JP5961475B2 - Manufacturing method of polarizing film - Google Patents

Description

The present invention relates to a method for producing a polarizing film . More specifically, the present invention has a high limit stretching ratio, and the film is not easily broken even when stretched at a high magnification. The present invention relates to a method for producing a polarizing film by using a polyvinyl alcohol polymer film capable of producing a stretched film having excellent optical performance with high yield and high productivity.

  A polarizing plate having a light transmission and shielding function is an important component of a liquid crystal display (LCD) together with a liquid crystal having a light switching function. The field of application of this liquid crystal display device is also used in small devices such as calculators and wristwatches in the early days of development, notebook computers, liquid crystal monitors, liquid crystal color projectors, liquid crystal televisions, in-vehicle navigation systems, mobile phones, and measurements used indoors and outdoors. It has been extended to a wide range of devices, especially for LCD monitors and LCD TVs.

  The polarizing plate is generally a method of uniaxially stretching a polyvinyl alcohol-based polymer film and then dyeing with iodine or a dichroic dye, and uniaxially stretching the polyvinyl alcohol-based polymer film and then fixing with a boron compound. A polarizing film is produced by a method of performing a fixing treatment simultaneously with dyeing in any one of the above methods, and a polarizing film obtained thereby has a cellulose triacetate film or an acetic acid / butyric acid cellulose film on one or both sides. It is manufactured by attaching a protective film.

In recent years, along with the expansion of applications of liquid crystal display devices, in addition to the enhancement of display quality, further cost reduction and further improvement in handling are required. From the viewpoint of cost reduction, improving the production speed when manufacturing a polarizing film, preventing breakage (breaking) when stretching a polyvinyl alcohol polymer film, reducing breakage loss, and improving yield. At the same time, it is necessary to prevent interruption of stretching work and stretching / dying work due to film breakage.
As one of the productivity improvements when manufacturing a polarizing film, shortening of the drying time when manufacturing a polarizing film is required. From this point, as a raw film for a polarizing film, the thickness is conventionally limited. In general, a polyvinyl alcohol polymer film having a thickness of about 75 μm has been used, but in recent years, a thinner polyvinyl alcohol polymer film having a thickness of less than 70 μm has been demanded.
However, as the polyvinyl alcohol polymer film becomes thinner, there is a problem that breakage is likely to occur when stretched at a high magnification. From this point, the limit stretch ratio is high, and even if thin, the high magnification without causing breakage. A polyvinyl alcohol polymer that can be produced by a polarizing film having a polarizing performance equal to or higher than that of a conventional product with good workability, high yield, low cost, and high productivity. There is a need for films.

  Conventionally, for the purpose of improving the stretchability of a polyvinyl alcohol polymer film, improving the uniformity during stretching, and improving the polarization performance and durability of a polarizing film obtained by stretching a polyvinyl alcohol polymer film, In forming a film while drying using a stock solution containing an alcohol-based polymer, adjustment of the film-forming draw (ratio of the conveyance speed of the polyvinyl alcohol-based polymer film between rolls used for film formation), during film formation Adjustment of the moisture content of the polyvinyl alcohol polymer film has been performed.

  As such a conventional technique, (1) in order to obtain a stretched film having a sufficient molecular orientation when uniaxially stretched, a film forming operation for producing a polyvinyl alcohol polymer film is performed at 1 or less. (2) High-stretching is possible (Patent Document 1, especially its paragraphs [0008] to [0009], Examples, etc.); When producing a polyvinyl alcohol polymer film using a drum film forming machine for the purpose of obtaining a suitable polyvinyl alcohol polymer film, [winding speed of the obtained polyvinyl alcohol polymer film] / [ Method of setting the speed of the drum located at the uppermost stream to which the film forming raw material is supplied to 0.8 to 1.3 (Patent Document 2); (3) Polyvinyl alcohol capable of high-stretching The process speed at the time when the volatile fraction of the film is 10% by weight or less in the drying process when producing a polyvinyl alcohol polymer film using a drum film forming machine for the purpose of obtaining a polymer film A method of making the speed ratio (Rf / Rc) of Rc and final winding speed Rf 0.9 to 1.1 (Patent Document 3) is known.

In addition, (4) in order to obtain a polyvinyl alcohol film capable of producing a wide polarizing film having uniform optical performance even in a large area, the drying is located in a step where the volatile content of the polyvinyl alcohol film is 10% or less. The speed ratio (Rf / Rc) between the roll speed (Rc) and the winding speed (Rf) is controlled to 0.9 to 1.1, and temperature fluctuations in the drying process are reduced, for example, in the MD direction. A method for producing a polyvinyl alcohol film having a ratio (S _M / S _T ) of the elongation (S _M ) to the tensile elongation (S _T ) in the TD direction of 0.7 to 1.3 (Patent Document 4); (5) In order to obtain a polyvinyl alcohol film capable of producing a wide polarizing film having uniform optical performance even in a large area, when the volatile content of the polyvinyl alcohol film reaches 10 to 50% by weight, the most upstream side The speed ratio of the speed V1 of the drum positioned on the most upstream side and the speed V2 of the drum positioned in the process where the volatile content of the polyvinyl alcohol film is less than 10% by weight for the first time while peeling the polyvinyl alcohol film from the positioned drum A method of making V2 / V1 1.0 to 1.3 (Patent Document 5) is known.

Furthermore, (6) in order to obtain a polyvinyl alcohol polymer film comprising a specific skin layer / core layer / skin layer which can be uniformly uniaxially stretched and gives a stretched film free from fine cracks and voids when stretched. A stock solution containing 50 to 90% by mass of a volatile fraction containing a polyvinyl alcohol polymer is heated with a first drying roll and simultaneously hot air is applied to the polyvinyl alcohol polymer film surface not in contact with the first drying roll under predetermined conditions. When sprayed, when the volatile content reaches 15 to 30% by mass, the polyvinyl alcohol polymer film is peeled off from the first drying roll and brought into contact with the second drying roll and dried. At that time, the first drying roll A method of making the ratio (S ₂ / S ₁ ) of the peripheral speed (S ₁ ) and the peripheral speed (S ₂ ) of the second drying roll to 1.000 to 1.100 (Patent Document 6) is known. .

  However, in Patent Documents 1 to 6 described above, when a polyvinyl alcohol polymer film, particularly a polyvinyl alcohol polymer film having a thin film thickness, is stretched uniaxially at a high magnification, the film does not break. However, there is no disclosure of this measure, particularly a measure for further improving the limit draw ratio of the film.

JP-A-6-136151 JP 2001-315141 A JP 2001-315146 A JP 2002-30164 A JP 2002-79531 A JP 2005-324355 A

“Polymer Science One Point 10 Photophysical Properties of Polymers”, first edition, third edition, Kyoritsu Shuppan Co., Ltd., December 15, 2007, p. 19-21

The purpose of the present invention is that the limiting stretch ratio is high and can be stretched at a high magnification without causing breakage, and thereby a stretched film such as a polarizing film having optical performance equal to or higher than that of a conventional product can It is providing the method of manufacturing a polarizing film using the polyvinyl-alcohol-type polymer film which can be manufactured with high productivity, high yield, low cost, and high productivity.
In particular, the object of the present invention is to have a high limit draw ratio even if it is thinner than the polyvinyl alcohol polymer film conventionally used in the production of polarizing films, and to cause breakage when stretched at a high ratio. The film can be smoothly uniaxially stretched to make a stretched film thinner than before, and the polarizing film can be produced with higher productivity by further reducing the drying time when producing the polarizing film. It is to provide a method for producing a polarizing film using a polyvinyl alcohol polymer film .

As a result of intensive studies by the present inventors to achieve the above object, the value and width obtained by averaging the birefringence in the machine flow direction (length direction) of the polyvinyl alcohol polymer film in the thickness direction of the film A value obtained by averaging the birefringence in the width direction of the polyvinyl alcohol polymer film in the thickness direction of the film while satisfying a specific relationship with the value obtained by averaging the birefringence in the direction in the thickness direction of the film When the film is in a specific numerical range, the limit stretching ratio of the film becomes high, and even if the film is stretched at a high magnification, the film is hardly broken, and a stretched film such as a polarizing film having excellent optical performance such as polarizing performance is stretched. They found that they can be manufactured with high yield, low cost, and high productivity without interrupting work. Moreover, when the value which averaged the birefringence of the machine flow direction of a polyvinyl alcohol-type polymer film to the thickness direction of a film was made into the specific numerical value range, it discovered that the limit draw ratio of a film improved further.
In particular, the value obtained by averaging the birefringence in the machine flow direction of the polyvinyl alcohol polymer film in the film thickness direction and the value obtained by averaging the birefringence in the width direction in the film thickness direction satisfy a specific relationship. In addition, the above-mentioned polyvinyl alcohol polymer film in which the value obtained by averaging the birefringence in the width direction in the thickness direction of the film is in a specific range has been conventionally used for the production of a polarizing film. Even with a thickness of about 30 to 65 μm, which is thinner than the thickness of the polyvinyl alcohol polymer film, because of having a high limit stretching ratio, it is smoothly uniaxially stretched at a high magnification without causing breakage. It has been found that it is possible to further reduce the thickness of the polarizing film during production, and further shorten the drying time when producing the polarizing film. .

  Then, the inventors of the present invention have the above-described polyvinyl alcohol-based polymer film having a high limit draw ratio on the first drying roll of the film-forming apparatus including a plurality of drying rolls. After being discharged, the film is sequentially dried with the plurality of drying rolls to form a film. At that time, the volatile fraction of the polyvinyl alcohol-based polymer film with respect to the peripheral speed of the first drying roll is 13% by mass. The ratio of the peripheral speed of the drying roll is set to a specific numerical range, and the ratio of the peripheral speed of the final drying roll to the peripheral speed of the drying roll when the volatile content of the polyvinyl alcohol polymer film becomes 13% by mass is specified. It was found that by making the numerical range and the ratio of the peripheral speed of the final drying roll to the peripheral speed of the first drying roll in a specific numerical range, it can be manufactured smoothly and continuously with high productivity.

