JP5731187B2 - Optical film manufacturing method and optical film - Google Patents
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- 238000004519 manufacturing process Methods 0.000 title claims description 28
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- 239000004973 liquid crystal related substance Substances 0.000 description 7
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- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 6
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- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 description 1
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Description
本発明は、熱可塑性樹脂組成物を支持体フィルム上で溶液キャスト法によりフィルム化する光学フィルムの製造方法、および光学フィルムに関する。 The present invention relates to an optical film manufacturing method for forming a thermoplastic resin composition on a support film by a solution casting method, and an optical film.
液晶テレビ・携帯電話・３Ｄメガネ・デジタルサーネージ等の液晶ディスプレイ用の光学フィルムには、低寸法変化性、三次元複屈折特性、低吸湿性、耐熱性、透明性等の様々な要求特性があり、これらを解決するために様々な光学フィルムの原料となる樹脂組成物が開発、提案されている。しかしながら、樹脂組成物からフィルムへと形成する製造段階で、要求される平均膜厚、膜厚の均一性、異物混入の排除等を得ることができなければ、それらが液晶ディスプレイで画像を表示する際に画質を乱すノイズとして表れ、満足な表示品質を得られない。特に近年の液晶ディスプレイは大画面化、高精細化、更に携帯端末など屋外で使用するケースが増えているため高輝度化しており、それによって光学フィルムの膜厚不均一性や異物混入による影響をなお受けやすくなっている。 Optical films for liquid crystal displays such as LCD TVs, mobile phones, 3D glasses, and digital signage have various required characteristics such as low dimensional change, three-dimensional birefringence, low moisture absorption, heat resistance, and transparency. In order to solve these problems, resin compositions serving as raw materials for various optical films have been developed and proposed. However, if the required average film thickness, film thickness uniformity, exclusion of foreign matters, etc. cannot be obtained in the production stage of forming the resin composition into a film, they display images on a liquid crystal display. When this occurs, it appears as noise that disturbs image quality, and satisfactory display quality cannot be obtained. In particular, recent LCDs have larger screens, higher definition, and higher brightness due to an increasing number of cases where they are used outdoors such as mobile devices. This has the effect of non-uniform film thickness and contamination by foreign matter. It is easier to receive.
また、光学フィルムに用いられる材料としては、非晶性熱可塑性樹脂が使用され、特に、ポリカーボネート系樹脂やポリアクリル系樹脂、ポリエステル系樹脂、セルロース系樹脂、非晶性環状ポリオレフィン系樹脂などが使用されている。これらを原料として作製される光学フィルムの製造方法としては、溶融押出成形法、溶液キャスト法（溶液流延法）などが知られている。 In addition, amorphous thermoplastic resins are used as materials for optical films, especially polycarbonate resins, polyacrylic resins, polyester resins, cellulose resins, and amorphous cyclic polyolefin resins. Has been. As a method for producing an optical film produced using these as raw materials, a melt extrusion molding method, a solution casting method (solution casting method) and the like are known.
溶融押出成形法は、特許文献１に記載されている通り、優れた生産性を有しているものの、溶融樹脂がダイから押出される際に掛かる応力により三次元複屈折が発生しやすいという課題や、ダイラインの発生などの視覚上の不具合が起きやすいという課題を有している。 The melt extrusion molding method has excellent productivity as described in Patent Document 1, but the problem that three-dimensional birefringence is likely to occur due to the stress applied when the molten resin is extruded from the die. In addition, there is a problem that visual defects such as die lines are likely to occur.
一方、溶液キャスト法は、特許文献２に記載されている通り、有機溶剤を使用するため、コスト及び環境負荷の点でデメリットがあるものの、光学等方性、平坦性などに優れる。また、樹脂は一旦、溶液の形態をとるため、可塑剤やレベリング剤等の添加剤を均一に混合することが容易であるため、作製されるフィルムの改質も行い易い。 On the other hand, as described in Patent Document 2, the solution casting method uses an organic solvent, and thus has disadvantages in terms of cost and environmental load, but is excellent in optical isotropy and flatness. In addition, since the resin once takes the form of a solution, it is easy to uniformly mix additives such as a plasticizer and a leveling agent, so that the produced film can be easily modified.
一般的に、溶液キャスト法では、樹脂溶液をキャストする支持体として金属製のエンドレスベルトやドラムを用いる場合と、プラスチックや金属のフィルムを用いる場合がある。特に、支持体としてプラスチックフィルムを用いる溶液キャスト法においては、均一な表面性・膜厚を有するフィルムを得るためには、走行中の支持体フィルムに樹脂溶液がキャストされる少なくとも瞬間には、支持体フィルムに振動を与えないことが必須となる。このため、樹脂溶液のキャスト部では、支持体フィルムの樹脂溶液がキャストされる反対面（以下、裏面と称す）に支持体フィルムと等速で回転する平滑な金属ロールなどを当てる必要があり、その様な金属ロールをバックアップロールと呼ぶ。 In general, in the solution casting method, a metal endless belt or drum may be used as a support for casting a resin solution, or a plastic or metal film may be used. In particular, in the solution casting method using a plastic film as a support, in order to obtain a film having a uniform surface property and film thickness, the support is provided at least at the moment when the resin solution is cast on the running support film. It is essential not to give vibration to the body film. For this reason, in the cast part of the resin solution, it is necessary to apply a smooth metal roll that rotates at the same speed as the support film to the opposite surface (hereinafter referred to as the back surface) where the resin solution of the support film is cast, Such a metal roll is called a backup roll.
