JP3122053B2 - Lamination method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for laminating a cellulose film and a polyvinyl alcohol film, and more particularly, to an optical laminate such as a polarizing plate or a retardation plate having a small appearance defect and good appearance quality. And a lamination method particularly useful in the production of

[0002]

2. Description of the Related Art Conventionally, a polyvinyl alcohol (hereinafter sometimes referred to as PVA) -based polarizing plate or retardation plate has a structure in which a cellulose film is provided on both sides of a polarizing film or a retardation film. When manufacturing such a polarizing plate or retardation plate, wet lamination using an aqueous adhesive is usually performed. Specifically, the adhesive is first applied to both sides of the polarizing film (or retardation film). A method of repeating lamination with a cellulose triacetate (hereinafter sometimes referred to as TAC) film one side at a time, first applying an adhesive to both sides of a polarizing film (or a retardation film), and simultaneously applying TAC on both sides. A method of laminating with a film, first apply an adhesive to one side of each TAC film and laminate with a polarizing film (or retardation film). A method in which the adhesive is applied to one side of each TAC film at the same time, and an adhesive is applied to one side of one TAC film first. Laminating with a polarizing film (or retardation film) to obtain a two-layer laminate, further applying an adhesive to the polarizing film (or retardation film) side of the two-layer laminate, and laminating with another TAC film. First, an adhesive is applied to one side of a polarizing film (or a retardation film) and laminated with one TAC film to obtain a two-layer laminate, and then the adhesive is applied to one side of the other TAC film. Coating, a method of laminating the TAC film and the two-layer laminate, a polarizing film (or a retardation film), a TAC film, and a three-layer adhesive simultaneously There are seven methods of coating and laminating (squeeze coat and lamination). Regarding such a laminating method, at the time of laminating, the base material should not be damaged, and the Ramiroll should not be stained by foreign substances such as a residual adhesive which remains behind. This is a degree to which static electricity is not extremely generated. There is no particular point to be taken into consideration, and the technique is easy in terms of the difficulty in lamination.

On the other hand, the progress of liquid crystal display devices using such a polarizing plate or a retardation plate has been remarkable in recent years. In the past, only TN type liquid crystal display devices such as small watches were used. The STN type liquid crystal display device and the TFT type liquid crystal display device represented by the car navigation system were invented and actually used. In particular, the progress of the TFT type liquid crystal display device is remarkable, and the large display and the display quality can be achieved as much as the CRT display device. Have been.

Accordingly, it is required that various performances of various parts such as a glass cell, a liquid crystal material, a polarizing plate, and a retardation plate in a liquid crystal display device are improved, and that defects in them are further reduced and the number thereof is reduced. It has become. The polarizing plate, which used to be only an 8-segment monochrome display, has been implemented in notebook PCs and car navigation systems, leading to more detailed and precise color moving image display, optical performance, durability, visibility, appearance quality, and large area. Various improvements in performance such as reduction in optical performance and unevenness in optical performance have been required. At the polarizing plate manufacturing site, when manufacturing TN type polarizing plates such as small watches in the past, defects
The size is 100-700 μm, and the number is 5-35 / m
Those had been at ^2, when the current TFT type polarizing plate production is required to be free from defects (that is, a 0 / m ^2), in reality, one / m ² or less in 60~100μm In the era of the requirement of 0.05 pieces / m ² , innovation in the manufacturing method has been rapidly demanded.

[0005]

Accordingly, the present inventors aimed at further improving the appearance of a laminate of a cellulose-based film and a polyvinyl alcohol-based film, and aimed to improve the appearance of the laminate of the cellulose-based film and the polyvinyl alcohol-based film. The content of water was examined, but as described in JP-A-56-159109 and JP-A-7-120617, a satisfactory content was not obtained simply by adjusting the water content to a few percent. Further study is needed. Improving the appearance of such a laminate refers to uneven defects generated on the surface of the laminate, that is,
Knick defect (a defect generated in a cellulosic film and a laminate thereof, which is a fine and locally uneven bending / buckling defect, has a size of 60 to 1500 μm, and is also called a pyramid or band mark. ), Wrinkle defects (defects that occur in cellulose-based films, polyvinyl alcohol-based films and their laminates during lamination, and are fine breakage defects that occur as streaks in the line direction (base material longitudinal direction). The length is 30 to 3500 μm.)
Vertical defects (defects that occur in cellulose-based films, polyvinyl alcohol-based films and their laminates during lamination, and occur as a tin plate with a height of 0.1 to 1.0 mm in the line direction (base length direction)) The size of the repetition pitch is 30 to 250 mm
is there. In the present invention, a laminate of a cellulose-based film and a polyvinyl alcohol-based film, in particular, a polarizing plate and a retardation plate for a TFT type liquid crystal display device (an optical laminate when collectively referred to) It is an object of the present invention to provide a lamination method in which such defects are less likely to occur.

