JP2022075144A - Polarizing plate with curved-surface processing and method for manufacturing the same - Google Patents

Abstract

To provide a polarizing plate capable of preventing display unevenness or color omission when applied to a picture display unit, even with curved-surface processing.SOLUTION: A polarizing plate includes a polarizer and a protective layer arranged at least on one side of the polarizer, and has been processed to have a curved surface, with a humidification treatment for 40 minutes or more under an environment of 40°C to 65°C and 85%RH to 95%RH after curved-surface processing. The polarizing plate satisfies a following relation: TsR-Ts0=ΔTs≤+1.5(%); PR-P0=ΔP≥-1.5(%); and -2.0 (nm)≤ReR-Re0=ΔRe≤+2.0 (nm). Here, Ts0 is a single body transmittance before the curved-surface processing, TsR is a single body transmittance after the humidification treatment; P0 is a polarization degree before the curved-surface processing, PR is a polarization degree after the humidification treatment; Re0 is an in-plane phase difference before the curved-surface processing and ReR is an in-plane phase difference after the humidification treatment.SELECTED DRAWING: Figure 1

Description

The present invention relates to a curved polarizing plate and a method for manufacturing the same.

Polarizing plates are widely used in image display devices such as liquid crystal displays and organic electroluminescence (EL) display devices in order to realize image display and / or enhance the performance of the image display. The polarizing plate may be required to be curved depending on the intended use. Curved surface processing typically includes forming a polarizing plate into a predetermined shape in a high temperature environment. However, the curved polarizing plate has a problem that display unevenness and / or color loss is likely to occur when applied to an image display device.

Japanese Unexamined Patent Publication No. 8-137731

The present invention has been made to solve the above-mentioned conventional problems, and its main purpose is to suppress display unevenness and color loss when applied to an image display device even though it is curved. It is an object of the present invention to provide a polarizing plate and a simple method for producing the same.

The polarizing plate according to the embodiment of the present invention includes a polarizing element and a protective layer arranged on at least one of the polarizing elements, is curved, and is 40 ° C. to 65 ° C. and 85% RH to 95% after the curved surface processing. It has been humidified for more than 40 minutes in the RH environment and satisfies the following relationship:
Ts _R -Ts ₀ = ΔTs ≤ + 1.5 (%)
PR _{−P 0} = ΔP ≧ −1.5 (%)
-2.0 (nm) ≤ Re _R -Re ₀ = ΔRe ≤ + 2.0 (nm)
Here, Ts ₀ is the single transmittance before the curved surface processing, Ts _R is the single transmittance after the humidification treatment; P ₀ is the degree of polarization before the curved surface processing, and _PR is the degree of polarization after the humidification treatment. Re ₀ is the in-plane phase difference before the curved surface processing, and Re _R is the in-plane phase difference after the humidification treatment.
In one embodiment, the polarizing plate defines an area in which a curved surface processed portion is divided into nine in a grid pattern, and the difference between the maximum value and the minimum value of nine Re _Rs measured in each area is 3.0 nm. It is as follows.
According to another aspect of the present invention, there is provided a method for manufacturing a curved polarizing plate. This manufacturing method prepares a polarizing plate including a polarizing element and a protective layer arranged on at least one of the polarizing elements; the polarizing plate is heated together with a mold having a predetermined curved shape to be curved. ; And, the curved polarizing plate is humidified for 40 minutes or more in an environment of 40 ° C. to 65 ° C. and 85% RH to 95% RH;
In one embodiment, the heating temperature in the curved surface processing is 100 ° C. or higher.

According to the embodiment of the present invention, by subjecting the curved polarizing plate to a predetermined humidification treatment, it is possible to realize a polarizing plate capable of suppressing display unevenness and color loss when applied to an image display device. ..

It is a schematic perspective view of the polarizing plate by one Embodiment of this invention. It is a schematic cross-sectional view of the polarizing plate of FIG. 3 (a) to 3 (c) are schematic views illustrating an example of a method for manufacturing a curved polarizing plate according to an embodiment of the present invention.