  Moreover, when manufacturing the polyvinyl alcohol-type polymer film with a high limit draw ratio by said method, the present inventors are the volatile content rate of the polyvinyl alcohol-type polymer film when peeling from a 1st drying roll. Is preferably in a specific numerical range, the roll surface temperature of each drying roll is preferably 65 ° C. or higher, and the volatile fraction of the film-forming stock solution containing the polyvinyl alcohol polymer is 60 to 75. If the first drying roll has a roll surface temperature of 80 to 120 ° C. even if the peripheral speed of the first drying roll is 8 m / min or more, the polyvinyl alcohol-based polymer film can be combined in the machine flow direction. A value obtained by averaging the refractive index in the thickness direction of the film and a value obtained by averaging the birefringence in the width direction in the thickness direction of the film satisfy a specific relationship, and the birefringence in the width direction. Has been found that a polyvinyl alcohol polymer film having a high limit draw ratio can be produced smoothly and with good productivity, and further studies are made based on these findings. The present invention has been completed.

That is, the present invention
(1) A method for producing a polarizing film, characterized in that a polyvinyl alcohol polymer film satisfying the following formulas (I) and (II) is dyed, uniaxially stretched, fixed and dried .
Δn (MD) _Ave −0.1 × 10 ⁻³ ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.25 × 10 ⁻³ (I)
Δn (TD) _Ave ≦ 2.5 × 10 ⁻³ (II)
[In the above formula, Δn (MD) _Ave represents a value obtained by averaging the birefringence in the machine flow direction of the polyvinyl alcohol polymer film in the thickness direction of the film, and Δn (TD) _Ave represents the polyvinyl alcohol type. The value obtained by averaging the birefringence in the width direction of the polymer film in the thickness direction of the film is shown. ]
And this invention,
(2) satisfies the formula (I) and (II) below, further wherein a reportage polyvinyl alcohol polymer film to satisfy (III) below, dyeing, monoaxial stretching, fixing treatment and drying treatment to This is a method for producing a polarizing film.
Δn (MD) _Ave −0.1 × 10 ⁻³ ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.25 × 10 ⁻³ (I)
Δn (TD) _Ave ≦ 2.5 × 10 ⁻³ (II)
1.3 × 10 ⁻³ ≦ Δn (MD) _Ave ≦ 2.0 × 10 ⁻³ (III)
[In the above formula, Δn (MD) _Ave represents a value obtained by averaging the birefringence in the machine flow direction of the polyvinyl alcohol polymer film in the thickness direction of the film, and Δn (TD) _Ave represents the polyvinyl alcohol type. The value obtained by averaging the birefringence in the width direction of the polymer film in the thickness direction of the film is shown. ]
The present invention also provides:
(3) The method for producing a polarizing film according to (1) or (2), wherein a thickness of the polyvinyl alcohol polymer film used for producing the polarizing film is in a range of 30 to 65 μm .

The aforementioned polyvinyl alcohol polymer film used for the production of the polarizing film is:
<1> A method for producing a polyvinyl alcohol polymer film,
(A) Using a film-forming apparatus provided with a plurality of drying rolls whose rotation axes are parallel to each other, a film-forming stock solution containing a polyvinyl alcohol polymer is discharged into a film on the first drying roll of the film-forming apparatus. Partial drying followed by further drying with a subsequent drying roll to form a film;
(B) Ratio of the peripheral speed (S _T ) of the drying roll when the volatile content of the polyvinyl alcohol polymer film is 13% by mass relative to the peripheral speed (S ₁ ) of the first drying roll (S _T / S ₁ ) from 0.990 to 1.050;
(C) Ratio of the peripheral speed (S _L ) of the final drying roll to the peripheral speed (S _T ) of the drying roll when the volatile content of the polyvinyl alcohol polymer film becomes 13% by mass (S _L / S _T ) To 0.960-0.980;
(D) is the peripheral speed of the first drying roll peripheral speed of the final drying roll against (S ₁₎ the ratio of _{(S L) (S L /} S 1) to 0.970 to 1.010;
It can be smoothly manufactured by a method for manufacturing a polyvinyl alcohol-based polymer film.

And the said polyvinyl alcohol-type polymer film used for manufacture of a polarizing film is,
<2> The method according to <1> , wherein the polyvinyl alcohol polymer film has a volatile content of 17 to 30% by mass when peeled from the first drying roll;
<3> The method according to <1> or <2> above, wherein the roll surface temperature of each drying roll is 65 ° C. or higher; and
<4> The film-forming stock solution containing the polyvinyl alcohol polymer has a volatile content of 60 to 75% by mass, the roll surface temperature of the first drying roll is 80 to 120 ° C., and the peripheral speed of the first drying roll ( S ₁₎ is 8～25M / min, one of the production method of <1> to <3>;
Can be manufactured more smoothly .

Since the polyvinyl alcohol-based polymer film used in the present invention has a high limit stretch ratio, even when uniaxially stretched at a high ratio when producing a stretched film, the film hardly breaks, A stretched film such as a polarizing film having excellent optical performance such as polarization performance can be produced with high yield, low cost and high productivity without interrupting the stretching operation.
In particular, the polyvinyl alcohol polymer film used in the present invention has a film thickness of about 30 to 65 μm, which is thinner than the thickness of a polyvinyl alcohol polymer film conventionally used for producing a polarizing film or the like. Even if it is a thickness, it has a high limit draw ratio, so it can be smoothly uniaxially stretched at a high ratio without causing breakage. Thus, it is possible to further shorten the drying time and improve the productivity due to the production of a polarizing film or the like.
In recent years, as a raw film for the polarizing film, but it is also used polyvinyl alcohol polymer film of more than 1000m in length, polyvinyl alcohol polymer film used in the present invention has a high critical draw ratio Therefore, the film can be stretched at a higher magnification than conventional ones, and thereby the amount of the polarizing film obtained from the polyvinyl alcohol polymer film can be increased more than before.
By employing the manufacturing method of the polyvinyl alcohol polymer film as described above, it can be produced smoothly and continuously a reportage polyvinyl alcohol polymer film having a superior characteristics described above with high productivity.

FIG. 1 is a schematic view showing a sample collection method when measuring Δn (MD) _Ave of a polyvinyl alcohol polymer film. FIG. 2 is a schematic view showing a method of collecting a sample when measuring Δn (TD) _Ave of a polyvinyl alcohol polymer film.

The present invention is described in detail below.
In general, in a transparent film manufactured using a transparent polymer such as a polyvinyl alcohol polymer, the polymer chain is oriented in the flow direction (machine flow direction: length direction) due to plastic deformation or strain due to shear stress. The polarization directions of the atomic groups constituting the are aligned macroscopically, thereby causing birefringence specific to the polymer (Non-patent Document 1).
The birefringence [Δn (MD)] in the machine flow direction of the polyvinyl alcohol polymer film is obtained from the following formula [i], and the birefringence [Δn (TD)] in the width direction is obtained from the following formula [ii] ].
Δn (MD) = nMD−nz [i]
Δn (TD) = nTD−nz [ii]
[Where nMD is the refractive index in the machine flow direction (length direction) of the film, nTD is the refractive index in the width direction of the film, and nz is the refractive index in the thickness direction of the film. ]
As described in Non-Patent Document 1, in a film manufactured using a transparent polymer such as a polyvinyl alcohol polymer, the polymer chains forming the film are oriented in the machine flow direction (length direction). In general, polyvinyl alcohol polymer films including the polyvinyl alcohol polymer films described in Patent Documents 1 to 6 described above generally have a “birefringence index in the machine flow direction [Δn (MD)]”> The relationship of “birefringence index [Δn (TD)]” in the width direction, that is, the birefringence index [Δn (MD)] in the machine flow direction is larger than the birefringence index [Δn (TD)] in the width direction. Prone.

On the other hand, the polyvinyl alcohol polymer film used in the present invention is different from the conventional polyvinyl alcohol polymer film in that it satisfies the following formulas (I) and (II).
Δn (MD) _Ave −0.1 × 10 ⁻³ ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.25 × 10 ⁻³ (I)
Δn (TD) _Ave ≦ 2.5 × 10 ⁻³ (II)
[In the above formula, Δn (MD) _Ave represents a value obtained by averaging the birefringence in the machine flow direction of the polyvinyl alcohol polymer film in the thickness direction of the film, and Δn (TD) _Ave represents the polyvinyl alcohol type. The value obtained by averaging the birefringence in the width direction of the polymer film in the thickness direction of the film is shown. ]

That is, as shown in the above formula (I), in the polyvinyl alcohol polymer film used in the present invention (hereinafter, “polyvinyl alcohol” is sometimes referred to as “PVA”), the machine flow direction of the PVA polymer film ( [Delta n], which is a value obtained by averaging the birefringence of the PVA polymer film in the thickness direction of the film (line direction when continuously forming the PVA polymer film) [hereinafter sometimes referred to as “length direction (MD)”]. MD) _Ave "averages the birefringence of the PVA polymer film in the width direction (direction perpendicular to the length direction) [hereinafter sometimes referred to as" width direction (TD) "] in the thickness direction of the film. Even if it is equal to or somewhat smaller than the obtained value “Δn (TD) _Ave ” or exceeds “Δn (TD) _Ave ”, the amount is small.
Furthermore, the PVA polymer film used in the present invention is also characterized by satisfying the above formula (II) together with the formula (I).