[0006]

Means for Solving the Problems However, in order to solve the above-mentioned problems, the present inventors have conducted intensive studies on a method of treating a polyvinyl alcohol-based film before lamination. In roll laminating, the surface of at least one side of the polyvinyl alcohol-based film whose water content is adjusted to 0.1 to 20.0% by weight is 5 to 45 ° C.
After treating with a calender roll having a nip linear pressure of 50 to 10000 kg / m, the water content of the polyvinyl alcohol-based film after the calender roll treatment is 0.3 to 16.
5% by weight, or the glossiness of the treated surface of the polyvinyl alcohol-based film after the calendar roll treatment (60%).
By laminating ゜) at 90 (degrees) or more, a laminate excellent in appearance without surface unevenness defects, that is, knick defects, wrinkle defects, and porosity defects can be obtained. By using a metal roll having a surface roughness of 5S, it has been found that the effects of the present invention can be particularly remarkable, and the present invention has been completed.

In the present invention, a film in which a polarizing property is imparted to a PVA film by the adsorption orientation of an iodine compound is called a "polarizing film", and a TAC film as a protective film is provided on both sides (or one side) of the "polarizing film". Are provided and are referred to as “polarizing plates” for distinction. A film to which retardation performance is imparted by stretching a PVA film is called a “retardation film”, and when a TAC film as a protective film is provided on both sides (or one side) of the “retardation film”, the “retardation film” "Plate" to distinguish them.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described specifically. The substrate used in the lamination method of the present invention will be described. The cellulose ester as a raw material of the cellulose-based film used in the present invention is not particularly limited as long as it is an ester of cellulose and an acid, preferably, an ester of cellulose and a fatty acid, cellulose triacetate, cellulose diacetate, cellulose Tripropionate, cellulose dipropionate and the like are used.
As a material for use as an optical laminate of such a cellulose-based film, cellulose triacetate (cellulose triacetate) is preferred from the viewpoint of low birefringence and high transmittance, and the cellulose triacetate film (TAC film) As a commercial product, specifically, "UV
-50 "," SH-50 "," UV-80 "," SH-
80 "," TD-80U ", Konica's" Cellulose Triacetate 80 µm Series ", Lonza Japan's" Cellulose Triacetate 80 µm Series "and the like. Among these, transmittance and durability In view of the above, a TAC film which is improved so as to be suitable for a TFT type liquid crystal display device is more preferable. The thickness of the cellulose-based film is not particularly limited, but is preferably 20 to 150 μm, and more preferably 50 to 85 μm. In addition, these cellulosic films are usually used for reinforcing adhesion during lamination.
The surface to be bonded is subjected to surface modification such as alkali saponification or corona treatment to be put to practical use.

The raw material (polyvinyl alcohol-based resin) of the polyvinyl alcohol-based film used in the present invention is:
Usually, it is produced by saponifying polyvinyl acetate obtained by polymerizing vinyl acetate. However, the present invention is not limited to this, and a small amount of unsaturated carboxylic acid (salt, ester, amide, nitrile, etc.) ), Olefins, vinyl ethers, unsaturated sulfonic acid salts, and the like. The polyvinyl alcohol-based film is not particularly limited as long as such a raw material is used, but after forming a polyvinyl alcohol-based resin, a polarizing film obtained by an iodine compound and a boron compound treatment or a polyvinyl alcohol-based resin is formed. 1.01-1.45 at 130-230 ° C
There is a retardation film obtained by double stretching,
Furthermore, a polarizing film having a high degree of polarization and a high transmittance suitable for a TFT type liquid crystal display device or a low retardation (3 to 50)
nm) of the retardation film. The thickness of the polyvinyl alcohol-based film is not particularly limited.
To 150 μm, more preferably 45 to 85 μm.

In the present invention, when the cellulose-based film and the polyvinyl alcohol-based film are roll-laminated (before lamination), the water content of the polyvinyl alcohol-based film is previously adjusted to 0.1 to 20.0% by weight. , At least one surface of the polyvinyl alcohol-based film at 5 to 45 ° C and a nip linear pressure of 50 to 1000.
The most characteristic feature is that lamination is performed after a calendering process of 0 kg / m is performed. Hereinafter, description will be made in the order of each process.