また、プラスチックフィルムを支持体として用いる場合には、搬送性、柔軟性、利便性に優れ、かつ特許文献３、特許文献４、特許文献５にあるように、支持体フィルムの表面粗度を制御することで、光学フィルムの表面性や生産性を向上させることができる。 When a plastic film is used as a support, the surface roughness of the support film is controlled as described in Patent Document 3, Patent Document 4, and Patent Document 5 with excellent transportability, flexibility, and convenience. By doing, the surface property and productivity of an optical film can be improved.
本発明の課題は、支持体であるプラスチックフィルムの裏面に存在する異物やキズによる該プラスチックフィルムの変形を抑制し、均一な膜厚、表面性を有する光学フィルムを得ることである。 The subject of this invention is suppressing the deformation | transformation of this plastic film by the foreign material which exists in the back surface of the plastic film which is a support body, and a damage | wound, and obtaining the optical film which has a uniform film thickness and surface property.
しかし、前記した様な溶液キャスト法においてプラスチックフィルムを支持体として使用して作製された光学フィルムには、透過光がスポット状に不均一になる欠点が多数生じる場合がある。この様な欠点は、光学フィルムとして液晶ディスプレイ等で使用された場合にも、画像の明暗部分として視認できる欠点となり、作製される液晶ディスプレイの歩留まりを大幅に低下させる原因となる。そのため、光学フィルムの透過光の不均一点を改善することは必須課題となっている。 However, an optical film produced by using a plastic film as a support in the solution casting method as described above may have a number of defects in which transmitted light is non-uniform in a spot shape. Such a defect is a defect that can be visually recognized as a light and dark part of an image even when used as an optical film in a liquid crystal display or the like, and causes a significant decrease in the yield of the liquid crystal display to be produced. Therefore, it is an essential subject to improve the nonuniformity of the transmitted light of the optical film.
この様に透過光がスポット状に不均一になるメカニズムを調査したところ、微小なスポット状の膜厚の不均一点が光学フィルムに発生しており、この不均一点がレンズ効果を発現し、フィルムを透過した光が屈折することにあると推定した。 As a result of investigating the mechanism in which the transmitted light becomes non-uniform in the spot shape, a non-uniform spot with a small spot-like film thickness occurs in the optical film, and this non-uniform point expresses the lens effect. It was assumed that the light transmitted through the film was refracted.
更にスポット状に膜厚が不均一になる発生メカニズムを調査したところ、前記した様な溶液キャスト装置において、支持体フィルムの裏面とバックアップロールの間隙に、支持体であるプラスチックフィルムの裏面に存在する微小な異物やキズが介在することで、該プラスチックフィルムが凹凸状に、それを発生させた異物やキズよりも大きく変形し、この上に樹脂溶液がキャスト、製膜されることで光学フィルムの膜厚が不均一になると推定した。 Furthermore, when the occurrence mechanism of the uneven film thickness in the spot shape was investigated, in the solution casting apparatus as described above, it exists in the gap between the back surface of the support film and the backup roll, and on the back surface of the plastic film as the support. By the presence of minute foreign matters and scratches, the plastic film is deformed to be more uneven than the foreign matter or scratches that generated it, and the resin solution is cast and formed thereon to form an optical film. The film thickness was estimated to be non-uniform.
また、この様なプラスチックフィルム表面に存在する異物やキズは微小であるため、一般的に使用されているインライン欠陥検査機で検知することは難しい。また、プラスチック表面に固着しているため、フィルム表面の異物を除去する目的で使用されている粘着ロールや接触・非接触タイプのフィルムクリーナーによる除去は非常に困難である。 Further, since foreign matter and scratches present on the surface of such a plastic film are very small, it is difficult to detect with a generally used inline defect inspection machine. Further, since it is fixed to the plastic surface, it is very difficult to remove it with an adhesive roll or a contact / non-contact type film cleaner used for removing foreign matter on the film surface.
