JP4512413B2 - Manufacturing method of optical film - Google Patents

Description

The present invention relates to a method for producing an optical film used for, for example, a retardation plate, and more specifically, an optical film having excellent optical quality uniformity and an orientation angle inclined with respect to the longitudinal direction of the film. The present invention relates to a film manufacturing method .

  A retardation plate made of a synthetic resin film is used as a wavelength conversion element or a viewing angle improvement element in various liquid crystal display devices. Usually, the phase difference plate is used in a state of being laminated with a polarizing plate.

  The retardation plate is generally produced by stretching a thermoplastic resin film between rolls or tenter. Therefore, the optical axis of the long thermoplastic resin film produced by continuously stretching is the longitudinal direction of the film or the direction perpendicular to the longitudinal direction. However, in many cases, when the polarizing plate and the retardation plate are bonded, the optical axis of the polarizing plate and the optical axis of the retardation plate are bonded so as to form a predetermined angle that is neither orthogonal nor parallel. ing. Accordingly, a polarizing plate slightly larger than the size of the product and a retardation plate are prepared by cutting in advance, and these optical axes are bonded so that they intersect at a predetermined angle. The ends are cut so that In this method, it is necessary to individually perform a cutting step for obtaining a large polarizing plate, a cutting step for obtaining a large retardation plate, and a step of bonding them together. Therefore, the work process is complicated, the productivity is low, and the number of parts to be discarded increases, so the cost has to be high.

  In order to solve such a problem, various methods have been proposed in which the film is oriented in a direction that is neither perpendicular to the longitudinal direction of the film nor parallel. For example, in the methods described in Patent Documents 1 and 2 below, the final skew angle is set by adjusting the difference in the distance between the left and right clips facing each other and the width of the film, thereby increasing the longitudinal direction. A method for obtaining a film oriented in an oblique direction with respect to the direction is disclosed. However, in this method, tension is generated in an oblique direction other than the portion between the left and right clips corresponding to the initial state. Therefore, the phase difference, the orientation angle, and the Nz coefficient must be varied, and although the orientation axis is inclined with respect to the longitudinal direction, a film with uniform optical quality cannot be obtained.

  Further, in the methods described in Patent Documents 3 and 4 below, a film in which the orientation axis is inclined with respect to the longitudinal direction can be obtained by providing a difference in the moving speed of the left and right clips and stretching in the oblique direction. ing. However, in this method, since there is an oblique stretching zone where there is a part where the width of the film is expanded, not only the oblique direction but also the lateral tension is applied, and a film with uniform optical quality is obtained. I could not.

  Furthermore, even in the methods described in Patent Documents 5 to 7, the film is stretched in an oblique direction using the difference in moving speed between the left and right edges of the film, but wrinkles and thickness unevenness due to the speed difference occur. It was apt. Therefore, it has been difficult to obtain a film having a uniform optical quality.

  In addition, in the method described in Patent Document 6, since the difference in distance traveled by the film side edge on the inner and outer circumferences of the concentric bent portion is utilized, the force in the oblique direction and the lateral direction work simultaneously during bending, Therefore, it is difficult to achieve uniform optical quality.

On the other hand, although the specific stretching method is not described in Patent Document 8 below, in the stretching method described in the drawing of Patent Document 8, the stress in the lateral direction and the oblique direction are applied to the arc portion in the stretching zone. There was a risk of stress. Therefore, it is impossible to obtain a film having a uniform optical quality.

Also, Patent Document 9 discloses a method for producing a film stretched in an oblique direction. However, in the production method described in Patent Document 9, not only an oblique stretching stress but also a lateral stress due to widening. Therefore, it has been difficult to obtain a film having a uniform optical quality.
JP 2002-86554 A JP 2003-276082 A JP 2001-281442 A JP 2003-342384 A Japanese Patent Laid-Open No. 50-83482 Japanese Patent Laid-Open No. 2-113920 Japanese Patent Laid-Open No. 2000-9912 JP 2004-20701 A JP 2003-215343 A

  As described above, in any of the conventional stretching methods, it is very difficult to obtain a film having a uniform optical quality even though it is possible to incline the orientation axis in an oblique direction with respect to the film longitudinal direction. there were. In any of the stretching methods described in the prior art described above, not only the force in the desired inclination angle direction but also the other direction such as the lateral direction acts on the film surface, so that the biaxiality is It was difficult to obtain an optical film having a small Nz coefficient and excellent uniaxiality.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described conventional state of the art, and aims to provide a method for producing an optical film that is not only inclined with respect to the film longitudinal direction but also excellent in optical quality uniformity. To do.