Hereinafter, typical embodiments of the present invention will be described with reference to the drawings, but the present invention is not limited to these embodiments. The drawings are schematically drawn for easy viewing, and the shapes, thicknesses, radii of curvature, etc. are different from the actual ones, and are also different between the drawings.

A. Polarizer A-1. Overall Configuration of Polarizer FIG. 1 is a schematic perspective view of a polarizing plate according to one embodiment of the present invention; FIG. 2 is a schematic cross-sectional view of the polarizing plate of FIG. The polarizing plate 100 in the illustrated example is curved. In other words, the polarizing plate is a polarizing plate whose characteristics (typically, optical characteristics, chemical characteristics, mechanical characteristics) have once deteriorated due to curved surface processing (that is, in a high temperature environment). According to the embodiment of the present invention, the characteristics can be restored by subjecting the polarizing plate whose characteristics have once deteriorated to the humidification treatment described later. As a result, when the polarizing plate after the curved surface is applied to the image display device, display unevenness and color loss can be suppressed. The curved surface processing temperature may be, for example, 100 ° C. or higher, 120 ° C. or higher, 140 ° C. or higher, or 160 ° C. or higher. The upper limit of the curved surface processing temperature may be, for example, 200 ° C. The curved surface processing time can be, for example, 15 seconds to 5 minutes.

As the curved surface processing shape, any appropriate shape according to the purpose can be adopted. Specific examples of the curved surface processing shape include a dome shape and a semi-cylindrical shape as shown in FIG. Examples of such a curved polarizing plate include a polarizing plate applied to a curved image display device. Examples of the curved image display device include virtual reality (VR) goggles and digital signage provided on a curved wall surface or pillar. Although the polarizing plate in the illustrated example is convex on the viewing side, the polarizing plate may be convex on the side opposite to the viewing side depending on the purpose.

The polarizing plate 100 typically includes a polarizing element 10 and a protective layer 20 arranged on one side (visual side in the illustrated example) and a protective layer 30 arranged on the other side. include. Depending on the purpose, either the protective layer 20 or the protective layer 30 may be omitted. In the present specification, the protective layer 20 may be referred to as a visible side protective layer, and the protective layer 30 may be referred to as an inner protective layer.

In the embodiment of the present invention, the polarizing plate is typically humidified (substantially heated / humidified) after curved surface processing. In the embodiment of the present invention, by subjecting the curved polarizing plate to a heating / humidifying treatment, the optical characteristics of the polarizing plate (substantially, a polarizing element) are restored, and the polarizing plate is applied to an image display device. If this is the case, display unevenness and color loss can be suppressed. The effect of such heating / humidifying treatment is an unexpectedly excellent effect. The details are as follows. The heating / humidifying treatment is usually performed as a durability test of the polarizing plate. The fact that a normal polarizing plate is subjected to heating / humidifying treatment is premised on the deterioration of the optical characteristics of the polarizing plate (the degree of deterioration is used as an index of durability). In other words, it is a common general knowledge in the industry that the optical properties of the polarizing plate are deteriorated by the heating / humidifying treatment. On the other hand, the present inventors have found that the deteriorated characteristics can be recovered by subjecting the polarizing plate whose characteristics have been once deteriorated (for example, by processing a curved surface) to a heating / humidifying treatment in a high temperature environment. That is, the heating / humidifying treatment in the embodiment of the present invention is performed based on the technical idea in the opposite direction to the common general technical knowledge in the art, and the effect is an unexpectedly excellent effect. The heating temperature in the heating / humidifying treatment is preferably 40 ° C. to 65 ° C., more preferably 55 ° C. to 65 ° C., further preferably 57 ° C. to 63 ° C., and particularly preferably 58 ° C. to 62 ° C. Yes, especially preferably about 60 ° C. If the heating temperature is too high or too low, the characteristics may not be fully restored. The humidity in the heating / humidifying treatment is preferably 85% RH to 95% RH, more preferably 87% RH to 93% RH, still more preferably 88% RH to 92% RH, and particularly preferably about. 90% RH. If the humidity is too high or too low, the characteristics may not be fully restored. The treatment time is preferably 40 minutes or more, more preferably 50 minutes or more, still more preferably 1 hour or more, and particularly preferably 2 hours or more. The upper limit of the processing time can be, for example, 5 hours. If the processing time is too short, the characteristics may not be fully restored. On the other hand, an excessively long treatment time may not be efficient because the effect obtained is substantially the same even if the treatment time is excessively long.