一方で、支持体であるプラスチックフィルムのキャスト面に微小な異物やキズは存在するため、その上に直接製膜される光学フィルムにも異物やキズの形状がそのまま転写するが、その光学フィルムの変形は異物やキズと同じ微小なサイズとなるため、レンズ効果は小さいため問題とならない場合が多い。通常特許文献５にあるように、キャスト面の粗度を裏面よりも小さくすることにより、作業性と光学フィルムの表面性を良くしている。しかし、上記したように、透過光がスポット状に不均一になることを防止するという観点からは、裏面の平坦性が重要であり、むしろキャスト面よりも裏面を平坦にすることが重要であることが判明した。 On the other hand, since there are minute foreign objects and scratches on the cast surface of the plastic film as the support, the shape of the foreign objects and scratches is transferred as it is to the optical film directly formed on the cast film. Since the deformation is as small as a foreign object or scratch, the lens effect is small and often not a problem. Usually, as described in Patent Document 5, the workability and the surface property of the optical film are improved by making the roughness of the cast surface smaller than that of the back surface. However, as described above, from the viewpoint of preventing the transmitted light from becoming uneven in a spot shape, the flatness of the back surface is important, and it is important to make the back surface flat rather than the cast surface. It has been found.
本発明者らは上記課題に鑑み、鋭意検討した結果、本発明を完成するに至った。 As a result of intensive studies in view of the above problems, the present inventors have completed the present invention.
すなわち本発明は、熱可塑性樹脂組成物を支持体フィルム上で溶液キャスト法によりフィルム化する光学フィルムの製造方法であって、該支持体フィルムの裏面に樹脂組成物のコーティングを施し、ＪＩＳ Ｂ０６０１−１９８２に基づいて測定される粗度Ｒｙの関係が、キャスト面＞裏面、である支持体フィルムを用いることを特徴とする光学フィルムの製造方法に関する。 That is, the present invention is a method for producing an optical film in which a thermoplastic resin composition is formed into a film by a solution casting method on a support film, and the back surface of the support film is coated with the resin composition, and JIS B0601- The present invention relates to a method for producing an optical film, wherein a support film in which the relationship of roughness Ry measured based on 1982 is such that cast surface> back surface is used.
好ましい実施態様としては、支持体フィルムのＲｙが、キャスト面は２００〜１２００ｎｍであり、コーティング後の裏面は６００ｎｍ以下であることを特徴とする上記記載の光学フィルムの製造方法に関する。 As a preferred embodiment, the present invention relates to the above-described method for producing an optical film, wherein Ry of the support film is 200 to 1200 nm on the cast surface and 600 nm or less on the back surface after coating.
好ましい実施態様としては、支持体フィルムの裏面に施されるコーティングの膜厚が１〜１０μｍであることを特徴とする上記記載の光学フィルムの製造方法に関する。 As a preferred embodiment, the present invention relates to the method for producing an optical film as described above, wherein the thickness of the coating applied to the back surface of the support film is 1 to 10 μm.
好ましい実施態様としては、コーティングが施された該支持体フィルム裏面のＪＩＳ Ｋ−５６００に基づいて測定される鉛筆硬度が１Ｈ以上であることを特徴とする上記記載の光学フィルムの製造方法に関する。 As a preferred embodiment, the present invention relates to the method for producing an optical film described above, wherein the pencil hardness measured based on JIS K-5600 on the back surface of the coated support film is 1H or more.
好ましい実施態様としては、熱可塑性樹脂がポリカーボネート系樹脂組成物であることを特徴とする上記記載の光学フィルムの製造方法に関する。 As a preferred embodiment, the present invention relates to the method for producing an optical film as described above, wherein the thermoplastic resin is a polycarbonate resin composition.
好ましい実施態様としては、支持体フィルムの材料がポリエチレンテレフタレート(ＰＥＴ）であることを特徴とする上記記載の光学フィルムの製造方法に関する。 As a preferred embodiment, the present invention relates to the method for producing an optical film as described above, wherein the material of the support film is polyethylene terephthalate (PET).
好ましい実施態様としては、樹脂組成物のコーティングがアクリル系樹脂組成物であることを特徴とする上記記載の光学フィルムの製造方法に関する。 As a preferred embodiment, the present invention relates to the method for producing an optical film as described above, wherein the coating of the resin composition is an acrylic resin composition.
また本発明は、上記記載の製造方法で得られることを特徴とする光学フィルムに関する。 The present invention also relates to an optical film obtained by the production method described above.
好ましい実施態様としては、光学フィルムが位相差フィルムであることを特徴とする上記記載の光学フィルムに関する。 As a preferred embodiment, the optical film is a retardation film, and relates to the optical film described above.
好ましい実施態様としては、フィルム面内の任意の点から１００ｍ２の範囲内において、５ｍｍ以上の透過光の不均一点が０個〜５０個であることを特徴とする上記記載の光学フィルムに関する。 As a preferred embodiment, the present invention relates to the above optical film, wherein 0 to 50 non-uniform points of transmitted light of 5 mm or more are within a range of 100 m 2 from an arbitrary point in the film plane.
好ましい実施態様としては、膜厚が２０〜１００μｍの範囲にあることを特徴とする上記記載の光学フィルムに関する。 As a preferred embodiment, the present invention relates to the optical film described above, wherein the film thickness is in the range of 20 to 100 μm.