The PVA polymer film used in the present invention satisfies the above formulas (I) and (II), and thus has a high limit draw ratio even when the thickness of the film is thinner than the conventional one. Even when uniaxially stretched at a high magnification during the manufacture of stretched films such as polarizing films, the film is less likely to break, and without causing interruption of the stretching work associated with the breakage of the film, it is excellent in optical performance such as polarization performance and thin film The stretched film can be manufactured with high yield and high productivity.
When deviating from the above formula (I), the limit stretching ratio of the PVA polymer film becomes low, and the film tends to be ruptured when uniaxially stretched at a high magnification, particularly when the film is thin. easy.
The PVA polymer film used in the present invention preferably satisfies the following formula (I ′), more preferably satisfies the following formula (I ″), and the following formula (I ′ ″) It is more preferable to satisfy
Δn (MD) _Ave −0.05 × 10 ⁻³ ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.23 × 10 ⁻³ (I ′)
Δn (MD) _Ave ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.2 × 10 ⁻³ (I ″)
Δn (MD) _Ave + 0.05 × 10 ⁻³ ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.18 × 10 ⁻³ (I ′ ″)

Moreover, if it deviates from the range of the above-mentioned formula (II) and Δn (TD) _Ave of the PVA polymer film exceeds 2.5 × 10 ⁻³ , the limit draw ratio of the PVA polymer film becomes low. Further, it becomes difficult to stretch the PVA polymer film in the length direction (MD) at a high magnification, and it becomes difficult to obtain a stretched film having excellent optical performance.
In order to make Δn (TD) _Ave too small, it is necessary to allow drying shrinkage in the width direction during the production of the PVA polymer film, and the effective width yield of the PVA polymer film tends to decrease. Therefore, the PVA polymer film used in the present invention preferably has Δn (TD) _{Ave in} the range of 1.5 × 10 ^{−3 to} 2.2 × 10 ⁻³ , and 1.6 × 10 ⁻³ to More preferably, it is in the range of 2.0 × 10 ⁻³ .

The PVA polymer film used in the present invention preferably further satisfies the following formula (III) in addition to the above formulas (I) and (II).
1.3 × 10 ⁻³ ≦ Δn (MD) _Ave ≦ 2.0 × 10 ⁻³ (III)
When the Δn (MD) _Ave of the PVA polymer film is 2.0 × 10 ⁻³ or less, the limit stretching ratio of the PVA polymer film is further increased, and the PVA polymer film is lengthwise (MD ) Can be easily stretched at a high magnification, and a stretched film having excellent optical performance can be obtained more easily. On the other hand, in order to make Δn (MD) _Ave of the PVA polymer film less than 1.3 × 10 ⁻³ , it is necessary to greatly reduce the peripheral speed ratio of the drying roll. There is a tendency that sagging is likely to occur in the polymer film.
The PVA polymer film used in the present invention preferably has Δn (MD) _{Ave in} the range of 1.4 × 10 ^{−3 to} 1.95 × 10 ⁻³ , and 1.5 × 10 ⁻³ to 1 More preferably, it is in the range of 9 × 10 ⁻³ .

In the PVA polymer film, Δn (MD) _Ave and / or Δn (TD) _Ave often fluctuate in the width direction (TD) of the film, and in particular, Δn (MD ) _Ave tends to be high, but at least the center of the PVA polymer film in the width direction (TD) should satisfy formulas (I) and (II), preferably satisfy formulas (I) to (III). The formulas (I) and (II) are preferably applied to the entire region of 80% or more of the width direction (TD) centering on the center portion in the width direction (TD) of the PVA polymer film, preferably the formulas (I) to (I) It is preferable to satisfy (III). Both ends in the width direction (TD) of the PVA polymer film not satisfying the formulas (I) and (II) are removed by cutting before the PVA polymer film is stretched in the length direction (MD). Take).

“Δn (MD) _Ave ” of the PVA polymer film [value obtained by averaging the birefringence in the length direction (MD) of the PVA polymer film in the thickness direction of the film] and “Δn (TD) _Ave ” The [value obtained by averaging the birefringence in the width direction (TD) of the PVA polymer film in the thickness direction of the film] can be measured by the following method.

<< 1 >> Δn (MD) _Ave measurement method:
(Here, a method for measuring Δn (MD) _Ave at the center in the width direction (TD) of the PVA polymer film is exemplified.)
(I) At an arbitrary position in the length direction (MD) of the PVA polymer film, as shown in FIG. 1 (a), MD × TD = 2 mm × 10 mm from the center in the width direction (TD) of the film Is cut out, sandwiched on both sides with a 100 μm thick PET film, and further sandwiched between wooden frames and attached to a microtome apparatus.
(Ii) Next, as shown in FIG. 1B (PET film and wooden frame are not shown), the strips collected in the above are spaced by 10 μm parallel to the length direction (MD) of the strips. And slice 10 pieces for observation (MD × TD = 2 mm × 10 μm) shown in FIG. From the slice pieces, five slice pieces having a smooth slice surface and no slice thickness unevenness are selected, and each slice piece is placed on a slide glass and the slice thickness is measured with a microscope (manufactured by Keyence Corporation). Observation is performed in a visual field of 10 times the eyepiece and 20 times the objective (total 200 times).
(Iii) Next, the slice piece is tilted as shown in FIG. 1D so that the slice surface can be observed and placed on the slide glass with the slice surface facing upward, and the cover glass and silicone oil (refractive index 1.04). And the retardation of five slice pieces is measured using a two-dimensional photoelasticity evaluation system “PA-micro” (manufactured by Photonic Lattice Co., Ltd.).
(Iv) With the retardation distribution of each slice piece displayed on the “PA-micro” measurement screen, a line α perpendicular to the original film surface is drawn across the slice piece, and a line is formed on the line segment α. Analysis is performed to obtain retardation distribution data in the thickness direction of the film. Observation is performed in a visual field of 10 times the eyepiece and 20 times the objective (total 200 times). Further, in order to suppress an error due to a change in the position where the line segment α passes on the slice piece, an average value of retardation is adopted with a line width of 300 pixels.
(V) The value of retardation distribution in the thickness direction of the film obtained above is divided by the thickness measured with a microscope to obtain a birefringence Δn (MD) distribution in the thickness direction of the film, and the thickness direction of the film is determined. The average value of the birefringence Δn (MD) distribution is taken. The average value of the birefringence Δn (MD) distribution in the thickness direction of each film obtained for the five slice pieces is further averaged to obtain “Δn (MD) _Ave ”.

<< 2 >> Δn (TD) _Ave measurement method:
(Here, a method of measuring Δn (TD) _Ave at the center in the width direction (TD) of the PVA polymer film is exemplified.)
(I) At an arbitrary position in the length direction (MD) of the PVA polymer film, as shown in FIG. 2 (a), MD × TD = 10 mm × 2 mm from the center in the width direction (TD) of the film Is cut out, sandwiched on both sides with a 100 μm thick PET film, and further sandwiched between wooden frames and attached to a microtome apparatus.
(Ii) Next, as shown in FIG. 2B (PET film and wooden frame are not shown), the strips collected in the above are parallel to the width direction (TD) of the strips at intervals of 10 μm. Slicing is performed to produce 10 slices for observation (MD × TD = 10 μm × 2 mm) shown in FIG. From the slice pieces, five slice pieces having a smooth slice surface and no slice thickness unevenness are selected, and each slice piece is placed on a slide glass and the slice thickness is measured with a microscope (manufactured by Keyence Corporation). Observation is performed in a visual field of 10 times the eyepiece and 20 times the objective (total 200 times).
(Iii) Next, the slice piece is tilted as shown in FIG. 2D so that the slice surface can be observed and placed on the slide glass with the slice surface facing upward, and the cover glass and silicone oil (refractive index 1.04). And the retardation of five slice pieces is measured using a two-dimensional photoelasticity evaluation system “PA-micro” (manufactured by Photonic Lattice Co., Ltd.).
(Iv) With the retardation distribution of each slice piece displayed on the “PA-micro” measurement screen, a line β perpendicular to the original film surface is drawn so as to cross the slice piece, and a line on the line segment β is drawn. Analysis is performed to obtain retardation distribution data in the thickness direction of the film. Observation is performed in a visual field of 10 times the eyepiece and 20 times the objective (total 200 times). Further, in order to suppress an error due to a change in the position where the line segment β passes on the slice piece, an average value of retardation is adopted with a line width of 300 pixels.
(V) The value of retardation distribution in the thickness direction of the film obtained above is divided by the thickness measured with a microscope to obtain the birefringence Δn (TD) distribution in the thickness direction of the film, and the thickness direction of the film is determined. The average value of the birefringence Δn (TD) distribution is taken. The average value of the birefringence Δn (TD) distribution in the thickness direction of each film obtained for the five slice pieces is further averaged to obtain “Δn (TD) _Ave ”.

The thickness of the PVA polymer film used in the present invention can be in the range of 5 to 150 μm, but is preferably 30 to 65 μm when used as a raw material for a polarizing film. Since the PVA polymer film used in the present invention has a high limit drawing ratio, the thickness of the PVA polymer film is higher than that of a PVA polymer film having a thickness of about 75 μm, which has been often used as a raw material for a polarizing film. When the thickness is 30 to 65 μm, the film can be stretched at a high magnification without causing breakage of the film. Thereby, a stretched film having optical properties such as polarization performance equal to or higher than that of a conventional product can be obtained at a high yield. It can be manufactured smoothly with good productivity, and by stretching a PVA polymer film having a thickness of 30 to 65 μm at a high magnification, the thickness of the stretched film can be made thinner than before, The drying time at the time of manufacturing a polarizing film can be shortened, and the manufacturing speed of a polarizing film can be improved.
When the thickness of the PVA polymer film is too thick, drying is difficult to be performed quickly when the polarizing film is produced. On the other hand, when the thickness of the PVA polymer film is too thin, the uniaxial for producing the polarizing film. The film is easily broken during stretching.

The width of the PVA polymer film used in the present invention is not particularly limited, but in recent years, liquid crystal televisions and monitors have become larger in screen, so the width may be 2 m or more so that they can be used effectively. Preferably, it is 3 m or more, more preferably 4 m or more. Moreover, when manufacturing a polarizing plate with a realistic production machine, if the width of the film is too large, uniform uniaxial stretching may be difficult. Therefore, the width of the PVA polymer film may be 8 m or less. preferable.