The water content of the polyvinyl alcohol-based film before the calender roll treatment is 0.1 to 20.0% by weight.
When the water content is less than 0.1% by weight, the polyvinyl alcohol-based film becomes too hard, and the treatment of the calender roll becomes inadequate. Defects increase, which is inconvenient. If it exceeds 20.0% by weight, the adhesion between the calendar roll and the polyvinyl alcohol-based film increases,
This is inconvenient because the number of defects in the polyvinyl alcohol-based film and the laminate increases.

When the polyvinyl alcohol-based film is a polarizing film, the content is preferably 2.5 to 17.5% by weight, more preferably 3.5 to 16.5% by weight. In the case of a retardation film, the content is preferably 0.3 to 6.0% by weight, more preferably 0.5 to 4.5% by weight. As a method for controlling the water content, a known method can be adopted. For example, when the water content of the polyvinyl alcohol-based film exceeds 20.0% by weight, a cylinder roll type dryer, a hot air dryer, a hot air floating dryer. And the like, and when the water content is less than 0.3% by weight, 15 to 30
Aging can be performed in a humidity control room at 75 ° C. and 75% to 95% RH for 3 to 600 minutes to control the water content, but in any case, it is not limited to these.

Next, the surface of the polyvinyl alcohol-based film whose water content is adjusted is subjected to a calender roll treatment. The treatment with such a calender roll usually means that the surface is smooth and the temperature can be controlled. The calendar roll means an industrial treatment in which the surface of the polyvinyl alcohol-based film is surface-modified while pressurizing the surface. There are two types of processes that are performed at the same time, and there are also two types of rolls, a calender finish roll and a calender back roll, and it is possible to determine two types of methods by using these rolls. . The method of calendering the surface of only one side of the polyvinyl alcohol-based film is a method of sandwiching the polyvinyl alcohol-based film between a calendering roll and a calender back roll, and the method of simultaneously treating both sides is a pair of calendering. This is a method of pinching with a roll, but the calendar roll processing is not limited to these.

Next, the conditions of the calender roll processing and the apparatus therefor will be described more specifically. The temperature of the calender roll treatment is preferably 5 to 45 ° C., and if the temperature is less than 5 ° C., the polyvinyl alcohol-based film and the laminate defect thereof due to condensation of the calender roll increase. Defects and wrinkle defects increase, which is inconvenient. As a method for controlling the temperature of the calender roll, the temperature can be controlled by disposing a heat exchange pipe and a dielectric heating device inside the calender roll, but the method is not limited to these.

[0015] The nip linear pressure during the calender roll treatment is preferably from 50 to 10,000 kg / m,
/ M, the number of defects in the laminate increases, and
If it exceeds 00 kg / m, scratches on the surface of the polyvinyl alcohol-based film increase, which is inconvenient. Such a nip line pressure can usually control the line pressure at the time of lamination by a pressing device provided at both ends of the rolls on at least one of these rolls and a bearing portion, but is not limited to this. Absent.

The calendar roll will be described.
As described above, the calender roll is usually composed of two types, a calendering roll and a calender back roll. The calendering roll is particularly limited as long as the roll has a smooth surface and does not cause scratches on the film. However, the following rubber rolls and metal rolls are practical and preferable, and metal rolls having a lower possibility of occurrence of a scratch defect are further preferable.

The rubber roll for the calendering roll has a rubber hardness of 85 to 90 (degrees) (more preferably 87) measured on the surface (measured according to a spring-type hardness test A type of hardness test according to JIS K6301). ~ 88 (degrees)
If the hardness is less than 85 (degrees), the bulge effect (a phenomenon in which the tip of the rubbing rubber is dented and deformed) occurs in the rubber, and a scratch is generated, and a roll is formed. The polyvinyl alcohol-based film itself is damaged by the scratch, and further causes a defect in the polyvinyl alcohol-based film. On the contrary, when the temperature exceeds 90 (degrees), a local non-nip point which is not nip is generated, which is disadvantageous because a scratch is generated.
Specifically, as a material of the rubber roll, EPDM (ethylene polypropylene rubber), NBR (nitrile butyl rubber), silicon, and ebonite are preferable. In addition, 85-
After curing to 90 (degrees), the surface of a rubber roll made of these materials is more preferably rotationally polished with a No. 1500 to 3000 sandpaper or emery paper.

The metal roll for the calendering roll preferably has a surface roughness of 0.1 to 1.5 S.
If it is less than 1 S, it is too mirror-like and the adhesion increases, causing slip marks on the surface of the polyvinyl alcohol-based film. If it exceeds 1.5 S, scratches are generated on the surface of the polyvinyl alcohol-based film, which is inconvenient. The surface of the metal was plated with nickel having a thickness of 5 to 40 μm, and hard chrome plating was further formed thereon with a thickness of 5 to 60 μm so that the surface (outermost surface) was 0.1 to 1 μm. .5
S is preferable, and furthermore, a polytetrafluoroethylene resin (Teflon resin) having 1 to
A coating having a thickness of 55 μm and a surface (outermost surface) of which is polished to 0.1 to 1.5 S is optimal, including a surface for removing dirt from the roll.