The method for producing an optical film according to the present invention includes the step of preheating in a preheating zone while conveying a long thermoplastic resin film in the longitudinal direction, and the preheating in the stretching zone disposed on the downstream side of the preheating zone. On the first rail and the second rail that extend from the zone into the extension zone, have a constant distance from each other, and are bent at least once or infinitely toward one side in the width direction. The width direction both ends of the thermoplastic resin film are gripped by the traveling first and second clips, and the direction connecting the first and second clips on the first and second rails is from the preheating zone. The first and second clips are allowed to travel on the first and second rails while maintaining the direction orthogonal to the conveyance direction of the thermoplastic resin film required for the stretching zone. A stretching step for orienting the thermoplastic resin film to molecules, whereby the difference between the maximum and minimum orientation angles is 1 ° or less, and the molecular orientation axis of the film is inclined with respect to the longitudinal direction of the film An optical film manufacturing method for obtaining an optical film.

Preferably, when the first and second clips run on the first and second rails, the first and second clips are accelerated on the first and second rolls. In that case, the longitudinal stretch ratio of the long thermoplastic resin film can be adjusted, whereby the molecular orientation angle can be adjusted with higher accuracy.

  Hereinafter, the present invention will be described in more detail with reference to the drawings.

The optical film obtained by the method for producing an optical film according to the present invention has a difference between the maximum value and the minimum value of the orientation angle of 1 ° or less, and the molecular orientation axis of the film is inclined with respect to the longitudinal direction. Features. Here, various thermoplastic resin films can be used as the resin film constituting the optical film.

According to this invention , an optical film is obtained by extending | stretching a thermoplastic resin film so that a molecular orientation axis may incline with respect to a longitudinal direction.

The optical film to be more obtained in the present invention is obtained by stretching a thermoplastic resin film, the thermoplastic resin used, for example, maleimide, polycarbonate, polysulfone, polyether sulfone, polystyrene, polyolefin, polyvinyl An appropriate thermoplastic resin such as alcohol, polyvinylidene fluoride, poly (meth) acrylate, polyethylene terephthalate, cellulose ester, or polynorbornene can be used. In addition, additives, such as a plasticizer and an ultraviolet absorber, may be appropriately added to the thermoplastic resin.

  In addition, the manufacturing method itself of the thermoplastic resin film used is not particularly limited. That is, the thermoplastic resin film can be used by various general film forming methods such as melt extrusion molding, solution casting molding, and calendar method. The thickness of the thermoplastic resin film before stretching is preferably in the range of about 30 to 200 μm. If it is 30 μm or less, the thickness becomes thin after stretching, the film strength may be insufficient, or the waist may be weak and handling may be difficult. If it exceeds 200 μm, the clip for gripping the film in the manufacturing method described later is high. May be easily removed due to tension. Further, it is disadvantageous for thinning the liquid crystal display device.

In the optical film to be more obtained in the present invention, as described above, the difference between the maximum value and the minimum value of the orientation angle of 1 ° or less, or the difference between the maximum value and the minimum value of the phase difference is 10nm or less, or orientation angle Since the difference between the maximum value and the minimum value is 1 ° or less and the difference between the maximum value and the minimum value of the phase difference is 10 nm or less, the optical quality is uniform in the film surface line direction. In addition, an optical element such as a retardation plate having uniform optical characteristics can be obtained. Such an optical film of the present invention having uniform optical quality can be obtained by stretching a thermoplastic resin film by, for example, the following production method.

  When the difference between the maximum value and the minimum value of the orientation angle exceeds 1 ° or when the difference between the maximum value and the minimum value of the phase difference exceeds 10 nm, it is bonded to the polarizing plate and incorporated into the liquid crystal display device. In this case, the display image quality deteriorates, such as display unevenness caused by deviation of each optical axis from a desired angle or display unevenness caused by phase difference unevenness.