The mass swelling degree of the PVA polymer film used in the present invention is preferably 180 to 250%, more preferably 185 to 240%, and further preferably 190 to 230%. If the mass swelling degree of the PVA polymer film is too low, it tends to be difficult to stretch and it becomes difficult to produce a stretched film having excellent optical performance. On the other hand, if the mass swelling degree is too high, Process passability may deteriorate, or a highly durable polarizing film may not be obtained.
The mass swelling degree here is a value obtained by dividing the mass when the PVA polymer film is immersed in distilled water at 30 ° C. for 30 minutes by the mass after drying at 105 ° C. for 16 hours after the immersion. It can be measured by the method described in the following examples.

Examples of the PVA polymer for forming the PVA polymer film used in the present invention include PVA obtained by saponifying polyvinyl ester obtained by polymerizing vinyl ester, and graft copolymerization with a comonomer on the main chain of PVA. Modified PVA polymer, modified PVA polymer produced by saponifying modified polyvinyl ester copolymerized with vinyl ester and comonomer, some of hydroxyl groups of unmodified PVA or modified PVA polymer are formalin, butyl Examples include so-called polyvinyl acetal resins crosslinked with aldehydes such as aldehyde and benzaldehyde.
When the PVA polymer forming the PVA polymer film used in the present invention is a modified PVA polymer, the amount of modification in the PVA polymer is preferably 15 mol% or less, preferably 5 mol% or less. More preferably.

  Examples of the vinyl ester used in the production of the PVA polymer include vinyl acetate, vinyl formate, vinyl laurate, vinyl propionate, vinyl butyrate, vinyl pivalate, vinyl versatate, vinyl stearate, and benzoic acid. Vinyl etc. can be mentioned. These vinyl esters can be used alone or in combination. Of these vinyl esters, vinyl acetate is preferred from the viewpoint of productivity.

  Examples of the comonomer described above include olefins having 2 to 30 carbon atoms such as ethylene, propylene, 1-butene, and isobutene (such as α-olefin); acrylic acid or a salt thereof; methyl acrylate, ethyl acrylate, Acrylic esters such as n-propyl acrylate, i-propyl acrylate, n-butyl acrylate, i-butyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, dodecyl acrylate, octadecyl acrylate ( For example, an acrylic ester having 1 to 18 carbon atoms of acrylic acid); methacrylic acid or a salt thereof; methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, i-propyl methacrylate, n-butyl methacrylate, i-methacrylate Butyl, t-butyl methacrylate, meta Methacrylic acid esters (for example, C1-C18 alkyl ester of methacrylic acid) such as 2-ethylhexyl silylate, dodecyl methacrylate, octadecyl methacrylate; acrylamide, N-methylacrylamide, N-ethylacrylamide, N, N- Acrylamide derivatives such as dimethyl acrylamide, diacetone acrylamide, acrylamide propane sulfonic acid or salts thereof, acrylamide propyl dimethylamine or salts thereof, N-methylol acrylamide or derivatives thereof; methacrylamide, N-methyl methacrylamide, N-ethyl methacrylamide, Methacrylamide propane sulfonic acid or its salt, methacrylamide propyl dimethylamine or its salt, N-methylol methacrylamide or its Methacrylamide derivatives such as derivatives; N-vinylamides such as N-vinylformamide, N-vinylacetamide, N-vinylpyrrolidone; methyl vinyl ether, ethyl vinyl ether, n-propyl vinyl ether, i-propyl vinyl ether, n-butyl vinyl ether, i -Vinyl ethers such as butyl vinyl ether, t-butyl vinyl ether, dodecyl vinyl ether and stearyl vinyl ether; Nitriles such as acrylonitrile and methacrylonitrile; Vinyl halides such as vinyl chloride, vinylidene chloride, vinyl fluoride and vinylidene fluoride; Acetic acid Allyl compounds such as allyl and allyl chloride; unsaturated dicarboxylic acids such as maleic acid and itaconic acid; derivatives thereof such as salts or esters thereof; Vinyl silyl compounds such emissions; isopropenyl acetate; an unsaturated sulfonic acid or its derivatives. Among these, α-olefins are preferable, and ethylene is particularly preferable.

The average degree of polymerization of the PVA polymer forming the PVA polymer film used in the present invention is preferably 1000 or more, more preferably 1500 or more, and more preferably 2000 or more, from the viewpoint of polarization performance and durability of the obtained polarizing film. Is more preferable. On the other hand, the upper limit of the average degree of polymerization of the PVA polymer is preferably 8000 or less, particularly preferably 6000 or less, from the viewpoint of ease of production of a homogeneous PVA polymer film and stretchability.
Here, the “average degree of polymerization” of the PVA polymer in the present specification refers to the average degree of polymerization measured according to JIS K6726-1994, and is 30 ° C. after re-saponifying and purifying the PVA polymer. It is obtained from the intrinsic viscosity measured in water.

The saponification degree of the PVA polymer forming the PVA polymer film used in the present invention is preferably 95.0 mol% or more, and preferably 98.0 mol% from the viewpoint of the polarization performance and durability of the obtained polarizing film. The above is more preferable, 99.0 mol% or more is further preferable, and 99.3 mol% or more is most preferable.
Here, the “degree of saponification” of the PVA polymer in the present specification refers to the total number of moles of structural units (typically vinyl ester units) and vinyl alcohol units that can be converted into vinyl alcohol units by saponification. The percentage of the number of moles of the vinyl alcohol unit (mol%). The degree of saponification of the PVA polymer can be measured according to the description of JIS K6726-1994.

The production method of the PVA polymer film used in the present invention is not particularly limited, and any method can be used as long as it can produce a PVA polymer film satisfying the above formulas (I) and (II). Although the PVA polymer film used in the present invention is good,
(A) A part in which a film forming apparatus including a plurality of drying rolls whose rotation axes are parallel to each other is used, and a film forming stock solution containing a PVA polymer is discharged into a film on the first drying roll of the film forming apparatus. After drying, it is further dried with a subsequent drying roll to form a film;
(B) Ratio of the peripheral speed (S _T ) of the drying roll when the volatile content of the PVA polymer film becomes 13% by mass with respect to the peripheral speed (S ₁ ) of the first drying roll (S _T / S ₁ ) from 0.990 to 1.050;
(C) Ratio of the peripheral speed (S _L ) of the final drying roll to the peripheral speed (S _T ) of the drying roll when the volatile content of the PVA polymer film becomes 13% by mass (S _L / _ST ) To 0.960-0.980;
(D) the peripheral speed of the first drying roll against (S _1), the peripheral speed of the final drying roll ratio of _{(S L) (S L /} S 1) to 0.970 to 1.010;
By the manufacturing method which consists of this, it can manufacture smoothly and continuously with high productivity.

The method for producing the PVA polymer film used in the present invention will be described more specifically below.
The film-forming stock solution containing the PVA polymer is prepared by mixing the PVA polymer with a liquid medium to form a solution, or by melting the PVA polymer pellets containing the liquid medium or the like into a melt. be able to.
The dissolution of the PVA polymer in the liquid medium and the melting of the PVA polymer pellets including the liquid medium can be performed using a stirring mixer, a melt extruder, or the like.
Examples of the liquid medium used at that time include water, dimethyl sulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, ethylenediamine, diethylenetriamine, and the like. More than one species can be used in combination. Among these, water, dimethyl sulfoxide, or a mixture of both are preferably used, and water is more preferably used.

A plasticizer is added to the film-forming stock solution from the viewpoints of accelerating dissolution and melting of the PVA polymer in a liquid medium, improving process passability during film production, and improving the stretchability of the resulting PVA polymer film. It is preferable.
As the plasticizer, polyhydric alcohol is preferably used, and examples thereof include ethylene glycol, glycerin, diglycerin, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, trimethylolpropane, and the like. 1 type can be used individually or in combination of 2 or more types. Among these, one or more of glycerin, diglycerin and ethylene glycol are preferably used because they are excellent in the effect of improving stretchability.

  The addition amount of the plasticizer is preferably 0 to 30 parts by mass, more preferably 3 to 25 parts by mass, and particularly preferably 5 to 20 parts by mass with respect to 100 parts by mass of the PVA polymer. When the addition amount of the plasticizer exceeds 30 parts by mass with respect to 100 parts by mass of the PVA polymer, the resulting PVA polymer film may become too soft and handleability may deteriorate.

It is preferable to add a surfactant to the film-forming stock solution from the viewpoint of improving the peelability from the drying roll when producing the PVA polymer film and the handleability of the resulting PVA polymer film. The type of the surfactant is not particularly limited, but an anionic surfactant or a nonionic surfactant is preferably used.
As the anionic surfactant, for example, a carboxylic acid type such as potassium laurate, a sulfate type such as octyl sulfate, and a sulfonic acid type anionic surfactant such as dodecylbenzene sulfonate are suitable.
Examples of nonionic surfactants include alkyl ether types such as polyoxyethylene oleyl ether, alkylphenyl ether types such as polyoxyethylene octylphenyl ether, alkyl ester types such as polyoxyethylene laurate, and polyoxyethylene. Alkylamine type such as laurylamino ether, alkylamide type such as polyoxyethylene lauric acid amide, polypropylene glycol ether type such as polyoxyethylene polyoxypropylene ether, alkanolamide type such as oleic acid diethanolamide, polyoxyalkylene allylphenyl An allyl phenyl ether type nonionic surfactant such as ether is preferred. These surfactants can be used alone or in combination of two or more.

  The addition amount of the surfactant is preferably 0.01 to 1 part by mass, more preferably 0.02 to 0.5 part by mass, and 0.05 to 0.3 part by mass with respect to 100 parts by mass of the PVA polymer. Is particularly preferred. When the amount is less than 0.01 parts by mass, the effect of improving the film-forming property and the peelability may be difficult to appear. On the other hand, when the amount is more than 1 part by mass, the surfactant elutes on the film surface and causes blocking. , The handleability may be reduced.

