトリアセチルセルロースなどのセルロース系ポリマー、ポリメチルメタクリレートなどのアクリル系ポリマー、ポリスチレンやアクリロニトリル・スチレン共重合体(AS樹脂)などのスチレン系ポリマー、ポリカーボネート系ポリマーなどが挙げられる。また、ポリエチレン、ポリプロピレン、シクロ系ないしはノルボルネン構造を有するポリオレフィン、エチレン・プロピレン共重合体の如きポリオレフィン系ポリマー、塩化ビニル系ポリマー、ナイロンや芳香族ポリアミドなどのアミド系ポリマー、イミド系ポリマー、スルホン系ポリマー、ポリエーテルスルホン系ポリマー、ポリエーテルエーテルケトン系ポリマー、ポリフェニレンスルフィド系ポリマー、ビニルアルコール系ポリマー、塩化ビニリデン系ポリマー、ビニルブチラール系ポリマー、アリレート系ポリマー、ポリオキシメチレン系ポリマー、エポキシ系ポリマー、または上記ポリマーのブレンド物なども上記透明保護フィルムを形成するポリマーの例として挙げられる。透明保護フィルム中には任意の適切な添加剤が1種類以上含まれていてもよい。添加剤としては、例えば、紫外線吸収剤、酸化防止剤、滑剤、可塑剤、離型剤、着色防止剤、難燃剤、核剤、帯電防止剤、顔料、着色剤などが挙げられる。透明保護フィルム中の上記熱可塑性樹脂の含有量は、好ましくは50〜100重量%、より好ましくは50〜99重量%、さらに好ましくは60〜98重量%、特に好ましくは70〜97重量%である。透明保護フィルム中の上記熱可塑性樹脂の含有量が50重量%以下の場合、熱可塑性樹脂が本来有する高透明性などが十分に発現できないおそれがある。
本発明の偏光フィルムは、実用に際して他の光学層と積層した光学フィルムとして用いることができる。その光学層については特に限定はないが、例えば、位相差フィルム(1/2や1/4等の波長板を含む)、視覚補償フィルム、輝度向上フィルム、反射板や反透過板、などの液晶表示装置等の形成に用いられることのある光学層となるものがあげられる。これらの光学層は、本発明において易接着層付基材フィルムの基材フィルムとして使用可能であり、必要に応じて表面改質処理を施すことにより、水酸基、カルボニル基やアミノ基などの反応性官能基を有する。したがって、表面に少なくとも反応性官能基を含有する位相差フィルムの少なくとも一方の面に、前記一般式(1)で表される化合物を備える易接着処理位相差フィルム、特には前記一般式(1)で表される化合物を含む易接着層が形成された易接着層付位相差フィルムなどは、位相差フィルムなどと接着剤層との密着性が向上し、その結果、接着性が特に向上するため好ましい。
0.70<Re[450]/Re[550]<0.97・・・(1)
1.5×10−3<Δn<6×10−3・・・(2)
1.13<NZ<1.50・・・(3)
(式中、Re[450]およびRe[550]は、それぞれ、23℃における波長450nmおよび550nmの光で測定した位相差フィルムの面内の位相差値であり、Δnは位相差フィルムの遅相軸方向、進相軸方向の屈折率を、それぞれnx、nyとしたときのnx−nyである面内複屈折であり、NZはnzを位相差フィルムの厚み方向の屈折率としたときの、厚み方向複屈折であるnx−nzと面内複屈折であるnx−nyとの比である)を満足する逆波長分散型の位相差フィルムを用いてもよい。
本発明の偏光フィルムまたは光学フィルムは液晶表示装置などの各種装置の形成などに好ましく用いることができる。液晶表示装置の形成は、従来に準じて行いうる。すなわち液晶表示装置は一般に、液晶セルと偏光フィルムまたは光学フィルム、および必要に応じての照明システムなどの構成部品を適宜に組立てて駆動回路を組込むことなどにより形成されるが、本発明においては本発明による偏光フィルムまたは光学フィルムを用いる点を除いて特に限定はなく、従来に準じうる。液晶セルについても、例えばTN型やSTN型、π型などの任意なタイプのものを用いうる。
まず、非晶性PET基材に9μm厚のPVA層が製膜された積層体を延伸温度130℃の空中補助延伸によって延伸積層体を生成し、次に、延伸積層体を染色によって着色積層体を生成し、さらに着色積層体を延伸温度65度のホウ酸水中延伸によって総延伸倍率が5.94倍になるように非晶性PET基材と一体に延伸された5μm厚のPVA層を含む光学フィルム積層体を生成した。このような2段延伸によって非晶性PET基材に製膜されたPVA層のPVA分子が高次に配向され、染色によって吸着されたヨウ素がポリヨウ素イオン錯体として一方向に高次に配向された薄型偏光子を構成する、厚さ5μmのPVA層を含む光学フィルム積層体を得た。