本発明により、支持体であるプラスチックフィルムの裏面に存在する異物やキズによる該プラスチックフィルムの変形を抑制し、均一な膜厚、表面性を有する光学フィルムを得ることができる。特に透過光がスポット状に不均一になる欠点が改善された光学フィルムを得ることができる。 By this invention, the deformation | transformation of this plastic film by the foreign material which exists in the back surface of the plastic film which is a support body, and a damage | wound can be suppressed, and the optical film which has a uniform film thickness and surface property can be obtained. In particular, it is possible to obtain an optical film having improved defects in which transmitted light is uneven in a spot shape.
本発明は、熱可塑性樹脂組成物を支持体フィルム上で溶液キャスト法によりフィルム化する光学フィルムの製造方法であって、該支持体フィルムの裏面に樹脂組成物のコーティングを施し、ＪＩＳ Ｂ０６０１−１９８２に基づいて測定される粗度Ｒｙの関係が、キャスト面＞裏面、である支持体フィルムを用いることを特徴とする光学フィルムの製造方法である。 The present invention relates to a method for producing an optical film in which a thermoplastic resin composition is formed into a film by a solution casting method on a support film, wherein the back surface of the support film is coated with the resin composition, and JIS B0601-1982. The method of manufacturing an optical film is characterized by using a support film in which the relationship of the roughness Ry measured based on the following formula is: cast surface> back surface.
本発明の光学フィルムの材料としては、光学的に使用可能な非晶性熱可塑性樹脂組成物である限り特に限定されない。例としてはポリカーボネート系樹脂組成物やポリアクリル系樹脂組成物、ポリエステル系樹脂組成物等が挙げられ、低複屈折や低光弾性係数が特徴である非晶性環状ポリオレフィン系樹脂組成物も好ましい。中でも、ポリカーボネート系樹脂組成物は量産されていて安価であり、透明性や加工性に優れているため好ましく、高複屈折性を有するため位相差フィルムとして特に好ましい。 The material of the optical film of the present invention is not particularly limited as long as it is an optically usable amorphous thermoplastic resin composition. Examples include polycarbonate resin compositions, polyacrylic resin compositions, polyester resin compositions, and the like, and amorphous cyclic polyolefin resin compositions characterized by low birefringence and low photoelastic coefficient are also preferred. Among them, the polycarbonate resin composition is preferable because it is mass-produced and inexpensive, and is excellent in transparency and workability, and is particularly preferable as a retardation film because it has high birefringence.
本発明では、上記の樹脂組成物より得られたフィルムの光学的、機械的機能を失わない範囲で、高分子重合体、可塑剤、酸化防止剤、紫外線吸収剤、レベリング剤、接着性付与剤、フィラー、不揮発性溶媒などを添加剤として配合することが出来る。 In the present invention, a polymer, a plasticizer, an antioxidant, an ultraviolet absorber, a leveling agent, and an adhesion-imparting agent are used as long as the optical and mechanical functions of the film obtained from the resin composition are not lost. , Fillers, non-volatile solvents and the like can be blended as additives.
本発明で使用する溶媒は、上記の非晶性熱可塑性樹脂及び、添加剤を溶解するものであれば、特に制限なく使用できる。例えば、直鎖状炭化水素類、環状炭化水素類、ハロアルカン類、環状エーテル類、ケトン類、環状ケトン類、芳香族類、ハロゲン系芳香族類であり、好ましくは樹脂の溶解性の面から、シクロヘキサン、ジクロロメタン、１，２−ジクロロエタン、１,３−ジオキソラン、１，４−ジオキサン、トルエン、キシレン、クロロベンゼンなどである。これらの溶媒は単独で用いてもよく、混合して用いてもよい。 The solvent used in the present invention can be used without particular limitation as long as it dissolves the above amorphous thermoplastic resin and additives. For example, linear hydrocarbons, cyclic hydrocarbons, haloalkanes, cyclic ethers, ketones, cyclic ketones, aromatics, halogenated aromatics, preferably from the viewpoint of the solubility of the resin, Cyclohexane, dichloromethane, 1,2-dichloroethane, 1,3-dioxolane, 1,4-dioxane, toluene, xylene, chlorobenzene and the like. These solvents may be used alone or in combination.
本発明では、製膜されるフィルムの膜厚は用途に応じて選択することができる。光学フィルムとして用いる場合、一般的には、１０〜５００μｍ、２０〜３００μｍ、より好ましくは２０〜１００μｍの範囲が用いられる。 In this invention, the film thickness of the film formed can be selected according to a use. When used as an optical film, generally, a range of 10 to 500 μm, 20 to 300 μm, more preferably 20 to 100 μm is used.