The roll for the calender back roll is not particularly limited, but a rubber roll is better than a metal roll in that it does not cause slippage. Such a rubber roll is not particularly limited, but does not damage the film. In terms of the surface, the rubber hardness (JIS A) of the surface is 60
When the hardness is less than 60 (degrees), the bulge effect is applied to the rubber (the tip of the rubber that is in contact with the rubber is dented and deformed). Of the roll), the rolls are scratched, and the roll itself is damaged, and the scratches cause further defects in the polyvinyl alcohol-based film. Conversely, when the roll exceeds 75 (degrees), scratches are generated. is there. Specifically, EPD is used as the material of the rubber roll.
M (ethylene polypropylene rubber), NBR (nitrile butyl rubber), and silicon are preferred. In addition, 60-75
After curing to (degree), the surface of the rubber roll made of these materials is more preferably rotated and polished with a sandpaper of No. 600 to No. 2000.

The diameter of the calender roll is not particularly limited, but usually the diameter (outer diameter) is 50 to 400 mm.
When the diameter is less than 75 mm, the roll itself may bend or the film may be excessively bent, resulting in an irregular surface defect of the resulting laminate. Also 300
When the thickness exceeds mm, the nip retention becomes weak and the tendency of the film to slip increases, which is also disadvantageous. Also, the structure of the calender roll is not particularly limited, but a roll having a large inertia (a heavy roll) is preferable in order to prevent vibration during the calender roll processing.

Next, specific methods of calender roll processing will be described, but the present invention is not limited to these methods. Normally, when only one side of the surface is calendered, the diameter of the calendering roll is made larger than the diameter of the calendering back roll, and the cellulosic film is applied to the calendering roll at an angle of 1 °.
It is nipped and calendered by a calendar back roll while attaching (holding) at 80 to 270 degrees. In addition, when both sides are simultaneously calendered, as described above, one of the two calendering rolls is made larger, and a smaller roll is nipped along with a larger roll. There is a method in which two rolls are made to have the same diameter, and the processing is performed so that the two rolls are pulled out without being attached to the rolls. The preferred method is to do so.

The speed of the calender roll treatment is not particularly limited, but is usually 1 to 15 m / min, preferably 3 to 10 m / min. The surface speed of the calender roll is different from the surface speed of the calender back roll and the calender finishing roll when one side is calendered, and the surface speed of the two calendering rolls is the same when both sides are calendered at the same time. is there. When one side is calendered, the calender back roll is set to the same speed as the film speed (line speed), and the calendering roll is increased by 0.1 to 4% from the film speed. In addition, the speed of the calender back roll becomes the same as that of the calender finishing roll (that is, the speed of 0.1-4% increase), and a device is devised so as not to cause scratches on the surface of the polyvinyl alcohol film on the calender back roll side. Have been.

The method includes: (I) a method in which the width of the polyvinyl alcohol-based film and the width of the calender back roll are made uniform, and then the two are separately driven to a calender back roll and a calender finishing roll, and (II) a polyvinyl alcohol-based film. The width of the calender back roll is aligned with the width of the calender back roll, and the calender back roll is not driven (free rotation with the line speed), but the calender finishing roll is driven. Without adjusting the width of the calender back roll, a clearance adjusting device is placed between the calender back roll and calender finishing roll to provide the clearance for the thickness of the film (strictly speaking, the clearance is set slightly smaller by 1 to 15 μm than the thickness). To prevent roll contact, Zehnder back roll is not driven (free rotate around as the line speed), the calendering rolls and a method of driving. When the rate of increase of the calender finish roll is less than 0.1%, the effect of the calender roll treatment is not obtained. When the rate exceeds 4%, the film tension is excessively increased, which is disadvantageous. When both sides are calendered at the same time, both rolls are also increased by 0.1 to 4% from the film speed, and both rolls are driven.