特開2010−284840号公報の製造例1に記載のイミド化MS樹脂100重量部およびトリアジン系紫外線吸収剤(アデカ社製、商品名:T−712)0.62重量部を、2軸混練機にて220℃にて混合し、樹脂ペレットを作製した。得られた樹脂ペレットを、100.5kPa、100℃で12時間乾燥させ、単軸の押出機にてダイス温度270℃でTダイから押出してフィルム状に成形した(厚み160μm)。さらに当該フィルムを、その搬送方向に150℃の雰囲気下に延伸し(厚み80μm)、次いで水性ウレタン樹脂を含む易接着剤を塗布した後フィルム搬送方向と直交する方向に150℃の雰囲気下に延伸して、厚み40μm(透湿度58g/m2/24h)の透明保護フィルムを得た。
活性エネルギー線として、可視光線(ガリウム封入メタルハライドランプ) 照射装置:Fusion UV Systems,Inc社製Light HAMMER10 バルブ:Vバルブ ピーク照度:1600mW/cm2、積算照射量1000/mJ/cm2(波長380〜440nm)を使用した。なお、可視光線の照度は、Solatell社製Sola−Checkシステムを使用して測定した。
化合物(A)として、γ―ブチロラクトンアクリレート(GBLA)を選択し、滴定試験を行うことにより、GBLAが疑似的な緩衝作用を示すことを確認した。表1に示すとおり、60℃に調整した0.1M_GBLA水溶液に0.1M_NaOH水溶液を滴下して、そのpH上昇を測定したところ、0.1M_NaOH水溶液を50.2g(=0.5当量)滴下しても、添加前に比してpHが2.5しか上昇していない。この滴定試験の結果から、GBLAが疑似的な緩衝作用を示すことが理解できる。
GBLA100重量部に対し、IRGACURE 907(重合開始剤、BASF社製)3重量部、KAYACURE DETX−S(重合開始剤、日本化薬社製)3重量%を含有する接着剤組成物を調整した。
15重量%に調整した4−ビニルフェニルボロン酸のイソプロピルアルコール溶液6.9重量部に対し、アクリロイルモルホリン5.1重量部、オルフィンEXP4200(日信化学社製)0.2重量部、純水87.9重量部を含有する易接着組成物を調整した。
ワイヤーバー(第一理化社製、No.2)を用いて、上記偏光子の厚さ5μmのPVA層を含む光学フィルム積層体のPVA面に、前記易接着組成物を塗布し、60℃で2分間風乾燥させることにより溶剤を除去して、易接着層付偏光子を作製した。
1,9−ノナンジオールジアクリレート(共栄社化学社製)100重量部に対し、IRGACURE 907(重合開始剤、BASF社製)3重量部、KAYACURE DETX−S(重合開始剤、日本化薬社製)3重量%を含有する接着剤組成物を調整した。
実施例1
前記易接着層付偏光子の易接着層面側に、MCDコーター(富士機械社製)(セル形状:ハニカム、グラビアロール線数:1000本/inch、回転速度140%/対ライン速)を用いて、上記硬化性組成物を厚み0.7μmになるように塗布し、耐久性向上層を形成した。次いで、ロール機を用いて、上記偏光子の耐久性向上層側から透明保護フィルムを貼り合わせた。その後、貼り合わせた透明保護フィルム側から、活性エネルギー線照射装置により上記可視光線を照射して、耐久性向上層を構成する硬化性組成物を硬化させて、偏光子と透明保護フィルムとを接着させた後、70℃で3分間熱風乾燥し、偏光子のもう片側に積層されていた非晶性PET基材を剥離除去することにより、偏光子の片側に透明保護フィルムを有する偏光フィルムを得た。貼り合わせのライン速度は25m/minで行った。
前記易接着層付偏光子の易接着層面側に、MCDコーター(富士機械社製)(セル形状:ハニカム、グラビアロール線数:1000本/inch、回転速度140%/対ライン速)を用いて、上記硬化性組成物を厚み0.7μmになるように塗布し、耐久性向上層を形成した。次いで、ロール機を用いて、上記偏光子の耐久性向上層側からポリエステルフィルム(ダイアホイルS−100 38μm 三菱ケミカル社製)を貼り合わせた。その後、貼り合わせたポリエステルフィルム側から、活性エネルギー線照射装置により上記可視光線を照射して、耐久性向上層を構成する硬化性組成物を硬化させた。続いて、ポリエステルフィルムを剥離した。