また、本発明の光学フィルムはフィルム面内の任意の点から１００ｍ２の範囲内において、５ｍｍ以上の透過光の不均一点の個数は０個〜５０個であることが好ましい。透過光の不均一点の個数は５０個以下、より好ましくは３０個以下、更に好ましくは１０個以下である。透過光の不均一点は液晶ディスプレイにおいて画像の欠点として現れるため、歩留まりを低下させる原因となる。従い、０個であることが最も好ましいが、上記数値範囲以下の個数であれば、生産性が著しく失われることは無い。 In the optical film of the present invention, the number of non-uniform points of transmitted light of 5 mm or more is preferably 0 to 50 within a range of 100 m 2 from an arbitrary point in the film plane. The number of non-uniform points of transmitted light is 50 or less, more preferably 30 or less, and even more preferably 10 or less. The non-uniform point of transmitted light appears as a defect of an image in a liquid crystal display, which causes a decrease in yield. Therefore, it is most preferable that the number is 0, but if the number is not more than the above numerical range, the productivity is not significantly lost.
支持体フィルムの材質はプラスチックであり、例えばポリオレフィン系樹脂組成物、塩化ビニル系樹脂組成物、ポリエステル系樹脂組成物、ポリアミド系樹脂組成物、ポリイミド系樹脂組成物、ポリフェニレンオキサイド系樹脂組成物、ポリサルホン系樹脂組成物を用いることができるが、これらに限定されるものではない。中でもポリエチレンテレフタレート（ＰＥＴ）のフィルムは安価であり且つ、耐溶剤性、機械特性の面において好ましい。 The material of the support film is plastic, for example, polyolefin resin composition, vinyl chloride resin composition, polyester resin composition, polyamide resin composition, polyimide resin composition, polyphenylene oxide resin composition, polysulfone. Although a resin composition can be used, it is not limited to these. Among them, a film of polyethylene terephthalate (PET) is inexpensive and preferable in terms of solvent resistance and mechanical properties.
支持体フィルムは一般的にはフィルムを巻き取ったロールの形態で運用されるため、支持体フィルムの膜厚は長尺性を考慮し、３００μｍ以下が好ましい。一方、安定な製膜性を確保するためには支持体の剛性がある程度必要であるため、支持体フィルムの膜厚は５０μｍ以上であることが好ましい。 Since the support film is generally operated in the form of a roll around which the film is wound, the film thickness of the support film is preferably 300 μm or less in consideration of the longness. On the other hand, since the rigidity of the support is required to some extent in order to ensure a stable film forming property, the film thickness of the support film is preferably 50 μm or more.
支持体フィルムの裏面に予め施されるコーティングの材質は樹脂組成物であり、該支持体フィルム上に均一に製膜され、元の支持体フィルムよりも平滑なコート面を安定に形成できるものである限り特に限定されない。例えば、アクリル系樹脂組成物、メラミン系樹脂組成物、ポリカーボネート系樹脂組成物、ポリイミド系樹脂組成物、ポリエステル系樹脂組成物、ポリオレフィン系樹脂組成物や非晶性環状ポリオレフィン系樹脂組成物などである。特に、硬質アクリル樹脂組成物のコーティングは、一般的に普及しているため入手も容易であり、硬質性と高耐溶剤性の優れた特徴を示すことから支持体フィルムとして好ましい。 The material of the coating previously applied to the back surface of the support film is a resin composition, which is uniformly formed on the support film and can stably form a smooth coated surface than the original support film. As long as there is no particular limitation. Examples include acrylic resin compositions, melamine resin compositions, polycarbonate resin compositions, polyimide resin compositions, polyester resin compositions, polyolefin resin compositions, and amorphous cyclic polyolefin resin compositions. . In particular, a coating of a hard acrylic resin composition is generally available and thus easily available, and is preferable as a support film because it exhibits excellent characteristics of hardness and high solvent resistance.
支持体フィルムに施されるコーティングの膜厚は、支持体フィルム表面の微細なキズや異物を埋没させるために、これらのキズや異物の高さ以上の膜厚が必要である。経験的にＰＥＴ表面には高さが０．９μｍ以下のキズや異物が多数存在することが多いため、支持体フィルムの裏面に施されるコーティングの膜厚が１μｍ以上が好ましい。また、コーティングの最大膜厚は、安定なコート膜を形成し保持できる膜厚であれば特に限定されない。ただし、膜厚が大きすぎる場合、コート層の剥離や、クラックが入りやすくなるため、１０μｍ以下が好ましい。 The film thickness of the coating applied to the support film is required to be greater than the height of these scratches and foreign objects in order to embed fine scratches and foreign objects on the surface of the support film. Empirically, there are many scratches and foreign matters having a height of 0.9 μm or less on the PET surface, and therefore the thickness of the coating applied to the back surface of the support film is preferably 1 μm or more. The maximum film thickness of the coating is not particularly limited as long as it is a film thickness that can form and hold a stable coating film. However, when the film thickness is too large, peeling of the coating layer and cracks are likely to occur, and therefore it is preferably 10 μm or less.