In an embodiment of the invention, the polarizing plate satisfies the following relationship:
Ts _R -Ts ₀ = ΔTs ≤ + 1.5 (%)
PR _{−P 0} = ΔP ≧ −1.5 (%)
-2.0 (nm) ≤ Re _R -Re ₀ = ΔRe ≤ + 2.0 (nm)
Here, Ts ₀ is the single transmittance before the curved surface processing, Ts _R is the single transmittance after the humidification treatment; P ₀ is the degree of polarization before the curved surface processing, and _PR is the degree of polarization after the humidification treatment. Re ₀ is the in-plane phase difference before the curved surface processing, and Re _R is the in-plane phase difference after the humidification treatment. By satisfying such a relationship, the polarizing plate can suppress display unevenness and color loss when the polarizing plate is applied to an image display device. ΔTs is preferably −2.0% to + 1.5%, more preferably −1.8% to + 1.3%, and even more preferably −1.5% to + 1.0%. ΔP is preferably −1.2% or more, more preferably −1.0% or more, and further preferably −0.8% to 0.0%. ΔRe is preferably −1.0 nm to +2.0 nm, and more preferably −0.8 nm to +1.8 nm. As described above, according to the embodiment of the present invention, the optical characteristics of the polarizing plate once deteriorated by the curved surface processing can be restored to the same level as before the curved surface processing. As a result, even though the polarizing plate is curved, display unevenness and color loss can be suppressed when applied to an image display device. Re _R and Re ₀ are in-plane phase differences of the entire polarizing plate, and are corrected so as to eliminate the influence of the polarizing element after measuring the entire polarizing plate. Re is obtained by the formula: Re = (nx-ny) × d, where d (nm) is the thickness of the film. nx is the refractive index in the direction in which the in-plane refractive index is maximized (that is, the slow-phase axis direction), and ny is the refractive index in the in-plane direction orthogonal to the slow-phase axis (that is, the phase-advancing axis direction). be. The measurement wavelengths of Re _R and Re ₀ can be, for example, 550 nm.

In one embodiment, the polarizing plate defines an area in which the curved surface processed portion is divided into nine in a grid pattern, and the difference between the maximum value and the minimum value of the nine Re _Rs measured in each area (hereinafter, phase difference). It may be referred to as variation), but it is preferably 3.0 nm or less, more preferably 2.5 nm or less, and further preferably 2.0 nm or less. The smaller the phase difference variation is, the more preferable it is, and the lower limit thereof is ideally zero, for example, 0.1 nm.

Hereinafter, the stator and the protective layer will be specifically described.

A-2. Polarizer The splitter is typically composed of a resin film containing a dichroic substance (eg, iodine, a dichroic dye). As the resin film, any suitable resin film that can be used as a polarizing element can be adopted. The resin film is typically a polyvinyl alcohol-based resin (hereinafter referred to as “PVA-based resin”) film. The resin film may be a single-layer resin film or a laminated body having two or more layers.

Specific examples of the polarizing element composed of a single-layer resin film include those obtained by subjecting a PVA-based resin film to a dyeing treatment with iodine and a stretching treatment (typically, uniaxial stretching). The dyeing with iodine is performed, for example, by immersing a PVA-based film in an aqueous iodine solution. The draw ratio of the uniaxial stretching is preferably 3 to 7 times. The stretching may be performed after the dyeing treatment or may be performed while dyeing. Further, it may be dyed after being stretched. If necessary, the PVA-based resin film is subjected to a swelling treatment, a crosslinking treatment, a cleaning treatment, a drying treatment and the like. For example, by immersing the PVA-based resin film in water and washing it with water before dyeing, it is possible not only to clean the dirt and blocking inhibitor on the surface of the PVA-based film, but also to swell the PVA-based resin film to cause uneven dyeing. Etc. can be prevented.