The film-forming stock solution is not limited to the properties of the PVA polymer film used in the present invention , and various additives such as stabilizers (for example, antioxidants, ultraviolet absorbers, heat stabilizers, etc.), compatibilizing Agents, antiblocking agents, flame retardants, antistatic agents, lubricants, dispersants, fluidizing agents, antibacterial agents and the like. These additives can be used alone or in combination of two or more.

60-75 mass% is preferable and, as for the volatile fraction of the film forming stock solution used for manufacture of a PVA-type polymer film, 65-70 mass% is more preferable. If the volatile fraction of the film-forming stock solution is less than 60% by mass, the viscosity of the film-forming stock solution becomes high, making filtration and defoaming difficult, and film-forming itself may be difficult. On the other hand, when the volatile fraction of the film-forming stock solution is larger than 75% by mass, the viscosity becomes too low and the thickness uniformity of the PVA polymer film may be impaired.
Here, “the volatile fraction of the film-forming stock solution” as used herein refers to the volatile fraction determined by the following formula [iii].
Volatile fraction (% by mass) of the film-forming stock solution = {(Wa−Wb) / Wa} × 100 [iii]
[Wherein, Wa represents the mass (g) of the film-forming stock solution, and Wb represents the mass (g) after the Wa (g) film-forming stock solution was dried in an electrothermal dryer at 105 ° C. for 16 hours. ]

In a film forming apparatus comprising a plurality of drying rolls whose rotation axes are parallel to each other used for the production of a PVA polymer film, the number of drying rolls is preferably 3 or more, more preferably 4 or more. 5 to 30 is more preferable.
The plurality of drying rolls are preferably formed of a metal such as nickel, chromium, copper, iron, stainless steel, and the like, and in particular, the roll surface is hardly corroded and is formed of a metallic material having a specular gloss. It is more preferable. In order to increase the durability of the drying roll, it is more preferable to use a drying roll plated with a single layer or a combination of two or more layers such as a nickel layer, a chromium layer, and a nickel / chromium alloy layer.
The roll surface temperature of each drying roll in the plurality of drying rolls is preferably 65 ° C. or higher, and more preferably 75 ° C. or higher. The roll surface temperature of each drying roll is preferably 100 ° C. or higher, more preferably 100 to 120 ° C., for the roll surface temperature of the drying roll that can be used as a heat treatment roll in the final step or a step close thereto. The roll surface temperature of the other drying rolls is preferably 100 ° C. or lower.

  The film forming apparatus used in the present invention may have a hot air oven type hot air drying apparatus, a heat treatment apparatus, a humidity control apparatus, etc., if necessary, following a plurality of drying rolls.

For discharging a film-forming stock solution containing a PVA polymer on the first drying roll of the film-forming apparatus into a film shape, for example, a T-type slit die, a hopper plate, an I-die, a lip coater die, etc. are known. The film-forming stock solution containing the PVA polymer is discharged (cast) in the form of a film onto the first drying roll using the film-like discharge device (film-like casting device).
The liquid containing the PVA polymer discharged in the form of a film on the first drying roll is dried on the first drying roll, and the volatile fraction of the PVA polymer film is preferably 17 to 30% by mass, more preferably Is peeled from the first drying roll when it becomes 17 to 29% by mass, more preferably 18 to 28% by mass.
When the volatile content of the PVA polymer film when peeled from the first drying roll is less than 17% by mass, the value of Δn (MD) _{Ave with} respect to Δn (TD) _Ave increases and satisfies the formula (I). On the other hand, when the volatile content of the PVA polymer film when peeling from the first drying roll exceeds 30% by mass, peeling from the first drying roll becomes difficult and sometimes breaks. Or tend to cause unevenness.

Here, “the volatile fraction of the PVA polymer film or PVA polymer film” in the present specification refers to the volatile fraction determined by the following formula [iv].
A (mass%) = {(Wc−Wd) / Wc} × 100 [iv]
[In the formula, A is the volatile fraction (% by mass) of the PVA polymer film or PVA polymer film, Wc is the mass (g) of the sample taken from the PVA polymer film or PVA polymer film, Wd represents the mass (g) when the sample Wc (g) is placed in a vacuum dryer at a temperature of 50 ° C. and a pressure of 0.1 kPa or less and dried for 4 hours. ]

  In the PVA polymer film or the PVA polymer film formed from a film-forming stock solution prepared using a PVA polymer, a polyhydric alcohol (plasticizer) such as glycerin, a surfactant and water, When dried under the conditions of “50 ° C., pressure of 0.1 kPa or less for 4 hours”, only water is volatilized, and most of the other components other than water are not volatilized, and PVA polymer film or PVA polymer film. The volatile fraction of the PVA polymer film or PVA polymer film is determined by measuring the amount of water (moisture content) contained in the PVA polymer film or PVA polymer film. It can ask for.

In drying with the first drying roll, the roll surface temperature of the first drying roll is preferably 80 to 120 ° C. and 85 to 105 ° C. from the viewpoint of uniform drying property, drying speed and the like. More preferably, it is 93-99 degreeC. If the surface temperature of the first drying roll exceeds 120 ° C., the film tends to foam, whereas if it is less than 80 ° C., drying on the first drying roll becomes insufficient, which tends to cause peeling failure.
The peripheral speed (S ₁ ) of the first drying roll is preferably 8 to 25 m / min from the viewpoints of uniform drying property, drying speed and productivity of the PVA polymer film, and is 11 to 23 m / min. More preferably, it is more preferably 14 to 22 m / min. When the peripheral speed (S ₁ ) of the first drying roll is less than 8 m / min, productivity is lowered and birefringence tends to increase, which is not preferable. On the other hand, if the peripheral speed (S ₁ ) of the first drying roll exceeds 25 m / min, drying on the first drying roll tends to be insufficient, such being undesirable.

The partial drying on the first drying roll of the film-forming stock solution containing the PVA polymer discharged in the form of a film may be performed only by the heat from the first drying roll. 1 Drying by blowing hot air to the film surface not in contact with the drying roll (hereinafter sometimes referred to as “first drying roll non-contact surface”) and applying heat from both sides of the PVA polymer film, It is preferable from the viewpoint of uniform drying property, drying speed and the like.
When the hot air is blown onto the first dry roll non-contact surface of the PVA polymer film on the first dry roll, the hot air having a wind speed of 1 to 10 m / sec is applied to the entire area of the first dry roll non-contact surface. Is preferably blown, more preferably hot air with a wind speed of 2 to 8 m / sec, and still more preferably hot air with a wind speed of 3 to 8 m / sec.
If the wind speed of the hot air blown onto the non-contact surface of the first drying roll is too small, it becomes difficult to obtain a PVA polymer film having a high limit draw ratio, which is the object of the present invention, and water vapor is dried during drying on the first drying roll. Condensation such as the above occurs, and the water droplets drop on the PVA polymer film, and defects in the PVA polymer film finally obtained tend to occur. On the other hand, if the wind speed of the hot air blown on the non-contact surface of the first drying roll is too high, it becomes difficult to obtain a PVA polymer film having a high limit draw ratio, which is the object of the present invention, and finally obtain a PVA-based weight. Thickness spots occur in the coalesced film, and troubles such as the occurrence of stained spots easily occur.

  The temperature of the hot air blown to the non-contact surface of the first drying roll of the PVA polymer film is preferably 50 to 150 ° C., and preferably 70 to 120 ° C. from the viewpoints of drying efficiency and drying uniformity. More preferably, it is 80-95 degreeC. Moreover, it is preferable that the dew point temperature of the hot air sprayed on the non-contact surface of the first drying roll of the PVA polymer film is 10 to 15 ° C. If the temperature of the hot air blown on the non-contact surface of the first drying roll of the PVA polymer film is too low, the drying efficiency, uniform drying properties, etc. are likely to be lowered, while if too high, foaming is likely to occur.

  The method for blowing hot air to the non-contact surface of the first dry roll of the PVA polymer film is not particularly limited, and hot air having a uniform wind speed and temperature is applied to the non-contact surface of the first dry roll of the PVA polymer film. Any of the methods that can be uniformly sprayed on the entire surface can be preferably used, and among them, a nozzle method, a current plate method, or a combination thereof is preferably used. Even if the blowing direction of the hot air to the first drying roll non-contact surface of the PVA polymer film is a direction facing the first drying roll non-contact surface, the first drying roll non-contact surface of the PVA polymer film May be in a direction substantially along the circumferential shape (direction substantially along the circumference of the roll surface of the first drying roll) or in other directions.

  Moreover, when the PVA polymer film is dried on the first drying roll, it is preferable to exhaust the volatile matter generated from the PVA polymer film by drying and the hot air after spraying. The exhaust method is not particularly limited, but it is preferable to employ an exhaust method that does not cause wind speed spots and temperature spots of hot air sprayed on the non-contact surface of the first drying roll of the PVA polymer film.

The PVA polymer film dried to a volatile fraction of 17 to 30% by mass on the first drying roll is preferably peeled off from the first drying roll, and this time, the first drying roll non-contact surface of the PVA polymer film. It is preferable to dry with a 2nd drying roll facing a 2nd drying roll.
The ratio (S ₂ / S ₁ ) of the peripheral speed (S ₂ ) of the second drying roll to the peripheral speed (S ₁ ) of the first drying roll is preferably 1.005 to 1.090, and 1.010 More preferably, it is -1.080. When the ratio (S ₂ / S ₁ ) is less than 1.005, the peeling point of the PVA polymer film from the first drying roll tends to be non-uniform, and the birefringence unevenness in the width direction becomes large, which is optical. It may become impossible to use as a film stock. Moreover, when the ratio (S ₂ / S ₁ ) exceeds 1.090, it becomes difficult to obtain a PVA polymer film having a high limit draw ratio.

  In drying with the second drying roll, the roll surface temperature of the second drying roll is preferably 65 to 100 ° C., and preferably 65 to 98 ° C. from the viewpoint of uniform drying property, drying speed and the like. More preferably, it is 75-96 degreeC.