支持体フィルムのＪＩＳ Ｂ０６０１−１９８２に基づいて測定される粗度Ｒｙは、樹脂溶液より形成される光学フィルムの表面性・平坦性を損なわず且つ、支持体フィルムの搬送性や巻き取り性等の作業性、生産性を損なわない範囲に設定することが好ましい。 Roughness Ry measured based on JIS B0601-1982 of the support film does not impair the surface property / flatness of the optical film formed from the resin solution, and the transportability and winding property of the support film, etc. It is preferable to set in a range that does not impair workability and productivity.
まず、裏面には平滑なコーティングが施され、元の支持体フィルムよりも平滑化するため、支持体フィルム両面のＲｙの関係がキャスト面＞裏面が成立する。 First, since a smooth coating is applied to the back surface and the support film is smoother than the original support film, the relationship of Ry on both surfaces of the support film is such that cast surface> back surface.
次に、コーティングを施した支持体フィルムの裏面のＲｙは、光学フィルムの膜厚の均一性を確保できる点で、６００ｎｍ以下が好ましい。但し、Ｒｙ値が小さい平滑な支持体の作製は製造コストが膨大になる可能性があるため、現実的には５０ｎｍ以上であることが好ましい。また、支持体フィルムのキャスト面のＲｙは１２００ｎｍ以下が好ましい。これ以上であると製膜されるフィルムのヘイズ値が高くなり、光学フィルム用途として適さなくなるだけでなく、支持体フィルムと光学フィルムの剥離力が重くなり、光学フィルムの表面に剥離のダメージが発生することもある。一方で、キャスト面のＲｙは２００ｎｍ以上に設定することが好ましい。これ以下であると支持体フィルム製造時の搬送、巻取りの際にブロッキングが生じ易く、製造上の不具合となる。即ち、支持体フィルムのＲｙが、キャスト面は２００ｎｍ〜１２００ｎｍであり、コーティング後の裏面は６００ｎｍ以下であることが好ましい。 Next, Ry on the back surface of the coated support film is preferably 600 nm or less from the viewpoint of ensuring the uniformity of the film thickness of the optical film. However, since production of a smooth support having a small Ry value may increase the manufacturing cost, it is preferably 50 nm or more in practice. The Ry of the cast surface of the support film is preferably 1200 nm or less. If it exceeds this value, the haze value of the film to be formed becomes high and not only is not suitable for optical film applications, but also the peeling force between the support film and the optical film becomes heavy, and peeling damage occurs on the surface of the optical film. Sometimes. On the other hand, the Ry of the cast surface is preferably set to 200 nm or more. If it is less than this, blocking is likely to occur at the time of conveyance and winding during production of the support film, resulting in a production defect. That is, the Ry of the support film is preferably 200 nm to 1200 nm on the cast surface, and the back surface after coating is preferably 600 nm or less.
支持体フィルムに施されるコート層の硬度は、溶剤キャスト製膜装置において、搬送中に容易にキズ等のダメージが発生しない程度あれば特に限定されない。一方、搬送ロールと支持体フィルムの擦れ等の理由で、裏面であるコート層にキズ等のダメージが発生すると、その部分の光学フィルムの膜厚が不均一となるため、ダメージを抑制するためにコート層の硬度は高い方が好ましい。経験的に、鉛筆硬度が１Ｈ以上あれば、鏡面仕上げされた搬送ロール上で擦れた場合にもキズが発生し難いため、コーティングが施された支持体フィルム裏面の鉛筆硬度が１Ｈ以上であることが好ましい。 The hardness of the coating layer applied to the support film is not particularly limited as long as damage such as scratches does not easily occur during transportation in the solvent cast film forming apparatus. On the other hand, if damage such as scratches occurs on the coating layer on the back side due to rubbing between the transport roll and the support film, the film thickness of the optical film in that part becomes non-uniform, so to suppress damage The higher the hardness of the coat layer, the better. Empirically, if the pencil hardness is 1H or higher, scratches are unlikely to occur when rubbed on a mirror-finished transport roll. Is preferred.
本発明の光学フィルムは、位相差フィルムとして有用に使用され、液晶テレビ・携帯電話・３Ｄメガネ・デジタルサーネージ等の液晶ディスプレイ用の画質補償フィルムとして使用できる。 The optical film of the present invention is usefully used as a retardation film and can be used as an image quality compensation film for liquid crystal displays such as liquid crystal televisions, mobile phones, 3D glasses, and digital signage.
以下に実施例に基づいて本発明の内容を具体的に説明するが、本発明はこれによって限定されるものではない。 The contents of the present invention will be specifically described below based on examples, but the present invention is not limited thereto.
なお、本発明で述べている各測定項目は以下の方法で測定した。 Each measurement item described in the present invention was measured by the following method.
（膜厚）
アンリツ株式会社製触針式膜厚計ＫＧ６０１Ａを使用し、フィルムの幅方向に４ｃｍの幅でカットしたサンプルを用いて測定し、得られた膜厚データの平均値を取った。
(Film thickness)
Using a stylus-type film thickness meter KG601A manufactured by Anritsu Corporation, measurement was performed using a sample cut with a width of 4 cm in the width direction of the film, and an average value of the obtained film thickness data was taken.