Specific examples of the polarizing element obtained by using the laminate include a laminate of a resin base material and a PVA-based resin layer (PVA-based resin film) laminated on the resin base material, or a resin base material and the resin. Examples thereof include a polarizing element obtained by using a laminate with a PVA-based resin layer coated and formed on a base material. The ligand obtained by using the laminate of the resin base material and the PVA-based resin layer coated and formed on the resin base material is, for example, a resin base material obtained by applying a PVA-based resin solution to the resin base material and drying the resin base material. It is produced by forming a PVA-based resin layer on top of the PVA-based resin layer to obtain a laminate of a resin base material and a PVA-based resin layer; obtain. In the present embodiment, a polyvinyl alcohol-based resin layer containing a halide and a polyvinyl alcohol-based resin is preferably formed on one side of the resin base material. Stretching typically involves immersing the laminate in an aqueous boric acid solution for stretching. Further, stretching may further comprise, if necessary, stretching the laminate in the air at a high temperature (eg, 95 ° C. or higher) prior to stretching in boric acid aqueous solution. In addition, in the present embodiment, preferably, the laminate is subjected to a drying shrinkage treatment in which the laminate is shrunk by 2% or more in the width direction by heating while being conveyed in the longitudinal direction. Typically, the production method of the present embodiment includes subjecting the laminate to an aerial auxiliary stretching treatment, a dyeing treatment, an underwater stretching treatment, and a drying shrinkage treatment in this order. By introducing the auxiliary stretching, even when PVA is applied on the thermoplastic resin, the crystallinity of PVA can be enhanced and high optical characteristics can be achieved. At the same time, by increasing the orientation of PVA in advance, it is possible to prevent problems such as deterioration of PVA orientation and dissolution when immersed in water in a subsequent dyeing step or stretching step, and high optical characteristics. Will be possible to achieve. Further, when the PVA-based resin layer is immersed in a liquid, the disorder of the orientation of the polyvinyl alcohol molecule and the decrease in the orientation can be suppressed as compared with the case where the PVA-based resin layer does not contain a halide. This makes it possible to improve the optical characteristics of the polarizing element obtained through a treatment step of immersing the laminate in a liquid, such as a dyeing treatment and a stretching treatment in water. Further, the optical characteristics can be improved by shrinking the laminated body in the width direction by the drying shrinkage treatment. The obtained resin base material / polarizing element laminate may be used as it is (that is, the resin base material may be used as a protective layer for the polarizing element), and the resin base material is peeled off from the resin base material / polarizing element laminate. Then, an arbitrary appropriate protective layer according to the purpose may be laminated on the peeled surface and used. Details of the method for producing such a polarizing element are described in, for example, Japanese Patent Application Laid-Open No. 2012-73580 and Japanese Patent No. 6470455. The entire description of these publications is incorporated herein by reference.

As the thickness of the splitter, any appropriate thickness may be adopted depending on the intended purpose. The thickness of the splitter is, for example, 35 μm or less, preferably 20 μm or less, more preferably 15 μm or less, still more preferably 12 μm or less, particularly preferably 10 μm or less, still more preferably 8 μm or less. It is particularly preferably 6 μm or less, and most preferably 5 μm or less. The lower limit of the thickness of the splitter is preferably 2 μm, more preferably 1 μm.

The initial degree of polarization (degree of polarization before curved surface processing) P ₀ of the polarizing element is preferably 97.0% or more, more preferably 99.0% or more, and further preferably 99.9% or more. The initial single transmittance (single transmittance before curved surface processing) Ts ₀ of the polarizing element is preferably 40.0% to 46.0%, more preferably 41.0% to 43.5%.