In the present invention, preferably, difference between the maximum value and the minimum value of the maximum value the difference between the minimum value is not less than 1 ° and a phase difference of Oriented angle is not less 10nm or less, and more preferably 5nm or less Is done.

FIG. 1 is a schematic plan view for explaining an example of a method for producing an optical film according to the present invention. In the embodiment , a manufacturing apparatus 1 schematically shown in FIG. 1 is used. The manufacturing apparatus 1 includes an unwinding unit 1a for unwinding a thermoplastic resin film from a roll, an extending unit 1b, and a winding unit 1c.

  The long thermoplastic resin film is conveyed from the unwinding portion 1a toward the winding portion 1c along the longitudinal direction.

  In the extending portion 1b, both ends in the width direction of the thermoplastic resin film to be conveyed are held by the clips 6 and 7.

  As shown in FIG. 1, in the extending portion 1b, corresponding clips 6 and 7 indicated by a one-dot chain line and two rails 4 and 5 are arranged. The rails 4 and 5 are extended from the unwinding part 1a side to the winding part 1c side in a state where the distance between them (corresponding distance between clips) is constant. However, the rails 4 and 5 are bent at least once or infinitely. In FIG. 1, the rails 4 and 5 are bent at the bending points A1, A2 and A3 toward the downstream side. That is, each of the rails 4 and 5 has three bending points.

  On the other hand, 2 and 3 are clip holding devices, and the clips 6 and 7 are supported by the clip holding devices 2 and 3. The clips 6 and 7 are configured to run on the rails 4 and 5. The clips 6 and 7 are configured to run on the rails 4 and 5 by a driving device (not shown), but the clips 6 and 7 are configured to grip the end portion in the width direction of the thermoplastic resin film. Yes. In the initial state before reaching the stretched portion 1b, the straight line connecting the corresponding clips 6 and 7 is orthogonal to the longitudinal direction of the thermoplastic resin film. That is, the corresponding clips 6 and 7 are arranged at the same position in the longitudinal direction of the thermoplastic resin film in the initial state, that is, the state before stretching. In FIG. 1, reference numerals 2 and 3 are attached to the portion before stretching, and a pair of clips is shown, but in practice, many pairs are formed along the longitudinal direction of the thermoplastic resin film. The formed clips 6 and 7 are arranged. In addition, 8 and 9 show a clip opening device, and 10 and 11 show cooling devices.

  In the extending | stretching part 1b, the preheating zone 6a, the extending | stretching zone 6b, and the cooling zone 6c are arrange | positioned in order from the upstream. Since the bending points A1 to A3 are provided for extending in an oblique direction, they are disposed in the extending zone 6b.

  At the time of stretching, the pair of clips 6 and 7 are moved on the rails 4 and 5 while gripping the width direction end of the thermoplastic resin film. Therefore, after preheating in the preheating zone 6a, the thermoplastic resin film held by the paired clips 6, 7 is stretched in an oblique direction as it passes through the bending points A1, A2 and A3 in the stretching zone 6b. Is done. That is, the first stretching, the second stretching, and the third stretching in FIG. 1 are performed, and the molecular orientation axis of the thermoplastic resin film is inclined with respect to the film longitudinal direction. The tilted orientation in the cooling zone 6c is fixed by cooling. Thereafter, the optical film of the present invention stretched in an oblique direction is wound up in the winding portion 1c through an opening process.

  The bending angles at the bending points A1 to A3 are arbitrary, the bending angle may be constant, and the bending angle may change along the longitudinal direction. One or more bending points may be present, but the larger the number of bending points, the better. The smaller the distance between a certain bending point and the next bending point, the more preferable. Therefore, the plane shape of the rails 4 and 5 is preferably closer to the arc shape, and an optical film having more uniform optical characteristics can be obtained.

As described above, a large number of pairs of clips 6 and 7 are arranged on the rails 4 and 5, but the smaller the pitch between the front and rear clips arranged on the rails 4 and 5, the better. . Preferably, the pitch between the clips along the rail longitudinal direction is 200 mm or less. The smaller the clip-to-clip pitch, the more uniform the optical film quality in the longitudinal direction of the film, which is desirable.