（粗度Ｒｙ）
株式会社ミツトヨ製触針式表面粗度測定器ＳＪ−３０１を使用し、ＪＩＳ規格 Ｂ０６０１−１９８２に従い測定した。
(Roughness Ry)
It measured according to JIS standard B0601-1982 using Mitutoyo Corporation stylus type surface roughness measuring device SJ-301.
（レタデーション）
王子計測機器株式会社製ＫＯＢＲＡ−２１ＳＤＨを使用し、波長は５９０ｎｍで測定した。サンプルは幅方向に４ｃｍ幅で切り出したものを用意し、自動フィルム送り幅を５ｃｍに設定し、全幅にわたって測定した。
(Retardation)
A wavelength was measured at 590 nm using KOBRA-21SDH manufactured by Oji Scientific Instruments. The sample was prepared by cutting out 4 cm in the width direction, the automatic film feed width was set to 5 cm, and measurement was performed over the entire width.
（残留溶媒量）
重量法を用い、乾燥前の重量と乾燥後の重量を計測して、次式｛（乾燥前重量）−乾燥後の重量｝／（乾燥前の重量）×１００（％）により算出した。
(Residual solvent amount)
Using the weight method, the weight before drying and the weight after drying were measured and calculated by the following formula {(weight before drying) −weight after drying} / (weight before drying) × 100 (%).
（透過光の不均一点）
浜松ホトニクス株式会社製の高安定キセノンランプ(規格Ｎｏ.Ｌ２２７４)から照射される光を、５０ｃｍ離したフィルムの面に対して直角に透過させ、更にフィルムから５０ｃｍ後に設置した白色版に投影される像を観察し、像が円換算直径で５ｍｍ以上乱れている点を透過光の不均一点と定め、その個数を数えた。
(Non-uniform point of transmitted light)
Light emitted from a highly stable xenon lamp (Standard No. L2274) manufactured by Hamamatsu Photonics Corporation is transmitted at a right angle to the surface of the film separated by 50 cm, and further projected onto a white plate installed 50 cm after the film. The image was observed, and a point where the image was disturbed by 5 mm or more in terms of a circle diameter was determined as a non-uniform point of transmitted light, and the number was counted.
（鉛筆硬度）
株式会社東洋精機製の鉛筆硬度計を使用し、ＪＩＳ Ｋ−５６００に基づいて測定した。
(Pencil hardness)
A pencil hardness meter manufactured by Toyo Seiki Co., Ltd. was used, and the measurement was performed based on JIS K-5600.
（実施例１）
溶媒としてジクロロメタンを用いて、ポリカーボネート系樹脂組成物の２０重量％溶液を調合した。支持体フィルムとして、長さ１０００ｍ、膜厚１００μｍ、幅１６００ｍｍの東レ株式会社製ＰＥＴルミラーの片側表面に膜厚１．２μｍのアクリル系樹脂組成物のコーティングを施したコーティングＰＥＴフィルムを用いた。本支持体のコーティング面の粗度Ｒｙは２１０ｎｍ、鉛筆硬度はＢであった。
Example 1
A 20% by weight solution of a polycarbonate resin composition was prepared using dichloromethane as a solvent. As the support film, a coated PET film in which an acrylic resin composition having a film thickness of 1.2 μm was coated on one surface of a PET mirror made by Toray Co., Ltd. having a length of 1000 m, a film thickness of 100 μm, and a width of 1600 mm was used. The roughness Ry of the coating surface of this support was 210 nm, and the pencil hardness was B.
この支持体フィルムを用いて、コーティング面の反対面に上記樹脂溶液を塗布し、乾燥を行い、得られた一次乾燥フィルムを支持体フィルムと共に巻き取った。引き続いて、得られた一次乾燥フィルムと支持体フィルムを剥離し、ロール懸垂型乾燥装置により、残留溶媒量が０．２５重量％になるまで乾燥し、平均膜厚６０μｍ、長さ９００ｍ、ガラス転移温度１４７℃の二次乾燥フィルムを得た。更に引き続いて、得られた二次乾燥フィルムをフローティング型延伸装置により、１．１倍の延伸を行うことで、平均膜厚６０μｍ、平均レタデーションが２００ｎｍの位相差フィルムを得た。この位相差フィルムについて、透過光の不均一点を探索したところ、１００ｍ２の範囲内に１０個発見した。 Using the support film, the resin solution was applied to the surface opposite to the coating surface, dried, and the obtained primary dry film was wound up together with the support film. Subsequently, the obtained primary dry film and the support film are peeled off, and dried with a roll suspension type drying apparatus until the residual solvent amount becomes 0.25% by weight. The average film thickness is 60 μm, the length is 900 m, and the glass transition. A secondary dry film having a temperature of 147 ° C. was obtained. Subsequently, the obtained secondary dry film was stretched 1.1 times with a floating type stretching apparatus to obtain a retardation film having an average film thickness of 60 μm and an average retardation of 200 nm. About this retardation film, when the nonuniform point of the transmitted light was searched, ten pieces were discovered in the range of 100 m < 2 >.