The tension on the inlet side of the calender roll treatment is not particularly limited, but is usually 5 to 130 kg / 1 m in width to increase the speed of the calendering roll, and the tension on the outlet side is not particularly limited. Usually 1-25k
g / 1m width, but 15-25 kg / 1m width on the inlet side and 1 on the outlet side for stable calender roll treatment.
The width is preferably 0 to 15 kg / 1 m. In controlling the tension, the speed and torque of the drive feed roll before and after the calender roll are controlled while detecting the tension with the tension detection rolls of the number of base materials (two) before and after the calender roll, and the dancer. The pressure of the roll can be controlled, and the tension of the film before and after the calender roll processing can be controlled. Such calendering is usually performed in a clean environment, preferably at a temperature of 15-25.
℃, humidity 50-70% RH, cleanliness 10,000-1
It is performed in a 00CFT clean room. Also,
Regarding the number of times of calender roll treatment, the present invention exerts its effect if at least one side of the polyvinyl alcohol-based film is calender roll treated.However, it is preferable that both sides are calender roll treated, and the calender rolls are arranged in another row. It is preferable that both sides are calendered (preferably 2 to 4 times) 2 to 10 times.

Thus, the surface in contact with the calendering roll is smooth, local irregularities are also removed, and a polyvinyl alcohol-based film having increased gloss is obtained. The glossiness of the calender roll-treated surface (60 °) (Nippon Denki) The reflectance was measured with a color VG-1D gloss meter, but in the present invention, it indicates the maximum measured value on the film surface.
At the time of 0 or more, preferably at 93 to 98 (degrees), the effect of the present invention can be exhibited most when laminating the cellulose-based film and the polyvinyl alcohol-based film, and 9
When the value is less than 0, knick defects tend to increase when laminated to form a laminate. Examples of such control methods include water content of polyvinyl alcohol-based film, temperature during calender roll treatment, nip linear pressure, calender finish roll. Is controlled by the rate of increase in speed, etc.
When the water content is high, when the temperature is high, when the pressure is high, and when the rate of speed increase is large, the gloss tends to increase generally, but these relationships have an interaction, and are not necessarily linear functions (linear ) Does not necessarily increase.

Next, a method for laminating a cellulose film and a polyvinyl alcohol film will be described. The polyvinyl alcohol-based film subjected to the calender roll treatment as described above is laminated with the cellulose-based film. At this time (before lamination), the water content may be 0.3 to 16.5% by weight. It is useful in the present invention, and when it is less than 0.3% by weight, the knick defect of the laminate tends to increase, and when it exceeds 16.5% by weight, the swelling defect tends to increase, which is inconvenient. .
The method for controlling the water content is the same as the method for controlling the water content of the film before the calender roll treatment, and is not particularly limited. Re) controls may be omitted.

Thus, a laminated body is obtained by laminating the polyvinyl alcohol-based film and the cellulose-based film whose water content has been adjusted. An adhesive is usually used for the lamination, and the adhesive is dried and solidified. It is not particularly limited as long as it is transparent later, but a water-based adhesive is preferred for obtaining the effects of the present invention remarkably, and among them, a polymerization degree of 500 to 45 is particularly preferable from the viewpoint of durability.
A 1 to 20% by weight aqueous solution of polyvinyl alcohol having a degree of saponification of 90 to 99.9 mol% is preferred.

In actual lamination, known laminating methods such as those described above can be employed. In the method, the water-based adhesive must be applied in advance to the base material to be laminated. Specific examples include a micro gravure coater, a mangle roll coater, a die coater, a sponge roll coater, and an exaine roll coater that can be applied thinly without damaging the base material to be used and have less foaming. The method is called squeeze coat and lamination in which the coater and the laminator are performed in the same place, and the method is preferable in terms of suppressing curl generated in the film, in terms of production efficiency and simplicity of equipment. It is a target. More specifically, there are the following two methods.

(I) Two laminating rolls are arranged horizontally, and a cellulose-based film (left) / polyvinyl alcohol-based film / cellulose-based film (right) is run from above on the laminating rolls and sandwiched therebetween. A method in which a plate is suspended under a roll and run, and an adhesive is supplied from above the roll between the cellulose-based film (left) / polyvinyl alcohol-based film and between the polyvinyl alcohol-based film / cellulose-based film (right). . (II) Two laminating rolls are arranged vertically, and between them, running from the side of one side of the laminating rolls in the order of cellulose-based film (vertical) / polyvinyl alcohol-based film (45 ° angle to vertical) / cellulose-based film (horizontal) Then, the laminated sheet is run from the other lateral side of the roll, and the adhesive is applied between the cellulose-based film (vertical) / polyvinyl alcohol-based film (45 degrees angle to the vertical) and the polyvinyl alcohol-based film. (45 degree angle with respect to vertical) / Method of supplying liquid between cellulose film (horizontal). Among them, the method (I) is practical and preferable from the viewpoint of defoaming bubbles in the adhesive by buoyancy and suppressing curling.