  The moving speeds of the paired left and right clips 6 and 7 are equal, that is, the corresponding left and right clips 6 and 7 are moved at the same speed. In this case, the moving speed may be constant and may be accelerated as going forward in the film longitudinal direction. When accelerated, the film is stretched in the longitudinal direction, and the stretching ratio in the longitudinal direction of the film is preferably about 1 to 2.5 times, although it depends on the desired orientation angle. When the draw ratio in the longitudinal direction exceeds 2.5 times, the orientation in the longitudinal direction becomes too strong, and the uniformity of the optical properties in the film longitudinal direction may be hindered.

  Next, the principle of the stretching method will be described.

As schematically shown in FIG. 2, when the bending point is only one point A, the unwinding direction is the x axis, the direction orthogonal to the x axis is the y axis, and the x axis is in the plane of the film 11. When stresses σ _x , σ _y and τ _xy are generated in the direction perpendicular to the y axis, the principal stress angle θ _{m with} respect to the x axis in any microelement surface in the plane is expressed by the following equation (1). It is.
θ _m = (1/2) × tan ⁻¹ {2 × τ _xy / (σ _x −σ _y )} (1)

The angle of the orientation axis of the molecule is substantially the same as the principal stress angle θ _m, and at the bending point A, σ _x and σ _y hardly work, and τ _xy , that is, stretching in which shear stress is dominant is performed. Therefore, from the formula (1), the direction around θ _m = 45 ° is substantially the principal stress angle, and the film can be stretched in a direction that always forms an angle of approximately 45 ° with respect to the unwinding direction, that is, the x-axis direction.

Therefore, when the traveling direction forms an angle α (°) with respect to the unwinding direction x-axis, the orientation angle θ (°) of the film is a value represented by the following formula (2).
θ≈45−α (where α <45) (2)

  Further, by stretching the film at the bending point A in the longitudinal direction of the film, a higher retardation can be realized. At this time, the orientation angle is a small angle with respect to the longitudinal direction of the film from the formula (1), and the inclination angle can be finely adjusted by adjusting the draw ratio in the film traveling direction. That is, for example, by accelerating the clips 6 and 7 described above, the film can be stretched in the longitudinal direction of the film, and the tilt angle can be finely adjusted by adjusting the stretching ratio in the film traveling direction.

  Therefore, it can be seen that if the bent portions corresponding to the bending point A are continuously arranged, the film can always be stretched only at a certain angle in the oblique direction during stretching. In addition, in the above-described prior art, it is necessary to provide a widened portion, whereas in the present invention, since the widened portion is not required, stress other than the oblique direction, particularly stress in the width direction is hardly applied. . Therefore, it is possible to obtain an optical film having uniform optical quality with little variation in orientation angle and retardation. Furthermore, as described above, it is possible to adjust the film molecular orientation axis to a desired tilt angle delicately and with high accuracy.

The stretching portion 1b has a configuration in which the preheating zone 6a, the stretching zone 6b, and the cooling zone 6c are arranged in this order. When the temperature of the preheating zone 6a is the glass transition point Tg of the thermoplastic resin film, It is preferable to set it as the range of Tg-50 degreeC-Tg + 50 degreeC. If the temperature is lower than Tg−50 ° C., the film is not sufficiently heated prior to stretching. Therefore, stretching in the heat stretching zone may not be performed smoothly. If the temperature exceeds Tg + 50 ° C., the thermoplastic resin film becomes too soft and heated. In the stretching zone, it is impossible to perform stretching with high accuracy.

  The temperature in the stretching zone 6b is preferably Tg or more and the melting point or less. If it is less than Tg, stretching cannot be performed smoothly, and if the melting point is exceeded, the stretching operation itself becomes impossible. More preferably, it is set as the range of Tg-Tg + 20 degreeC.

  The temperature in the cooling zone 6c is not particularly limited as long as it can fix the molecular orientation, but is generally set to a temperature equal to or lower than Tg.