（実施例２）
実施例１と同じ樹脂溶液、支持体フィルムとそのコーティング材を用いた。ただし、コーティングの膜厚のみを変更し４．５μｍとした。本支持体フィルムのコーティング面の粗度Ｒｙは２００ｎｍ、鉛筆硬度はＢであった。
(Example 2)
The same resin solution, support film and coating material as in Example 1 were used. However, only the film thickness of the coating was changed to 4.5 μm. The roughness Ry of the coating surface of this support film was 200 nm, and the pencil hardness was B.
同様の手法により得られた位相差フィルムは、平均膜厚、平均レタデーションは実施例１と同等となったが、透過光の不均一点を探索したところ、１００ｍ２の範囲内に４個発見した。 The retardation film obtained by the same method had an average film thickness and an average retardation equivalent to those of Example 1. However, when searching for a non-uniform point of transmitted light, four pieces were found within a range of 100 m 2 . .
（実施例３）
実施例１〜２と同じ樹脂溶液、支持体フィルムを用いた。コーティングの膜厚は実施例１と同様に１．２μｍとした。ただし、コーティング材質を硬質アクリル系樹脂組成物に変更した。本支持体フィルムのコーティング面の粗度Ｒｙは２１０ｎｍ、鉛筆硬度は２Ｈであった。
(Example 3)
The same resin solution and support film as in Examples 1 and 2 were used. The film thickness of the coating was 1.2 μm as in Example 1. However, the coating material was changed to a hard acrylic resin composition. The roughness Ry of the coating surface of this support film was 210 nm, and the pencil hardness was 2H.
同様の手法により得られた位相差フィルムは、平均膜厚、平均レタデーションは実施例１〜２と同等となったが、透過光の不均一点を探索したところ、１００ｍ２の範囲内に８個発見した。 The retardation film obtained by the same method had an average film thickness and an average retardation equivalent to those of Examples 1 and 2 , but when searching for a non-uniform point of transmitted light, it was 8 within a range of 100 m 2. discovered.
（実施例４）
実施例１〜２と同じ樹脂溶液、支持体フィルムとそのコーティング材を用いた。コーティングの膜厚は実施例２と同様に４．５μｍとした。ただし、コーティング材質は実施例３と同じ硬質アクリル系樹脂に変更した。本支持体フィルムのコーティング面の粗度Ｒｙは２００ｎｍ、鉛筆硬度は２Ｈであった。
Example 4
The same resin solution, support film and coating material as in Examples 1 and 2 were used. The film thickness of the coating was 4.5 μm as in Example 2. However, the coating material was changed to the same hard acrylic resin as in Example 3. The roughness Ry of the coating surface of this support film was 200 nm, and the pencil hardness was 2H.
同様の手法により得られた位相差フィルムは、平均膜厚、平均レタデーションは実施例１〜３と同等となったが、透過光の不均一点を探索したところ、１００ｍ２の範囲内に２個発見した。 The retardation film obtained by the same method had an average film thickness and an average retardation equivalent to those of Examples 1 to 3. However, when a nonuniform point of transmitted light was searched, two pieces were within a range of 100 m 2. discovered.
（実施例５）
実施例３〜４と同じ樹脂溶液、支持体フィルムとそのコーティング材を用いた。コーティングの膜厚は０．２μｍとした。
(Example 5)
The same resin solution, support film and coating material as in Examples 3-4 were used. The film thickness of the coating was 0.2 μm.
同様の手法により得られた位相差フィルムは、平均膜厚、平均レタデーションは実施例１〜４と同等となったが、透過光の不均一点を探索したところ、１００ｍ２の範囲内に５５個発見した。 The retardation film obtained by the same method had an average film thickness and an average retardation equivalent to those of Examples 1 to 4, but when searching for a non-uniform point of transmitted light, 55 films were within a range of 100 m 2. discovered.
（比較例１）
実施例１〜４と同じ樹脂溶液を用い、支持体フィルムとして実施例１〜４及び比較例１で用いたＰＥＴフィルムをコーティングは施さずそのまま使用した。
(Comparative Example 1)
The same resin solution as in Examples 1 to 4 was used, and the PET film used in Examples 1 to 4 and Comparative Example 1 was used as a support film without coating.
同様の手法により得られた位相差フィルムの平均膜厚、平均レタデーションは実施例１〜４及び比較例１と同等となったが、透過光の不均一点を探索したところ、１００ｍ２の範囲内に７５個発見した。 The average film thickness and average retardation of the retardation film obtained by the same method were the same as those of Examples 1 to 4 and Comparative Example 1, but when the nonuniform point of transmitted light was searched, it was within the range of 100 m 2 . I found 75 of them.
Claims (11)
A film thickness exists in the range of 20-100 micrometers, The optical film in any one of Claims 8-10 characterized by the above-mentioned.
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