透明保護フィルムの貼合面に、MCDコーター(富士機械社製)(セル形状:ハニカム、グラビアロール線数:1000本/inch、回転速度140%/対ライン速)を用いて、上記接着剤組成物を厚み0.7μmになるように塗布し、ロール機を用いて、上記偏光子の耐久性向上層形成面と透明保護フィルムの接着剤組成物塗布面とを貼り合わせた。その後、貼り合わせた透明保護フィルム側から、活性エネルギー線照射装置により上記可視光線を照射して、接着剤層を構成する接着剤組成物を硬化させた後、70℃で3分間熱風乾燥し、偏光子のもう片側に積層されていた非晶性PET基材を剥離除去することにより、偏光子の片側に透明保護フィルムを有する偏光フィルムを得た。貼り合わせのライン速度は25m/minで行った。
前記易接着層付偏光子の易接着層面側に、MCDコーター(富士機械社製)(セル形状:ハニカム、グラビアロール線数:1000本/inch、回転速度140%/対ライン速)を用いて、上記硬化性組成物を厚み0.7μmになるように塗布し、耐久性向上層を形成した。次いで、ロール機を用いて、上記偏光子の耐久性向上層側からポリエステルフィルム(ダイアホイルS−100 38μm 三菱ケミカル社製)を貼り合わせた。その後、貼り合わせたポリエステルフィルム側から、活性エネルギー線照射装置により上記可視光線を照射して、耐久性向上層を構成する硬化性組成物を硬化させた。続いて、ポリエステルフィルムを剥離することにより、耐久性向上層を一方の表面に備える偏光子からなる偏光フィルムを得た。
偏光子として、耐久性向上層を備えない偏光子を使用したこと以外は、実施例2と同様の方法により、偏光フィルムを製造した。
前記硬化性組成物に代えて、接着剤組成物を塗布すること以外は、実施例3と同様の方法により、接着剤層を一方の表面に備える偏光子からなる偏光フィルムを得た。
製造した偏光フィルムの透過率および偏光度を、積分球付き分光透過率測定器(村上色彩技術研究所のDot−3c)を用いて測定した。なお、偏光度Pは、2枚の同じ偏光フィルムを両者の透過軸が平行となるように重ね合わせた場合の透過率(平行透過率:Tp)および、両者の透過軸が直交するように重ね合わせた場合の透過率(直交透過率:Tc)を以下の式に適用することにより求められるものである。
偏光度P(%)={(Tp−Tc)/(Tp+Tc)}1/2×100
各透過率は、グランテラープリズム偏光子を通して得られた完全偏光を100%として、JIS Z8701の2度視野(C光源)により視感度補整したY値で示したものである。この偏光フィルムの偏光子面にコロナ処理を施し厚み20μmのアクリル系粘着剤を貼り合せ、アクリル系粘着剤のもう一方の面を無アルカリガラスに貼り合せ、上述の定義に基づく偏光度Pおよび透過率の初期値を測定した。次いでこのガラス付偏光フィルムを60℃95%RHの環境下に48時間投入し、ガラス付偏光フィルムの経時後の偏光度を測定した。経時後の偏光度Pから初期の偏光度Pを引いた数値を偏光度変化とした。偏光度変化の絶対値が小さいほど、加湿耐久性に優れることを意味する。
Claims (10)
- 少なくとも一方の表面に耐久性向上層を備える偏光子であって、
前記耐久性向上層が、60℃における滴定試験において、塩基性成分を0.5当量添加してもpH上昇が3.0以内である化合物(A)を含有する硬化性組成物により形成されたものであることを特徴とする偏光子。 - 前記化合物(A)が、γ―ブチロラクトン(メタ)アクリレートである請求項1に記載の偏光子。
- 前記硬化性組成物が含有する前記化合物(A)の少なくとも一部が重合されたものである請求項1または2に記載の偏光子。
- 前記硬化性組成物がさらに重合開始剤を含有するものである請求項1〜3のいずれかに記載の偏光子。
- 前記耐久性向上層が、前記硬化性組成物の硬化物層により形成されたものである請求項4に記載の偏光子。
- 請求項1〜5のいずれかに記載の偏光子を備える偏光フィルム。
- 前記偏光子の少なくとも一方の面に透明保護フィルムが積層されており、
前記偏光子が備える前記耐久性向上層側に前記透明保護フィルムが積層されたものである請求項6に記載の偏光フィルム。 - 前記耐久性向上層と前記透明保護フィルムとの間に、さらに接着剤層を備える請求項7に記載の偏光フィルム。
- 請求項6〜8のいずれかに記載の偏光フィルムが少なくとも1枚積層されていることを特徴とする光学フィルム。
- 請求項6〜8のいずれかに記載の偏光フィルム、あるいは請求項8に記載の光学フィルムが用いられていることを特徴とする画像表示装置。
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