  As described above, when stretching is performed so that molecules are oriented in an oblique direction, even if the optical quality is uniform during stretching, the contraction stress generated upon cooling in the cooling zone 6c is parallel to the orientation angle. Therefore, the optical quality may vary in the cooling zone 6c. That is, the orientation angle and phase difference that are uniform at the instant of cooling and solidification vary, and the final optical quality may be nonuniform. Therefore, it is preferable to set the boundary line between the stretching zone 6b and the cooling zone 6c in a direction orthogonal to the film orientation angle, thereby making the optical quality uniform in the direction orthogonal to the film orientation angle. Can be increased.

  The heating means in the preheating zone 6a and the stretching zone 6b is not particularly limited, and examples thereof include an appropriate heating device such as a hot air heater, a panel heater, and a halogen heater, and a heating device using a pipe through which a heat medium passes. . Especially, since the temperature control in the boundary of the heating extending | stretching zone 6b and the cooling zone 6c can be performed with high precision, a hot air type heating apparatus is preferable.

  The stretching zone 6b and the cooling zone 6c mean a zone in which the thermoplastic resin film is substantially stretched and a zone in which the orientation generated by the stretching is cooled and fixed. Therefore, the stretching zone 6b and the cooling zone 6c do not necessarily mean mechanically and structurally independent zones, and are not limited to a zone at which the thermoplastic resin film can be stretched, and a temperature at which the orientation can be fixed. It means the zone that is.

According to the production method of the present invention, the preheating step and the stretching step are performed in the same manner as described above in the preheating zone and the stretching zone, and not only the molecular orientation axis of the film is inclined with respect to the film longitudinal direction, Since the difference between the maximum value and the minimum value of the orientation angle is 1 ° or less, an optical film having excellent optical quality uniformity can be obtained . Thus, an optical film more obtained in the present invention, for example, when used as a raw film of the retardation plate, a case of stacking by matching the longitudinal direction of the film original film of the polarizing plate and the optical film In addition, it is possible to easily obtain a laminated structure in which both orientation axes intersect. Therefore, for example, when obtaining a wavelength conversion element or a viewing angle improvement element of a liquid crystal display device, the process and cost can be reduced, and the optical characteristics of the wavelength conversion element and the viewing angle improvement element can be improved.

In the present invention, an optical film is provided as an elongated film Runode, the optical film along its longitudinal direction and laminated to match the longitudinal direction and the like raw film of the polarizing plate, easily and efficiently A laminated structure of a retardation plate and a polarizing plate can be obtained. Therefore, it is possible to reduce the cost of elements such as a wavelength conversion element and a viewing angle improvement element, simplify the manufacturing process, and improve the optical quality.

  Hereinafter, the present invention will be described in more detail with reference to specific examples of the present invention. In addition, this invention is not limited to a following example.

Example 1
In this example, a thermoplastic resin film was stretched using the above-described stretching apparatus 1 shown in FIG. 1 to produce an optical film. As a thermoplastic resin film, polynorbornene (manufactured by Nippon Zeon Co., Ltd., trade name “Zeonor # 1420R”, Tg = 142 ° C.) is supplied to an extrusion molding machine and extruded at 230 ° C. to obtain a width of 400 mm and a thickness. A 60 μm polynorbornene film was prepared. The polynorbornene film was stretched by the stretching apparatus to obtain a retardation film.

  In the stretching apparatus 1 shown in FIG. 1, the polynorbornene film held by the paired left and right clips 6, 7 is heated to 130 ° C. by a hot air heating device in the preheating zone 6a, and then stretched in the stretching zone 6b. Led to. In the stretching zone 6 b, the temperature is raised to 140 ° C. by a hot air heating device, the left and right rails 4, 5 are bent three times, and with respect to the film conveyance direction before the straight line connecting the corresponding left and right bending points is bent. Two rails 4 and 5 having the same shape on the left and right are arranged so as to be orthogonal to each other. A number of pairs of clips 6 and 7 holding both ends in the width direction of the polynorbornene film were moved on the two left and right rails 4 and 5 to give the polynorbornene film an orientation. The pitch between the front and rear clips was 160 mm. Moreover, the moving speed of the clips 6 and 7 was set so that the draw ratio with respect to the traveling direction of the polynorbornene film was 1.7 times.

  The polynorbornene film provided with the orientation as described above is blown in a direction substantially orthogonal to the orientation direction given to the polynorbornene film in the cooling zone 6c set at a temperature of 100 ° C. by a hot air heating device. The orientation was fixed by cooling by spraying.