A-3. Protective Layer The visible side protective layer and the inner protective layer are each formed of any suitable film that can be used as a protective layer for the stator. Specific examples of the material that is the main component of the film include cellulosic resins such as triacetylcellulose (TAC), polyesters, polyvinyl alcohols, polycarbonates, polyamides, polyimides, polyethersulfones, and polysulfones. , Polyester-based, polynorbornene-based, polyimide-based, (meth) acrylic-based, acetate-based transparent resins and the like. Further, thermosetting resins such as (meth) acrylic, urethane, (meth) acrylic urethane, epoxy, and silicone, or ultraviolet curable resins can also be mentioned. In addition to this, for example, glassy polymers such as siloxane-based polymers can also be mentioned. Further, the polymer film described in JP-A-2001-343529 (WO01 / 37007) can also be used. As the material of this film, for example, a resin composition containing a thermoplastic resin having a substituted or unsubstituted imide group in the side chain and a thermoplastic resin having a substituted or unsubstituted phenyl group and a nitrile group in the side chain. Can be used, and examples thereof include a resin composition having an alternating copolymer composed of isobutene and N-methylmaleimide and an acrylonitrile / styrene copolymer. The polymer film can be, for example, an extruded product of the above resin composition.

The inner protective layer is preferably optically isotropic. In the present specification, "optically isotropic" means that the in-plane phase difference Re (550) (before curved surface processing) is 0 nm to 10 nm, and the phase difference Rth (550) in the thickness direction is -10 nm to. It means that it is +10 nm. Here, "Rth (λ)" is a phase difference in the thickness direction measured with light having a wavelength of λ nm at 23 ° C. For example, "Rth (550)" is a phase difference in the thickness direction measured with light having a wavelength of 550 nm at 23 ° C. Rth (λ) is obtained by the formula: Rth (λ) = (nx-nz) × d, where d (nm) is the thickness of the layer (film). nz is the refractive index in the thickness direction.

When the polarizing plate is arranged on the visible side of the image display device, the visible side protective layer is subjected to surface treatment such as hard coat treatment, antireflection treatment, sticking prevention treatment, and antiglare treatment, if necessary. May be good. Further / or, if necessary, the visual-viewing side protective layer is provided with a process for improving visibility when visually recognizing through polarized sunglasses (typically, a (elliptical) circular polarization function is imparted, and an ultra-high level is provided. (Giving a phase difference) may be applied.

Any suitable thickness can be adopted as the thickness of the protective layer. The thickness of the protective layer is, for example, 10 μm to 90 μm, preferably 20 μm to 80 μm, more preferably 20 μm to 60 μm, and further preferably 20 μm to 40 μm. When the surface treatment is applied, the thickness of the protective layer is the thickness including the thickness of the surface treatment layer.

B. Method for manufacturing a polarizing plate The polarizing plate according to the above item A is typically a polarizing plate whose characteristics have been restored by a humidification treatment after processing a curved surface. Therefore, the embodiment of the present invention also includes a method for manufacturing a polarizing plate including curved surface processing and humidification treatment. 3 (a) to 3 (c) are schematic views illustrating an example of a method for manufacturing a curved polarizing plate according to an embodiment of the present invention.

In the manufacturing method according to the embodiment of the present invention, first, as shown in FIG. 3A, a polarizing plate 100'including a polarizing element and a protective layer arranged on at least one of the polarizing elements is prepared. At the same time, as shown in FIG. 3A, a mold 200 having a predetermined curved shape (dome shape in the illustrated example) is also prepared.

Then, in one embodiment, as shown in FIG. 3B, the polarizing plate 100'is attached to the mold 200. The bonding of the polarizing plate 100'to the mold 200 can be performed by any suitable method. In the illustrated example, the polarizing plate 100'is attached to the mold 200 via, for example, an adhesive. Next, the polarizing plate is heated with the polarizing plate 100'attached to the mold 200, and the polarizing plate is curved (molded). In another embodiment (not shown), the polarizing plate 100'is placed on the mold 200 and heated to the curved surface processing temperature in a vacuum state, and after reaching the curved surface processing temperature, the system is opened and the curved surface is subjected to air pressure (atmospheric pressure). Process (mold). The curved surface processing temperature is as described in Section A above.