The PVA polymer film dried by the second drying roll is peeled from the second drying roll, and the third drying roll, the fourth drying roll, and the fifth drying are selected according to the number of drying rolls provided in the film forming apparatus. A plurality of drying rolls such as rolls,.
At that time, in the present invention, the ratio of the peripheral speed (S _T ) of the drying roll when the volatile content of the PVA polymer film becomes 13% by mass with respect to the peripheral speed (S ₁ ) of the first drying roll. Drying is performed while adjusting the tension applied to the PVA polymer film such that (S _T / S ₁ ) is 0.990 to 1.050. Here, “the drying roll when the volatile content of the PVA polymer film is 13% by mass” means that the volatile content of the PVA polymer film is 13% by mass on the drying roll. Means the drying roll, and when the volatile content is 13% by mass between the two drying rolls, it means the drying roll positioned later among the two drying rolls. By setting the ratio (S _T / S ₁ ) within the above range, troubles such as sagging and winding of the film may occur in the drying process until the volatile content of the PVA polymer film reaches 13% by mass. The value [Δn (MD) _Ave ] obtained by averaging the birefringence in the length direction (MD) in the film thickness direction and the value obtained by averaging the birefringence in the width direction (TD) in the film thickness direction [ [Delta] n (TD) _Ave ] can smoothly produce the PVA polymer film used in the present invention satisfying the above formulas (I) and (II) and further the above formula (III).
The ratio (S _T / S ₁ ) when producing the PVA polymer film is preferably 1.000 to 1.045.

In the present invention, the PVA polymer film having a volatile content of 13% by mass is further dried with a subsequent drying roll to produce a PVA polymer film. At that time, in the present invention, the ratio of the peripheral speed (S _L ) of the final drying roll to the peripheral speed (S _T ) of the drying roll when the volatile content of the PVA polymer film is 13% by mass. Drying is performed while keeping (S _L / S _T ) in the range of 0.960 to 0.980. By setting the ratio (S _L / S _T ) in the above-described range, in the drying process until the final PVA polymer film is obtained, troubles such as sagging or winding of the film do not occur and the length direction The value [Δn (MD) _Ave ] obtained by averaging the birefringence of (MD) in the thickness direction of the film and the value [Δn (TD) _{Ave obtained} by averaging the birefringence in the width direction (TD) in the thickness direction of the film. ], The PVA polymer film used in the present invention satisfying the above formulas (I) and (II) and further the above formula (III) can be produced smoothly.
The above-described ratio (S _L / S _T ) when producing the PVA polymer film is preferably 0.963 to 0.976.

Further, in producing a PVA polymer film by the above-described method, a value obtained by averaging the birefringence in the length direction (MD) of the PVA polymer film in the thickness direction of the film [Δn (MD) _Ave ] and the value [Δn (TD) _Ave ] obtained by averaging the birefringence in the width direction (TD) in the film thickness direction are the peripheral speed (S ₁ ) of the _first drying roll and the peripheral speed ( It varies according to the ratio of S _L ) (S _L / S ₁ ). In order to smoothly produce the PVA polymer film satisfying the above formulas (I) and (II), and further the above formula (III), the final drying with respect to the peripheral speed (S ₁ ) of the first drying roll The ratio (S _L / S ₁ ) of the peripheral speed (S _L ) of the roll needs to be in the range of 0.970 to 1.010, preferably in the range of 0.972 to 1.008, A range of 0.975 to 1.006 is more preferable. Accordingly, a PVA polymer film satisfying the above formulas (I) and (II) and further the above formula (III) can be smoothly produced while suppressing generation of wrinkles and sagging.

In the above-described method for producing a PVA polymer film , the final drying roll or the drying roll close to the final and the final drying roll may be used as a heat treatment roll with a higher surface temperature. When the drying roll is used as a heat treatment roll, the roll surface temperature is preferably 90 to 140 ° C, more preferably 100 to 130 ° C.
Moreover, you may provide the heat processing apparatus separately from a drying roll.

  There is no particular limitation on the heating direction when the PVA polymer film is dried in the process from the first drying roll to the final drying roll, but the PVA polymer film can be dried more uniformly. It is preferable to dry so that the front surface and the back surface in an arbitrary part of the united film alternately contact each drying roll from the first drying roll to the final drying roll.

The PVA polymer film subjected to the above drying treatment is subjected to heat treatment, humidity conditioning treatment, etc., if necessary, and finally wound into a roll with a predetermined length to be used in the present invention. A film can be obtained.
The volatile content of the PVA polymer film finally obtained by the series of treatments described above is preferably in the range of 1 to 5% by mass, and more preferably in the range of 2 to 4% by mass.

In order to produce a polarizing film from the above PVA polymer film, for example, the PVA polymer film may be dyed, uniaxially stretched, fixed, dried, and further heat treated as necessary. The order of dyeing and uniaxial stretching is not particularly limited, and the dyeing process may be performed before the uniaxial stretching process, the dyeing process may be performed simultaneously with the uniaxial stretching process, or the dyeing process may be performed after the uniaxial stretching process. You may go. In addition, steps such as uniaxial stretching and dyeing may be repeated a plurality of times.

  Examples of the dye used for dyeing the PVA polymer film include iodine or dichroic organic dyes (for example, DirectBlack 17, 19, 154; DirectBrown 44, 106, 195, 210, 223; DirectRed 2, 23, 28, 31, 37, 39, 79, 81, 240, 242, 247; DirectBlue 1, 15, 22, 78, 90, 98, 151, 168, 202, 236, 249, 270; DirectViolet 9, 12, 51, 98; DirectGreen 1 85; Direct Yellow 8, 12, 44, 86, 87; Dichroic dyes such as Direct Orange 26, 39, 106, 107). These dyes can be used alone or in combination of two or more. Dyeing can usually be performed by immersing the PVA polymer film in a solution containing the dye, but the treatment conditions and treatment method are not particularly limited.

Uniaxial stretching for stretching the PVA polymer film in the length direction (MD) may be performed by either a wet stretching method or a dry heat stretching method. When uniaxially stretching by a wet stretching method, it may be uniaxially stretched in warm water containing boric acid, may be uniaxially stretched in a solution containing the above-described dye or in the fixing treatment bath described later, or after water absorption The PVA polymer film may be uniaxially stretched in the air, or may be uniaxially stretched by other methods. The stretching temperature during the uniaxial stretching treatment is not particularly limited, but when the PVA polymer film is stretched in warm water (wet stretching), it is preferably 30 to 90 ° C, more preferably 40 to 70 ° C, still more preferably 45. A temperature of ˜65 ° C. is employed, and a temperature of 50 ° C. to 180 ° C. is preferably employed when dry heat stretching is performed. Further, the stretching ratio of the uniaxial stretching treatment (the total stretching ratio in the case of performing uniaxial stretching in multiple stages) is preferably stretched as much as possible from the point of polarization performance until just before the film is cut, specifically 4 times or more. Preferably, it is 5 times or more, more preferably 5.5 times or more. The upper limit of the stretching ratio is not particularly limited as long as the film is not broken, but is preferably 8.0 times or less in order to perform uniform stretching.
The thickness of the stretched film (polarizing film) is preferably 5 to 35 μm, particularly 20 to 30 μm.

  In the production of a polarizing film, a fixing treatment is often performed in order to strengthen the adsorption of the dye to the uniaxially stretched film. As the fixing treatment, a method of immersing a film in a treatment bath to which boric acid and / or a boron compound is added is generally widely adopted. In that case, you may add an iodine compound in a processing bath as needed.

  The film subjected to the uniaxial stretching treatment or the uniaxial stretching treatment and the fixing treatment is preferably subjected to a drying treatment (heat treatment). The temperature of the drying treatment (heat treatment) is preferably 30 to 150 ° C, particularly 50 to 140 ° C. If the temperature of the drying treatment (heat treatment) is too low, the dimensional stability of the obtained polarizing film tends to be lowered, while if too high, the polarizing performance is likely to deteriorate due to decomposition of the dye.

The polarizing film obtained as described above can be bonded to an optically transparent protective film having mechanical strength on both sides or one side to form a polarizing plate. As the protective film in this case, a cellulose triacetate (TAC) film, an acetic acid / cellulose butyrate (CAB) film, an acrylic film, a polyester film, or the like is used. Moreover, as an adhesive for laminating a protective film, a PVA adhesive or a urethane adhesive is generally used, and among them, a PVA adhesive is preferably used.
The polarizing plate obtained as described above can be used as a component of a liquid crystal display device after being coated with an acrylic-based pressure-sensitive adhesive and then being bonded to a glass substrate. When the polarizing plate is bonded to the glass substrate, a retardation film, a viewing angle improving film, a brightness improving film, or the like may be bonded simultaneously.

EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to the following examples.
In the following examples and comparative examples, the volatile fraction of the film-forming stock solution, the volatile fraction (moisture percentage) of the PVA film or PVA film, each physical property of the PVA film, and the optical performance of the polarizing film were measured by the following methods. .

(1) Volatile content of the film-forming stock solution:
It calculated | required by said formula [iii] according to the above-mentioned method.
(2) Volatile content (water content) of the PVA film or PVA film:
It calculated | required by said formula [iv] according to the above-mentioned method.
In addition, the measurement of the volatile matter rate (moisture content) of a PVA film or a PVA film was performed using the sample extract | collected from the width direction (TD) center part of the PVA film or PVA film taken out from the drying roll.

(3) Δn (MD) _{Ave of} PVA film:
Δn (MD) _Ave at the central portion in the width direction (TD) of the PVA film was determined by the method described above in the section “<< 1 >> Measuring method of Δn (MD) _Ave ”, and this was obtained by Δn (MD) _{Ave of the} PVA film It was.
(4) Δn (TD) _{Ave of} PVA film:
Δn (TD) _Ave at the central portion in the width direction (TD) of the PVA film is determined by the method described above in the section “<< 2 >> Measuring method of Δn (TD) _Ave ”, and this is obtained by Δn (TD) _{Ave of the} PVA film. It was.