  The polynorbornene film, the orientation of which was fixed as described above, was wound up at the winding portion 1c to obtain a retardation film.

  About the obtained retardation film, an automatic birefringence meter (manufactured by Oji Scientific Instruments Co., Ltd.) at a total of five points, two points 50 mm from the width direction center and both ends in the width direction, and two points of the middle part in the width direction. The orientation angle and phase difference were measured by the name “KOBRA-21ADH”). The variation in the orientation angle and the phase difference was defined as the difference between the maximum value and the minimum value among the values measured at the above five points.

  Table 1 below shows the orientation angle of the obtained retardation film, the dispersion of the orientation angle, the retardation, and the dispersion of the retardation.

(Example 2)
The material of the thermoplastic resin film used was changed to polycarbonate (manufactured by Teijin Chemicals, trade name “Panlite C-1400”, Tg = 160 ° C.), and the left and right rails were bent three times in the stretching zone, Except that the draw ratio with respect to the traveling direction was 1.1 times, the temperature in the preheating zone was 160 ° C, the temperature in the drawing zone was 170 ° C, and the temperature in the cooling zone was 130 ° C, the same as in Example 1. A retardation film was obtained and evaluated.

(Example 3)
As shown in FIG. 3, the left and right rails 4 and 5 in the stretching zone have been changed to arc-shaped ones having a radius of curvature of 7500 mm, and the stretching ratio in the traveling direction of the thermoplastic resin film is 1.4 times. A retardation film was obtained and evaluated in the same manner as in Example 1 except that the moving speed of the clip was set.

(Comparative Example 1)
A pair of rails having a curvature radius of 900 mm, wherein the position of the bending point in the inner rail 4 in the stretching zone is shifted to the position 450 mm upstream in the film transport direction with respect to the position of the bending point of the outer rail 5. A retardation film was obtained and evaluated in the same manner as in Example 1 except that the moving speed of the clip was set so that the stretching ratio with respect to the film traveling direction was 1.4 times.

(Comparative Example 2)
As shown in FIG. 4, a retardation film was obtained and evaluated in the same manner as in Comparative Example 1 except that in the stretching zone, the left and right rails were configured to have an arc shape with a curvature radius of 7100 mm.

The typical top view for demonstrating the manufacturing apparatus used for the manufacturing method of the optical film of this invention. Explanatory drawing which shows the principle by which the orientation angle in the manufacturing method of the optical film of this invention is determined. FIG. 6 is a schematic plan view for explaining a stretching apparatus used in Example 3. FIG. 3 is a schematic plan view for explaining a stretching apparatus used in Comparative Example 1.

DESCRIPTION OF SYMBOLS 1 ... Manufacturing apparatus 1a ... Unwinding part 1b ... Extending part 1c ... Winding part 2, 3 ... Clip holding | grip apparatus 4, 5 ... Rail 6, 7 ... Clip 8, 9 ... Clip releasing apparatus 10, 11 ... Cooling apparatus A, A1, A2, A3 ... Bending point

Claims (2)

A step of preheating in the preheating zone while conveying the long thermoplastic resin film in the longitudinal direction;
In the stretching zone disposed on the downstream side of the preheating zone, the stretching zone extends from the preheating zone into the stretching zone, the mutual distance is constant, and at least once or infinitely toward one side in the width direction. The both ends of the thermoplastic resin film in the width direction are held by the first and second clips that run on the first and second rails that are bent and turned on the first and second rails. The first and second clips are connected to the first and second clips while maintaining the direction in which the direction connecting the first and second clips is orthogonal to the conveyance direction of the thermoplastic resin film required from the preheating zone to the stretching zone. And a stretching step of causing the thermoplastic resin film to run on the second rail and orienting the molecules, whereby the difference between the maximum value and the minimum value of the orientation angle is 1 ° or less. Obtaining an optical film molecular orientation axis of Lum is inclined relative to the longitudinal direction of the film, method for producing an optical film. 2. The optical according to claim 1, wherein the first and second clips are accelerated on the first and second rolls when the first and second clips run on the first and second rails. 3. A method for producing a film.

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