JP6000103B2 - 偏光板の製造方法 - Google Patents
偏光板の製造方法 Download PDFInfo
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- JP6000103B2 JP6000103B2 JP2012272608A JP2012272608A JP6000103B2 JP 6000103 B2 JP6000103 B2 JP 6000103B2 JP 2012272608 A JP2012272608 A JP 2012272608A JP 2012272608 A JP2012272608 A JP 2012272608A JP 6000103 B2 JP6000103 B2 JP 6000103B2
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- polarizing plate
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- hardness
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- NIMLQBUJDJZYEJ-UHFFFAOYSA-N isophorone diisocyanate Chemical compound CC1(C)CC(N=C=O)CC(C)(CN=C=O)C1 NIMLQBUJDJZYEJ-UHFFFAOYSA-N 0.000 description 1
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- UUORTJUPDJJXST-UHFFFAOYSA-N n-(2-hydroxyethyl)prop-2-enamide Chemical compound OCCNC(=O)C=C UUORTJUPDJJXST-UHFFFAOYSA-N 0.000 description 1
- JTHNLKXLWOXOQK-UHFFFAOYSA-N n-propyl vinyl ketone Natural products CCCC(=O)C=C JTHNLKXLWOXOQK-UHFFFAOYSA-N 0.000 description 1
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- 229910052759 nickel Inorganic materials 0.000 description 1
- JFNLZVQOOSMTJK-KNVOCYPGSA-N norbornene Chemical group C1[C@@H]2CC[C@H]1C=C2 JFNLZVQOOSMTJK-KNVOCYPGSA-N 0.000 description 1
- 125000003518 norbornenyl group Chemical group C12(C=CC(CC1)C2)* 0.000 description 1
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- 229920002959 polymer blend Polymers 0.000 description 1
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- 229920001155 polypropylene Polymers 0.000 description 1
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- 229920005749 polyurethane resin Polymers 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- UIIIBRHUICCMAI-UHFFFAOYSA-N prop-2-ene-1-sulfonic acid Chemical compound OS(=O)(=O)CC=C UIIIBRHUICCMAI-UHFFFAOYSA-N 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
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- HGBOYTHUEUWSSQ-UHFFFAOYSA-N valeric aldehyde Natural products CCCCC=O HGBOYTHUEUWSSQ-UHFFFAOYSA-N 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Images
Classifications
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
- G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
- G02B5/305—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/18—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets by squeezing between surfaces, e.g. rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
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Description
前記第1透明保護フィルムおよび第2透明保護フィルムは、弾性率(MPa)×厚み(μm)の値で定義される弾性が異なり、高い弾性を有する方を高弾性フィルム、低い弾性を有する方を低弾性フィルムと定義し、
かつ、前記一対のロールはロール硬度が異なり、高硬度を有する方を高硬度ロール、低い硬度を有する方を低硬度ロールと定義する場合に、
前記低硬度ロールの側から高弾性フィルムを搬送し、
前記高硬度ロールの側から低弾性フィルムを搬送することを特徴とする偏光板の製造方法、に関する。
弾性率(グラフの傾き)を求める際の横軸: 歪(ひずみ)(%)