(5) Mass swelling degree of PVA film:
The PVA film was cut to 1.5 g, immersed in 1000 g of distilled water at 30 ° C. for 30 minutes, immersed for 30 minutes, the PVA film was taken out, the surface water was blotted with filter paper, and its mass (W _e ) Was measured. Subsequently, the PVA film was dried with a dryer at 105 ° C. for 16 hours, and then its mass (W _f ) was measured. From the obtained mass W _e and W _f, the following formula [v], was determined by mass degree of swelling of the PVA film.
Mass swelling degree (%) = (W _e / W _f ) × 100 [v]

(6) Limit stretching ratio of PVA film:
A test piece of length direction (MD) × width direction (TD) = 10 cm × 5 cm was collected from the central part of the width direction (TD) of the PVA film before stretching obtained in the following examples or comparative examples, and the Both ends in the length direction of the test piece are fixed to a stretching jig so that the size of the stretched portion is length direction (MD) × width direction (TD) = 5 cm × 5 cm, and immersed in water at 30 ° C. for 38 seconds. During uniaxial stretching (first-stage stretching) in the length direction (MD) to 2.2 times the original length at a stretching speed of 12 cm / min, 0.03% by mass of iodine and iodide While immersed for 90 seconds in an iodine / potassium iodide aqueous solution containing 3% by mass of potassium at a temperature of 30 ° C., the length direction is 3.3 times the original length at a stretching rate of 12 cm / min. (MD) is uniaxially stretched (second-stage stretching), and then boric acid is 3% by mass and iodinated. While immersed in a boric acid / potassium iodide aqueous solution containing 3% by weight of rhodium at a temperature of 30 ° C. for about 20 seconds, the length is increased to 3.6 times the original length at a stretching rate of 12 cm / min. Boric acid / potassium iodide aqueous solution at a temperature of about 60 ° C. containing uniaxial stretching (third-stage stretching) in the longitudinal direction (MD) and subsequently containing boric acid at a concentration of 4 mass% and potassium iodide at a concentration of about 5 mass% While immersing in, uniaxially stretching in the length direction (MD) until the test piece broke at a stretching speed of 12 cm / min, and the stretch ratio when the test piece broke (the length at the time of breaking relative to the original length) Ratio).
About the same PVA film, the above-mentioned extending | stretching test was done 5 times, the average value was taken, and it was set as the limiting draw ratio (times) of a PVA film.

(7) Optical performance of polarizing film:
(I) Transmittance:
Two square samples of 1.5 cm × 1.5 cm were taken in parallel with the orientation direction of the polarizing film from the center in the width direction of the polarizing film obtained in the following examples or comparative examples. Using a spectrophotometer V-7100 (attached to an integrating sphere) made in accordance with JIS Z8722 (measurement method of object color), the visibility correction of the visible light region of the C light source and the two-degree field of view is performed. For the polarizing film sample, the light transmittance when tilted by 45 degrees with respect to the stretching axis direction and the light transmittance when tilted by −45 degrees were measured, and the average value (Y ₁ ) was obtained.
For the other polarizing film sample, the light transmittance when tilted by 45 degrees and the light transmittance when tilted by −45 degrees were measured in the same manner as described above, and the average value (Y ₂ ) of them was measured. Asked.
Y ₁ and Y ₂ obtained above were averaged to obtain the transmittance (Y) (%) of the polarizing film.
(Ii) Polarization degree:
Light transmittance (Y‖) when the two polarizing film samples collected in (i) above are stacked so that the alignment directions are parallel, and light when the alignment directions are orthogonal to each other Was measured by the same method as the above transmittance measurement method, and the degree of polarization (V) (%) was determined from the following formula [vi].
Polarization degree (V) (%) = {(Y‖−Y⊥) / (Y‖ + Y⊥)} ^1/2 × 100 [vi]
(Iii) Polarization degree at a transmittance of 44.25%:
As described in the following Examples and Comparative Examples, in each Example or Comparative Example, five polarizing films produced by changing the immersion time in the iodine / potassium iodide aqueous solution at the time of second-stage stretching The transmittance (Y) and the degree of polarization (V) were determined by the method described above for each example, and for each example or comparative example, the transmittance (Y) was abscissa and the degree of polarization (V) was ordinate. Was plotted on a graph to obtain an approximate curve, and the degree of polarization (V) when the transmittance (Y) was 44.25% was obtained from the approximate curve.

Example 1
(1) Production of PVA film:
(I) 100 parts by mass of PVA (saponification degree 99.9 mol%, polymerization degree 2400) obtained by saponifying polyvinyl acetate, 12 parts by mass of glycerol, 0.1 part by mass of lauric acid diethanolamide and water A film-forming stock solution having a volatile content rate of 66% by mass was discharged in a film form from a T-die onto a first drying roll (surface temperature 93 ° C., peripheral speed (S ₁ ) 16.7 m / min). , Drying at 90 ° C. hot air on the entire non-contact surface of the first drying roll at a wind speed of 5 m / sec until the moisture content reaches 18% by mass, then peeling off from the first drying roll, The second and subsequent drying rolls are dried at a roll surface temperature of about 85 ° C. so that the front and back surfaces of the portion are alternately in contact with each drying roll, and finally heat treatment is performed with a final drying roll (heat treatment roll) having a surface temperature of 108 ° C. The After performing, it wound up and obtained the PVA film (Thickness 60 micrometers, width 3m, volatile matter rate 3 mass%). In Example 1, the drying roll when the volatile content rate was 13% by mass was the seventh drying roll.
In this Example 1, (α) of the peripheral speed (S _T ) of the drying roll (seventh drying roll) when the volatile content rate becomes 13 mass% with respect to the peripheral speed (S ₁ ) of the first drying roll. The ratio (S _T / S ₁ ) is 1.000; (β) of the final drying roll relative to the peripheral speed (S _T ) of the drying roll (seventh drying roll) when the volatile content rate is 13% by mass The ratio (S _L / S _T ) of the peripheral speed (S _L ) is 0.974; (γ) the ratio of the peripheral speed (S ₂ ) of the second drying roll to the peripheral speed (S ₁ ) of the first drying roll (S ₂ / S ₁ ) is set to 1.030; (δ) The following drying roll (S _T ) with respect to the peripheral speed (S _T ) of the drying roll (seventh drying roll) when the volatile fraction becomes 13% by mass ( eighth ratio of the peripheral speed of the drying roll) (S _{T + 1)} a _{(S T / S T + 1} ) and 0.998; (epsilon) the peripheral speed of the first drying roll against (S _1), final drying b Circumferential speed of the Le a ratio of _{(S L) (S L /} S 1) as 0.975, was prepared PVA films.
(Ii) Δn (MD) _Ave , Δn (TD) _Ave , mass swelling degree and limit draw ratio of the PVA film obtained in (i) above were measured by the methods described above, and as shown in Table 1 below. there were.

(2) Production of polarizing film:
(I) A test piece of length direction (MD) × width direction (TD) = 10 cm × 5 cm was collected from the center part in the width direction (TD) of the PVA film obtained in the above (1), and the test piece Both ends in the length direction are fixed to a stretching jig so that the size of the stretched portion is length direction (MD) × width direction (TD) = 5 cm × 5 cm, and immersed in water at a temperature of 30 ° C. for 38 seconds. During uniaxial stretching (first stage stretching) in the length direction (MD) to 2.2 times the original length at a stretching speed of 12 cm / min, 0.03% by mass of iodine and potassium iodide While immersed for 60 seconds in an iodine / potassium iodide aqueous solution at a temperature of 30 ° C. and contained at a concentration of 3% by mass, the length direction (MD) was increased to 3.3 times the original length at a stretching rate of 12 cm / min. ) Is uniaxially stretched (second-stage stretching), then boric acid is 3% by mass and potassium iodide is 3%. While immersed in an aqueous solution of boric acid / potassium iodide at a temperature of 30 ° C. and contained at a concentration of% by weight for about 20 seconds, it is stretched up to 3.6 times the original length at a stretching speed of 12 cm / min ( MD) and then immersed in a boric acid / potassium iodide aqueous solution at a temperature of about 60 ° C. containing 4% by weight of boric acid and about 5% by weight of potassium iodide. While uniaxially stretching (fourth stage stretching) in the length direction (MD) to the stretching ratio immediately before the limit stretching ratio of the PVA film measured above at a stretching speed of 12 cm / min, 3% by mass of potassium iodide. The film was immersed for 10 seconds in an aqueous potassium iodide solution having a concentration of 1, and then impregnated with iodine ions, and then dried for 4 minutes with a dryer at 60 ° C. to produce a polarizing film (thickness of about 21 μm).
The transmittance (Y) and the degree of polarization (V) of the polarizing film thus obtained are obtained by the above-described method, and the points are shown in the graph in which the horizontal axis represents the transmittance (Y) and the vertical axis represents the degree of polarization (V). Plotted.