Next, the curved polarizing plate is humidified. The humidification treatment may be performed with the polarizing plate attached to the mold, or may be performed after the polarizing plate is removed from the mold as shown in FIG. 3 (c). The conditions for the humidification treatment are as described in Section A above. In this way, the curved polarizing plate 100 can be obtained.

Hereinafter, the present invention will be specifically described with reference to Examples, but the present invention is not limited to these Examples. The evaluation items in the examples are as follows. Further, unless otherwise specified, "parts" and "%" in the examples are based on weight.

(1) Single-unit transmittance and degree of polarization With respect to the polarizing plates used in Examples and Comparative Examples, the single-unit transmittance and degree of polarization of the polarizing plates used before the curved surface processing and after the curved surface processing into a dome shape were measured. Specifically, for each polarizing plate, the single transmittance Ts, the parallel transmittance Tp, and the orthogonal transmittance Tc measured by using an ultraviolet-visible spectrophotometer (manufactured by Otsuka Electronics Co., Ltd., “LPF-200”) are obtained. The ligands were Ts, Tp and Tc. These Ts, Tp and Tc are Y values measured by the JIS Z8701 two-degree visual field (C light source) and corrected for luminosity factor.
From the obtained Tp and Tc, the degree of polarization P was determined by the following formula.
Degree of polarization P (%) = {(Tp-Tc) / (Tp + Tc)} ^1/2 × 100
The single transmittance before curved surface processing was Ts ₀ , the single transmittance after curved surface processing was Ts _R , the degree of polarization before curved surface processing was P ₀ , and the degree of polarization after curved surface processing was _PR .
The measurement of the curved polarizing plate was performed as follows: The area divided into 9 in a grid pattern except for the lower end of the dome-shaped polarizing plate was defined (one area size: 15 mm × 15 mm). The measurement was performed for each area, and the maximum value was Ts _R for the single transmittance and the minimum value was _PR for the degree of polarization. In addition, the measurement was performed by fixing a dome-shaped polarizing plate with a sample holder and positioning each area so that the measurement could be performed accurately. The Ts and P of the polarizing plate are substantially dominated by the characteristics of the substituent.
(2) In-plane phase difference For the polarizing plates used in Examples and Comparative Examples, the in-plane phase difference before curved surface processing and after curved surface processing into a dome shape was measured. Specifically, the in-plane phase difference was measured for each polarizing plate using a phase difference measuring device (product name "KOBRA-WPR") manufactured by Oji Measuring Instruments Co., Ltd. The measurement wavelength of the in-plane phase difference was 550 nm, and the measurement temperature was 23 ° C. The measurement of the curved polarizing plate was performed in the same manner as in (1) above. In order to improve the measurement accuracy, the measurement was performed with the λ / 4 plate stacked on each polarizing plate. The λ / 4 plate was superposed on the polarizing plate so that its slow axis was at an angle of 45 ° with respect to the absorption axis of the substituent. The in-plane phase difference before curved surface processing was Re ₀ , and the in-plane phase difference after curved surface processing was Re _R.
(3) Appearance The appearance of the curved polarizing plate obtained in Examples and Comparative Examples when placed in the state of a standard polarizing plate and cross Nicol was visually observed and evaluated according to the following criteria.
◯: Neither unevenness nor color loss was observed. Δ: Unevenness was observed. ×: Color loss was observed.