In this lamination, (a) two sets of laminating rolls are arranged on both sides, and two or three sheets of a film for a laminate substrate (that is, a cellulose film / polyvinyl alcohol film, a polyvinyl alcohol film / (B) a method of sandwiching and laminating a cellulose-based film, a cellulose-based film / polyvinyl alcohol-based film / cellulose-based film), and
A laminating roll is arranged on one side, and an air slit or an air knife is arranged on the other side.
There is a method of passing through a film for a laminate substrate, holding the film with compressed air coming out of an air slit or an air knife while attaching each film to a laminating roll, and laminating, and does not disturb the flow of air near the laminating process The former method (a) is adopted rather than the advantage.

The laminating roll used in the laminating step is usually a rubber roll having a smooth surface and no damage, a metal roll, or a roll (coating roll) coated with Teflon or silicon to prevent the surface of the metal roll from being stained. Is used. Although the linear pressure at the time of lamination is not particularly limited, industrially, the linear pressure is preferably from 10 to 1000 kg / m. Although the tension of each film is not particularly limited, industrially, the tension is 1 to 20 kg.
/ Width is preferable, while controlling the speed and torque of the drive feed roll before and after the laminating roll while detecting the tension with the tension detecting rolls of the number of substrates before and after the laminating roll (in the case of the method, four), The tension of each film at the time of lamination can be controlled by controlling the pressure of the dancer roll or controlling the unwinding brake.

The laminating speed is not particularly limited, but is preferably 1 to 15 m / min. The temperature of the laminating roll is not particularly limited.
When it is out of this range, wrinkles tend to be generated, which is not preferable. In order to control the temperature of the laminating roll, a bearing having a rotary joint or a slip ring mounted on a bearing portion is used, and a temperature control pipe is provided inside the roll, or a roll having a dielectric heating device is used. That can be dealt with. After lamination with such treatment, 30-1
Drying treatment is performed at 00 ° C. for 1 to 10 minutes to form a laminate having a good appearance without knick defects, wrinkle defects, and swelling defects.

Such a lamination method is particularly useful for optical laminates such as a polarizing plate and a retardation plate, and only a TAC film of a type which has not been improved in terms of transmittance and durability so as to be compatible with a TFT type liquid crystal display device. TAC films, which are useful for improved TAC films, but have a clear hard coat layer or an anti-glare hard coat layer having a thickness of 1 to 10 μm coated on one surface of these films, and TAC films of those types. An ITO layer on the surface of the film,
It is also useful for laminated TAC films provided with layers imparting various functions, such as an antifouling treatment layer, an antistatic layer, and a low reflection layer, and is free from knick defects, wrinkle defects, or vertical defects. Which is suitable for a TFT type liquid crystal display device for applications such as word processors, televisions, personal computers, and car navigation systems.

Although the method for laminating an optical laminate such as a polarizing plate or a retardation plate has been described above, the present invention is not limited to these optical laminates, and other polyvinyl alcohol-based films and cellulose-based films can be used. In other words, the laminated film of film condenser, manga cell screen plate, anti-fog film, anti-glare film, ground glass film, colored film, etc. Useful during manufacturing.

[0035]

Next, the present invention will be described in more detail with reference to examples.
In Examples, “%” is based on weight unless otherwise specified. Example 1 Polyvinyl alcohol having an average polymerization degree of 5500 and a saponification degree of 99.6 mol% was dissolved in water to obtain a 2.0% solution. The solution was cast on a polyethylene terephthalate film and dried to obtain a raw film (65 μm, width 1200 mm). The film was immersed in an aqueous solution consisting of 0.20 g / l of iodine and 50 g / l of potassium iodide at 18 ° C. for 360 seconds, and then 45 g / l of boric acid and 55 g of potassium iodide
/ L, an immersion in an aqueous solution having a composition of 2 ppm of iodine, and a boric acid treatment for 12 minutes while simultaneously performing uniaxial stretching 5.5 times at 51.5 ° C. Next, after being immersed in a water washing tank at 6 ° C. for 4 seconds, it is immersed in an aqueous solution containing 0.15 g / l of iodine and 20 g / l of potassium iodide at 15 ° C. for 15 seconds, and then dried at 55 ° C. for 2 minutes. And thickness 2
A polarizing film having a thickness of 0 μm, a width of 640 mm and a water content of 14.3% by weight was obtained.