(Ii) In the above (i), the same operation as in the above (i) was performed except that the immersion time in the iodine / potassium iodide aqueous solution at a temperature of 30 ° C. at the second stage stretching was changed from 60 seconds to 75 seconds. The polarizing film (thickness of about 21 μm) was produced by performing [the stretching speed in each stretching step was 12 cm / min, the same as in (i) above].
The transmittance (Y) and the degree of polarization (V) of the polarizing film thus obtained were determined by the method described above, and the points were plotted in the graph of (i) above.
(Iii) In the above (i), the same operation as in the above (i) was performed except that the immersion time in the iodine / potassium iodide aqueous solution at the temperature of 30 ° C. at the second stage stretching was changed from 60 seconds to 90 seconds. The polarizing film (thickness of about 21 μm) was produced by performing [the stretching speed in each stretching step was 12 cm / min, the same as in (i) above].
The transmittance (Y) and the degree of polarization (V) of the polarizing film thus obtained were determined by the method described above, and the points were plotted in the graph of (i) above.
(Iv) In the above (i), the same operation as in the above (i) was performed except that the immersion time in the iodine / potassium iodide aqueous solution at the temperature of 30 ° C. at the second stage stretching was changed from 60 seconds to 105 seconds. The polarizing film (thickness of about 21 μm) was produced by performing [the stretching speed in each stretching step was 12 cm / min, the same as in (i) above].
The transmittance (Y) and the degree of polarization (V) of the polarizing film thus obtained were determined by the method described above, and the points were plotted in the graph of (i) above.
(V) In the above (i), the same operation as in the above (i) was performed except that the immersion time in the iodine / potassium iodide aqueous solution at a temperature of 30 ° C. at the second stage stretching was changed from 60 seconds to 120 seconds. The polarizing film (thickness of about 21 μm) was produced by performing [the stretching speed in each stretching step was 12 cm / min, the same as in (i) above].
The transmittance (Y) and the degree of polarization (V) of the polarizing film thus obtained were determined by the method described above, and the points were plotted in the graph of (i) above.
(Vi) The approximate curve of the five points plotted on the graphs in (i) to (v) above is drawn on the graph, and the degree of polarization when the transmittance (Y) is 44.25% from the approximate curve. When the value of (V) was determined, it was 99.98 as shown in Table 1 below.

<< Examples 2 to 5 >>
(1) In Example 1, the PVA film was manufactured in the same manner as in Example 1 (1) by changing the film forming conditions for manufacturing the PVA film as described in Table 1 below. However, in Example 2, 100 parts by mass of PVA (degree of saponification 99.9 mol%, degree of polymerization 2400) obtained by saponifying polyvinyl acetate as a film forming stock solution, 12 parts by mass of glycerin, diethanolamine laurate A film-forming stock solution consisting of 0.1 parts by mass of water and 73% by mass of volatile fraction was used.
The Δn (MD) _Ave , Δn (TD) _Ave , mass swelling degree and limit draw ratio of each PVA film obtained as described above were measured by the methods described above, and as shown in Table 1 below.
(2) Implementation using a test piece of length direction (MD) × width direction (TD) = 10 cm × 5 cm taken from the center of the width direction (TD) of each PVA film obtained in (1) above The same operation as in Example 1 (2) was performed to produce five types of polarizing films for each example, the transmittance (Y) and the degree of polarization (V) of each polarizing film were determined, and the horizontal axis was transmitted. The point is plotted on a graph with the rate (Y) and the vertical axis indicating the degree of polarization (V), and an approximate curve of five points plotted on the graph is drawn on the graph, and the transmittance (Y) is calculated from the approximate curve. When the value of polarization degree (V) was found to be 44.25%, it was as shown in Table 1 below.

<< Comparative Examples 1-5 >>
(1) In Example 1, the PVA film was produced in the same manner as in (1) of Example 1, except that the film forming conditions for producing the PVA film were changed as described in Table 2 below.
Each PVA film thus obtained was measured for Δn (MD) _Ave , Δn (TD) _Ave , mass swell and limit draw ratio by the methods described above, and the results were as shown in Table 2 below.
(2) Implementation using a test piece of length direction (MD) × width direction (TD) = 10 cm × 5 cm taken from the center of the width direction (TD) of each PVA film obtained in (1) above The same operation as in Example 1 (2) was performed to produce five types of polarizing films for each comparative example, the transmittance (Y) and the degree of polarization (V) of each polarizing film were determined, and the horizontal axis was transmitted. The point is plotted on a graph with the rate (Y) and the vertical axis indicating the degree of polarization (V), and an approximate curve of five points plotted on the graph is drawn on the graph, and the transmittance (Y) is calculated from the approximate curve. When the value of polarization degree (V) was found to be 44.25%, it was as shown in Table 2 below.

As seen in Table 1 and Table 2 above, the PVA films of Examples 1 to 5 were obtained by averaging Δn (MD) _Ave [birefringence index in the length direction (MD) of the PVA film in the thickness direction of the film. Value] and Δn (TD) _Ave [value obtained by averaging the birefringence index in the width direction (TD) of the PVA film in the thickness direction of the film] satisfies the formulas (I) and (II). The polarizing film obtained from the PVA film of Examples 1 to 5 has an excellent polarizing performance equal to or higher than that of the conventional polarizing film, having a high limit draw ratio of 72 to 6.94. .
On the other hand, the PVA films of Comparative Examples 1 to 4 do not satisfy the formula (I), and the PVA films of Comparative Examples 4 and 5 do not satisfy the formula (II). In any case, the limit draw ratio is lower than that of the PVA film.

When producing a polarizing film from a PVA polymer film, uniaxial stretching is usually performed at a stretching ratio somewhat lower than the limit stretching ratio in order to avoid breakage of the film during stretching. The PVA films of Examples 1 to 5 have a high draw ratio of 6 times or more when the polarizing films are produced under the conditions of the examples, because the limit draw ratio of the PVA film of 5 is as high as 6.72 or more. The film can be uniaxially stretched and can be smoothly stretched without causing breakage of the film even when uniaxially stretched at a high draw ratio of 6.5 times or more.
On the other hand, among the PVA films of Comparative Examples 1 to 5, since the PVA film of Comparative Example 4 has a limit draw ratio smaller than 6, when the polarizing film is produced under the conditions of the comparative example, it is 6 times or more. The film cannot be uniaxially stretched at a stretch ratio, and the film is easily broken when stretched. In addition, the PVA films of Comparative Examples 1 to 3 and 5 are also uniaxially stretched at a stretch ratio of 6 times or more. I am worried about the point.

In addition, in a raw film for a polarizing film, there is a roll having a length of 1000 m or more. For example, in a PVA polymer film having a total length of 1000 m, the limit draw ratio is 0.1 point (0.1 Increase) means that the length of the stretched film obtained by uniaxial stretching is increased by 100 m (1000 m × 0.1 times = 100 m), so that more polarized light from the same length of the original film. A film is obtained.
When this is seen about Examples 1-5, the PVA film of Examples 1-5 has a limit draw ratio of 0.10-0.98 points (times) compared with the PVA film of Comparative Examples 1-5. Therefore, for example, assuming that the length of the PVA film is 1000 m, when the polarizing film is produced using the PVA film under the conditions of the above examples, the length of the polarizing film is the PVA of Comparative Examples 1 to 5. Compared to the case where a film is used, the length is 100 to 980 m, and more polarizing films can be obtained.

The PVA polymer film used in the present invention has a high limit stretching ratio even when the film thickness is as thin as about 30 to 65 μm, and is uniaxially stretched at a high ratio when manufacturing a polarizing film or the like. However, since the film does not easily break, a stretched film such as a polarizing film having excellent optical performance such as polarization performance can be obtained at a high yield and with a drying time shorter than before without interrupting the stretching operation. Since it can be manufactured with high productivity, in the case of the present invention, the PVA polymer film can be used as a raw fabric film to smoothly manufacture a polarizing film, which is useful.

Claims (4)

A method for producing a polarizing film, comprising subjecting a polyvinyl alcohol polymer film satisfying the following formulas (I) and (II) to dyeing, uniaxial stretching, fixing treatment and drying treatment.
Δn (MD) _Ave −0.1 × 10 ⁻³ ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.25 × 10 ⁻³ (I)
Δn (TD) _Ave ≦ 2.5 × 10 ⁻³ (II)
[In the above formula, Δn (MD) _Ave represents a value obtained by averaging the birefringence Δn (MD) in the machine flow direction of the polyvinyl alcohol polymer film in the thickness direction of the film, and Δn (TD) _Ave is , birefringence in the width direction of the polyvinyl alcohol polymer film [Delta] n the (TD) shows the averaged value in the thickness direction of the film, wherein, the machine flow direction of the birefringence [Delta] n (MD) is the following The birefringence Δn (TD) in the width direction is a value obtained from the following equation [ii].
Δn (MD) = nMD−nz [i]
Δn (TD) = nTD−nz [ii]
(In the formula, nMD represents the refractive index in the machine flow direction (length direction) of the film, nTD represents the refractive index in the width direction of the film, and nz represents the refractive index in the thickness direction of the film.) A polarizing film characterized in that a polyvinyl alcohol polymer film satisfying the following formulas (I) and (II) and further satisfying the following formula (III) is dyed, uniaxially stretched, fixed and dried: Manufacturing method.
Δn (MD) _Ave −0.1 × 10 ⁻³ ≦ Δn (TD) _Ave ≦ Δn (MD) _Ave + 0.25 × 10 ⁻³ (I)
Δn (TD) _Ave ≦ 2.5 × 10 ⁻³ (II)
1.3 × 10 ⁻³ ≦ Δn (MD) _Ave ≦ 2.0 × 10 ⁻³ (III)
[In the above formula, Δn (MD) _Ave represents a value obtained by averaging the birefringence Δn (MD) in the machine flow direction of the polyvinyl alcohol polymer film in the thickness direction of the film, and Δn (TD) _Ave is , birefringence in the width direction of the polyvinyl alcohol polymer film [Delta] n the (TD) shows the averaged value in the thickness direction of the film, wherein, the machine flow direction of the birefringence [Delta] n (MD) is the following The birefringence Δn (TD) in the width direction is a value obtained from the following equation [ii].
Δn (MD) = nMD−nz [i]
Δn (TD) = nTD−nz [ii]
(In the formula, nMD represents the refractive index in the machine flow direction (length direction) of the film, nTD represents the refractive index in the width direction of the film, and nz represents the refractive index in the thickness direction of the film.)   The manufacturing method of the polarizing film of Claim 1 or 2 whose thickness of the said polyvinyl alcohol-type polymer film used for manufacture of a polarizing film exists in the range of 30-65 micrometers.   The manufacturing method of the polarizing plate characterized by sticking a protective film on both surfaces or one side of the polarizing film manufactured by the manufacturing method of any one of Claims 1-3.

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