弾性率(グラフの傾き)を求める際の縦軸: 引張応力σ(MPa=N/mm2)=F/試験片の初期断面積A(mm2)
弾性率(グラフの傾き)を求める際の範囲: 歪0.05〜0.25%間の線形回帰
試験片形状:帯状(長方形)
チャック間距離:100mm
得られた偏光子から、180mm×500mmのサンプルを切り出し、その初期重量(W(g))を測定した。そのサンプルを120℃の乾燥機内で2時間放置した後、乾燥後重量(D(g))を測定した。これらの測定値より、下記式により水分率を求めた。
水分率(%)={(W−D)/W}×100
平均重合度2400、ケン化度99.9モル%の厚み75μmのポリビニルアルコールフィルムを、30℃の温水中に60秒間浸漬し膨潤させた。次いで、ヨウ素/ヨウ化カリウム(重量比=0.5/8)の濃度0.3%の水溶液に浸漬し、3.5倍まで延伸させながらフィルムを染色した。その後、65℃のホウ酸エステル水溶液中で、トータルの延伸倍率が6倍となるように延伸を行った。延伸後に、40℃のオーブンにて3分間乾燥を行い、PVA系偏光子(厚み23μm)を得た。この偏光子の厚さは23μm、水分率は18重量%であった。
TAC:厚さ60μmのトリアセチルセルロースフィルム(富士フィルム社製:TD60UL,弾性率4000MPa);
COP:厚さ50μmの環状ポリオレフィンフィルム(日本ゼオン社製:ZEONOR,弾性率1800MPa);
アクリル:厚さ40μmのアクリルフィルム(弾性率2000MPa);を示す。
活性エネルギー線として、紫外線(ガリウム封入メタルハライドランプ) 照射装置:Fusion UV Systems,Inc社製Light HAMMER10 バルブ:Vバルブ ピーク照度:1600mW/cm2、積算照射量1000/mJ/cm2(波長380〜440nm)を使用した。なお、紫外線の照度は、Solatell社製Sola−Checkシステムを使用して測定した。
ラジカル重合性化合物(A)として、N−ヒドロキシエチルアクリルアミド(興人社製)を38.3部、
ラジカル重合性化合物(B)として、トリプロピレングリコールジアクリレート(商品名:アロニックスM−220,東亞合成社製)を19.1部、
ラジカル重合性化合物(C)として、アクリロイルモルホリン(興人社製)を38.3部、および
光重合開始剤(商品名:KAYACURE DETX−S,ジエチルチオキサントン,日本化薬社製)1.4部を混合して50℃で1時間撹拌して活性エネルギー線硬化型接着剤を得た。
<偏光板の作製>
図1に示す方法にて、偏光板を作製した。偏光子Aには上記偏光子を用いた。第1透明保護フィルムB1には上記厚さ50μmの環状ポリオレフィンフィルムを用いた。当該環状ポリオレフィンフィルム上に、厚さ0.5μmのウレタン系易接着処理層を形成した後に、当該易接着処理層に、上記活性エネルギー線硬化型接着剤を、MCDコーター(富士機械社製)(セル形状:ハニカム、グラビアロール線数:1000本/inch、回転速度140%/対ライン速)を用いて、接着剤層の厚みが0.5μmになるように塗工した。第2透明保護フィルムB2には、前記環状ポリオレフィンフィルムの代わりにTACフィルムを用いたこと以外は、上記同様にして接着層付のTACフィルムを作製した。次いで、前記接着剤層を介して、前記第1透明保護フィルムB1および第2透明保護フィルムB2を、上記偏光子A(偏光子)の両面にロール機で貼り合わせた。ロール機には、第1ロールR1として、直径200mmの鉄ロールを用い、第2ロールR2として、直径200mmの硬度60°の弾性ロールを用いた。図1に示すように、第1透明保護フィルムB1は第2ロールR2の側から、第2透明保護フィルムB2は、第1ロールR1の側から搬送した。その後、貼り合わせた第1および第2透明保護フィルムの両側から、IRヒーターを用いて50℃に加温し、上記紫外線を両面に照射して、活性エネルギー線硬化型接着剤を硬化させた。さらに、70℃で3分間熱風乾燥して、偏光子の両面に透明保護フィルムを有する偏光板を得た。貼り合わせのライン速度は25m/minで行った。
実施例1において、第1透明保護フィルム、第2透明保護フィルムの種類、第1ロール、第2ロールの種類を表1に示すように変えたこと以外は実施例1と同様にして、偏光板を得た。
得られた偏光板を水平板上に静置して、偏光板の辺部と水平板との距離が最大となる箇所の長さをカール量(mm)とした。
得られた偏光板から1000mm×1000mmのサンプルを切り出し、偏光子と透明保護フィルムの間の気泡の数を確認した。
B1 第1透明保護フィルム(低弾性フィルム)
B2 第2透明保護フィルム(高弾性フィルム)
R1 第1ロール(低硬度ロール)
R2 第2ロール(高硬度ロール)
Claims (4)
- 偏光子の両面に、第1透明保護フィルムおよび第2透明保護フィルムを接着層を介して、一対のロール間を同時に通過することにより圧着して、貼り合わせる偏光板の製造方法において、
前記第1透明保護フィルムおよび第2透明保護フィルムは、弾性率(MPa)×厚み(μm)の値で定義される弾性が異なり、高い弾性を有する方を高弾性フィルム、低い弾性を有する方を低弾性フィルムと定義し、
かつ、前記一対のロールはそれぞれのロール硬度が異なり、高硬度を有する方を高硬度ロール、低い硬度を有する方を低硬度ロールと定義する場合に、
前記高弾性フィルムと低弾性フィルムの弾性の差が0を超え170000以下であり、
前記高硬度ロールおよび低硬度ロールが弾性ロールであり、かつ
前記高硬度ロールと低硬度ロールの硬度差が10°以上40°以下であり、
前記低硬度ロールの側から高弾性フィルムを搬送し、
前記高硬度ロールの側から低弾性フィルムを搬送することを特徴とする偏光板の製造方法。 - 少なくとも低硬度ロールが金属製の芯部がゴム層または樹脂層でコーティングされた弾性ロールであることを特徴とする請求項1記載の偏光板の製造方法。
- 高硬度ロールおよび低硬度ロールが、いずれも金属製の芯部がゴム層または樹脂層でコーティングされた弾性ロールであることを特徴とする請求項1または2記載の偏光板の製造方法。
- 弾性ロールのロール硬度が40〜100°であることを特徴とする請求項1〜3のいずれかに記載の偏光板の製造方法。
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