Both sides of the obtained polarizing film were subjected to calender roll treatment under the following conditions using the following calender roll treatment apparatus. The calender finish roll is a metal roll having a temperature controllable outer diameter of 250 mm, a surface length of 900 mm, a core metal material SS410, a surface hard chrome plating of 20 μm, and a surface roughness of 0.2 S.
With a drive, the surface speed is rotating at 5.10 m / min, and the calender back roll has an outer diameter of 150 m.
m, surface length 640 mm, rubber thickness on one side 20 mm, core material SS410, rubber hardness (measured according to JIS K6301 hardness test spring type hardness test A type test method) It is a rubber roll that is polished and rotated with sandpaper. The position and surface length of the polarizing film are 640 m.
m were arranged so as to coincide with each other, there was no drive, and the surface speed was 5.00 m / min, which was the same as the line speed of the polarizing film. Nip with such a calender finishing roll and calender back roll to 1
An operation of performing a calender roll treatment on one side of the polarizing film at a roll temperature of 38 ° C. by applying pressure at a pressure of 000 kg / m twice on both sides twice to obtain a water content of 10.
A polarizing film having 5% by weight and a gloss of 95.50 (degree) was obtained.

On both sides of the obtained polarizing film, a thickness of 80
While arranging a cellulose triacetate film having a thickness of 670 mm (a film having a width of 670 mm with an alkali-saponified adhesive surface) so that the polarizing film enters the center of the cellulose triacetate film in the width direction, a diameter of 150 mm (rubber thickness: 15 mm; Diameter 120mm, Roll surface length 950mm, Core material S
In step S410), an EPDM rubber roll having a hardness of 85 (degrees) is
Using a set of two rubber rolls that were rotationally polished with a # 500 sandpaper, each tension was 10 kg / 1 m width, lamination speed was 5.00 m / min, and linear pressure was 20.
0 kg / 1 m width, no clearance (a situation where the distance between the Lami rolls can be approached to 0 μm in a state where no film is sandwiched between the Lami rolls), a polyvinyl alcohol-based adhesive, a polymerization degree of 1700, and a saponification degree of 99.9 mol 3% (TAC film / adhesive / polarizing film / adhesive / TAC film) were simultaneously laminated while supplying a 2.8% aqueous solution of polyvinyl alcohol (2%), and then dried at 85 ° C. for 4 minutes to obtain polarized light. I got a board.

The obtained polarizing plate was cut into a total length in the width direction and a length in the longitudinal direction of 1000 mm to obtain a polarizing plate sample for evaluation. The obtained polarizing plate was evaluated as follows. (Knic defect) The number of knick defects in the area of the polarizing plate sample excluding 13 mm from the edge of the polarizing film was confirmed by visual inspection, and the number was counted while checking the size with a microscope. (Wrinkle Defects) Wrinkle defects in the area of the polarizing plate sample excluding 13 mm from the edge of the polarizing film are observed by visual inspection from the direction perpendicular to the polarizing plate and from a direction inclined at an angle of 45 degrees from the perpendicular. After checking the location, the number was counted while checking the thickness with a microscope.・ (Portrait defect) The polarizer sample of the polarizer sample was inspected for the vertical defect at an area 4 mm apart from the ear end of the polarizing film by visual inspection with respect to the polarizing plate at an angle of 4 ° from the vertical direction.
After observing from a direction inclined at 5 degrees and confirming the location, the number was counted while confirming the height (measured from the cross section) with a microscope.
For knick defects, the size should be 60 μm or more,
A distribution of 0.1 / m ² or less is indicated by “○”, and a distribution exceeding the distribution is indicated by “×”.
With respect to wrinkle defects, there is no wrinkle, and even if there are wrinkles, those having a thickness of less than 50 μm are evaluated as ○, those having a wrinkle of 50 μm or more are evaluated as ×, and Was evaluated as ○ when there was no mannequin or even when mannequins were present and the height of the mane was less than 0.1 mm, and x when the height of the generated mane was 0.1 mm or more.

Example 2 A retardation film was obtained in the same manner as in Example 1 except that the retardation film produced under the following conditions was used instead of the polarizing film used in Example 1. A phase difference plate sample for cutting evaluation was obtained and evaluated in the same manner as in Example 1. Average degree of polymerization 550
0, polyvinyl alcohol having a saponification degree of 99.6 mol% was dissolved in water to obtain a 2.0% solution. The solution was cast on a polyethylene terephthalate film and dried to obtain a raw film (65 μm, width 650 mm). The film was stretched 1.03 times at 190 ° C. to obtain a water content of 0.8% by weight.
Was obtained. The gloss after the calender roll treatment was 96.0, and the water content was 0.4% by weight.

Comparative Example 1 A polarizing plate was obtained in the same manner as in Example 1 except that the temperature of the calender roll treatment in Example 1 was changed to 3 ° C. (The glossiness of the polarizing film after the calender roll treatment was 88. .7
(Degree) and the water content was 13.3% by weight). A polarizing plate sample for cut-out evaluation was obtained and evaluated in the same manner as in Example 1.