<Example 1>
1. 1. Fabrication of Polarizer As a thermoplastic resin base material, an amorphous isophthal copolymer polyethylene terephthalate film (thickness: 100 μm) having a long shape and a Tg of about 75 ° C. was used, and one side of the resin base material was treated with corona. Was given.
100 parts by weight of PVA-based resin in which polyvinyl alcohol (polymerization degree 4200, saponification degree 99.2 mol%) and acetacetyl-modified PVA (manufactured by Nippon Synthetic Chemical Industry Co., Ltd., trade name "Gosefimer") are mixed at a ratio of 9: 1. A PVA aqueous solution (coating solution) was prepared by dissolving 13 parts by weight of potassium iodide in water.
The PVA aqueous solution was applied to the corona-treated surface of the resin base material and dried at 60 ° C. to form a PVA-based resin layer having a thickness of 13 μm, and a laminate was prepared.
The obtained laminate was uniaxially stretched 2.4 times in the vertical direction (longitudinal direction) in an oven at 130 ° C. (aerial auxiliary stretching treatment).
Next, the laminate was immersed in an insolubilizing bath at a liquid temperature of 40 ° C. (a boric acid aqueous solution obtained by blending 4 parts by weight of boric acid with 100 parts by weight of water) for 30 seconds (insolubilization treatment).
Next, in a dyeing bath having a liquid temperature of 30 ° C. (an aqueous iodine solution obtained by mixing iodine and potassium iodide in a weight ratio of 1: 7 with respect to 100 parts by weight of water), the polarizing element finally obtained is charged. It was immersed for 60 seconds while adjusting the concentration so that the single transmittance (Ts) became a predetermined value (staining treatment).
Then, it was immersed in a cross-linked bath having a liquid temperature of 40 ° C. (a boric acid aqueous solution obtained by blending 3 parts by weight of potassium iodide and 5 parts by weight of boric acid with respect to 100 parts by weight of water) for 30 seconds. (Crossing treatment).
Then, while immersing the laminate in a boric acid aqueous solution (boric acid concentration 4% by weight, potassium iodide concentration 5% by weight) at a liquid temperature of 70 ° C., the total in the longitudinal direction (longitudinal direction) between rolls having different peripheral speeds. Uniaxial stretching was performed so that the stretching ratio was 5.5 times (underwater stretching treatment).
Then, the laminate was immersed in a washing bath having a liquid temperature of 20 ° C. (an aqueous solution obtained by blending 3 parts by weight of potassium iodide with 100 parts by weight of water) (cleaning treatment).
Then, while drying in an oven kept at about 90 ° C., the sauce was brought into contact with a heating roll made of SUS whose surface temperature was kept at about 75 ° C. (dry shrinkage treatment).
In this way, a substituent was formed on the resin base material, and a laminate having a resin base material / a polarizing element configuration was obtained.

2. 2. Fabrication of polarizing plate An acrylic resin film (thickness 40 μm) was applied as a protective layer on the visible side to the surface of the polarizing element of the laminate obtained above (the surface opposite to the resin substrate), and an ultraviolet curable adhesive was applied. It was pasted together through. Specifically, the curable adhesive was coated so as to have a total thickness of about 1.0 μm, and bonded using a roll machine. Then, a UV ray was irradiated from the acrylic resin film side to cure the adhesive. Next, the resin base material was peeled off to obtain a polarizing plate having an acrylic resin film (protective layer on the visible side) / a polarizing element.

3. 3. Curved surface processing of the polarizing plate The obtained polarizing plate was punched into a single-wafer shape and curved (molded) into dome shapes having radii of curvature of 48 mm, 65 mm and 105 mm, respectively. Specifically, the punched polarizing plate is placed on a dome-shaped mold having each radius of curvature and heated to 100 ° C. in a vacuum state, and after reaching the system, the system is opened and a curved surface is formed by air pressure (atmospheric pressure). Processed (molded). The actual processing time (pressurization time) was 150 seconds. Next, the curved polarizing plate was put into a chamber set at 65 ° C. and 95% RH for 2 hours, and heated and humidified. In this way, a curved polarizing plate was obtained. The obtained polarizing plate was used for the evaluation of (1) to (3) above. The results are shown in Table 1.

<Example 2>
Using a polyvinyl alcohol film with a thickness of 75 μm (manufactured by Kuraray Co., Ltd .: VF-PS7500), it was stretched to a stretching ratio of 2.5 times while being immersed in pure water at 30 ° C for 60 seconds, and then an aqueous iodine solution at 30 ° C ( Weight ratio: Stain in pure water / iodine (I) / potassium iodide (KI) = 100 / 0.01 / 1) for 45 seconds to increase the total draw ratio to 5.8 times in a 4 wt% boric acid aqueous solution. After being soaked in pure water for 10 seconds, the film was dried at 60 ° C. for 3 minutes while maintaining the tension of the film to obtain a substituent (thickness 28 μm).

A triacetyl cellulose (TAC) film (thickness 47 μm) was attached to one surface of the obtained polarizing element as a visible side protective layer, and an acrylic resin film (thickness 30 μm) was attached to the other surface as an inner protective layer. A polarizing plate was obtained.

The following procedure was the same as in Example 1 to obtain a curved polarizing plate. The obtained polarizing plate was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Examples 3 and 4>
A curved polarizing plate was obtained in the same manner as in Example 1 except that the polarizing plate having the configuration shown in Table 1 was used. The obtained polarizing plate was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Comparative Example 1>
A polarizing plate with a curved surface was obtained in the same manner as in Example 2 except that the heating / humidifying treatment was not performed. The obtained polarizing plate was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Comparative Examples 2 and 3>
A curved polarizing plate was obtained in the same manner as in Comparative Example 1 except that the polarizing plate having the configuration shown in Table 1 was used. The obtained polarizing plate was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

As is clear from Table 1, according to the embodiment of the present invention, the characteristics of the polarizing plate deteriorated by the curved surface processing can be restored by the heating / humidifying treatment. More specifically, as is clear from comparing Example 2 and Comparative Example 1, Example 3 and Comparative Example 2, and Example 4 and Comparative Example 3, the polarizing plate of the example was deteriorated by curved surface processing. The single transmittance and the degree of polarization have been dramatically restored by the heating and humidifying treatment. It can be seen that the polarizing plate of such an embodiment suppresses unevenness and color loss in the cross Nicol state (corresponding to the black display of the image display device).

The polarizing plate according to the embodiment of the present invention can be suitably used for an image display device having a curved surface (for example, a curved image display device).

10 Polarizer 20 Protective layer 30 Protective layer 100 Polarizing plate

Claims (4)

Includes a polarizing element and a protective layer disposed on at least one of the polarizing elements.
The curved surface is machined, and after the curved surface is machined, it is humidified for 40 minutes or more in an environment of 40 ° C. to 65 ° C. and 85% RH to 95% RH.
Polarizing plate that satisfies the following relationship:
Ts _R -Ts ₀ = ΔTs ≤ + 1.5 (%)
PR _{−P 0} = ΔP ≧ −1.5 (%)
-2.0 (nm) ≤ Re _R -Re ₀ = ΔRe ≤ + 2.0 (nm)
Here, Ts ₀ is the single transmittance before the curved surface processing, Ts _R is the single transmittance after the humidification treatment; P ₀ is the degree of polarization before the curved surface processing, and _PR is the degree of polarization after the humidification treatment. Re ₀ is the in-plane phase difference before the curved surface processing, and Re _R is the in-plane phase difference after the humidification treatment. According to claim 1, an area in which the curved surface processed portion of the polarizing plate is divided into nine in a grid pattern is defined, and the difference between the maximum value and the minimum value of the nine Re _Rs measured in each area is 3.0 nm or less. The polarizing plate described. Preparing a polarizing plate containing a polarizing element and a protective layer arranged on at least one of the polarizing elements;
The polarizing plate is heated to be curved with a mold having a predetermined plaque shape; and the curved polarizing plate is subjected to 40 ° C. to 65 ° C. and 85% RH to 95% RH for 40 minutes. Humidification treatment above;
A method for manufacturing a curved polarizing plate, including. The manufacturing method according to claim 3, wherein the heating temperature in the curved surface processing is 100 ° C. or higher.

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