Comparative Example 2 A polarizing plate was obtained in the same manner as in Example 1 except that the temperature of the calender roll treatment in Example 1 was changed to 55 ° C. (The glossiness of the polarizing film after calender roll treatment was 87. .9
(Degree) and the water content was 9.3% by weight). A polarizing plate sample for cut-out evaluation was obtained and evaluated in the same manner as in Example 1.

Comparative Example 3 The nip linear pressure of the calender roll treatment of Example 1 was set to 40 k.
A polarizing plate was obtained in the same manner as in Example 1 except that g / m was changed. (The glossiness of the polarizing film after the calendar roll treatment was 85.5 (degrees), and the water content at that time was 13. 8
Wt%). A polarizing plate sample for cut-out evaluation was obtained and evaluated in the same manner as in Example 1.

Comparative Example 4 The nip linear pressure of the calender roll treatment of Example 1 was set to 110
A polarizing plate was obtained in the same manner as in Example 1 except that the water content was changed to 00 kg / m (the glossiness of the polarizing film after the calendar roll treatment was 87.7 (degrees), and the water content at that time was 9. 8% by weight). A polarizing plate sample for cut-out evaluation was obtained and evaluated in the same manner as in Example 1.

Comparative Example 5 The procedure of Example 1 was repeated, except that the polarizing film having a water content of 0.07% by weight was obtained by drying at 98 ° C. for 13 minutes instead of the drying at 55 ° C. for 2 minutes. A polarizing plate was obtained in the same manner as in Example 1. (The glossiness of the polarizing film after the calendar roll treatment was 86.3 (degrees), and the water content at that time was 0.3.
06% by weight). A polarizing plate sample for cut-out evaluation was obtained and evaluated in the same manner as in Example 1.

Comparative Example 6 The procedure of Example 1 was repeated, except that the polarizing film having a water content of 23.5% by weight was obtained by drying at 30 ° C. for 1 minute in place of the drying at 55 ° C. for 2 minutes. A polarizing plate was obtained in the same manner as in Example 1. (The glossiness of the polarizing film after the calendar roll treatment was 85.4 (degrees), and the water content at that time was 19.
3% by weight). A polarizing plate sample for cut-out evaluation was obtained and evaluated in the same manner as in Example 1. Table 1 shows the evaluation results of the knick defect, the wrinkle defect, and the vertical defect of the example and the comparative example.

[0046]

[Table 1] Knick defect Wrinkle defect Vertical defect Example 1 ○ ○ ○ 〃 2 ○ ○ ○ Comparative example 1 × × × 〃 2 × × × 〃 3 × × × ４ 4 × × × ５ 5 × × × 〃 6 × × ×

[0047]

According to the present invention, at least one surface of the polyvinyl alcohol-based film is adjusted to have a water content of 0.3 to 16.5% by weight when the cellulose film and the polyvinyl alcohol-based film are roll-laminated. At 5 to 45 ° C, nip linear pressure 50 to 10000k
After laminating after treatment with a calender roll of g / m, a laminate having good appearance performance is obtained without knick defects, wrinkle defects, and swelling defects. In particular, a polyvinyl alcohol-based film can be used as a polarizing film or a retardation film. In the case of the optical laminate of the above, it is useful for a TFT type liquid crystal display device for applications such as word processors, televisions, personal computers, and car navigation systems.

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-8-302139 (JP, A) JP-A-8-171016 (JP, A) JP-A-7-306316 (JP, A) JP-A-7-306 294733 (JP, A) JP-A-6-88004 (JP, A) JP-A-6-88003 (JP, A) JP-A-6-88002 (JP, A) JP-A-4-204803 (JP, A) (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 G02B 5/30

Claims (6)

(57) [Claims] In a roll lamination of a cellulose film and a polyvinyl alcohol film,
The surface of at least one side of the polyvinyl alcohol-based film adjusted to have a water content of 0.1 to 20% by weight is 5 to 45%.
A laminating method using a polyvinyl alcohol-based film which has been treated at 50 ° C with a calender roll having a nip linear pressure of 50 to 10,000 kg / m. 2. The water content of a polyvinyl alcohol-based film after being treated with a calender roll is 0.3 to 16.
The lamination method according to claim 1, wherein the content is 5% by weight. 3. The glossiness (60 °) of the surface of the polyvinyl alcohol-based film after being treated with a calender roll is 9
The lamination method according to claim 1 or 2, wherein the temperature is 0 (degrees) or more. 4. A calender roll having a thickness of 0.1 to 1.5 S
The lamination method according to any one of claims 1 to 3, wherein a metal roll having a surface roughness of? 5. The laminating method according to claim 1, wherein the polyvinyl alcohol-based film is a polarizing film or a retardation film. 6. The lamination method according to claim 1, wherein the cellulose-based film is a cellulose triacetate film.