JP6239919B2 - Method for producing retardation film and method for producing circularly polarizing plate - Google Patents

Description

  The present invention relates to a method for producing a retardation film and a method for producing a circularly polarizing plate.

  In an image display device such as a liquid crystal display device (LCD) or an organic electroluminescence display device (OLED), a circularly polarizing plate is used for the purpose of improving display characteristics and preventing reflection. In a circularly polarizing plate, typically, a polarizer and a retardation film (typically λ / 4 plate) form an angle of 45 ° between an absorption axis of the polarizer and a slow axis of the retardation film. Thus, they are laminated. Conventionally, a retardation film is typically produced by uniaxially or biaxially stretching in the machine direction and / or the transverse direction, so that the slow axis is often the transverse direction of the original film. Appears in the direction (width direction) or longitudinal direction (long direction). As a result, in order to produce a circularly polarizing plate, it was necessary to cut the retardation film so as to form an angle of 45 ° with respect to the horizontal direction or the vertical direction and to bond them one by one.

  In order to solve such a problem, a technique has been proposed in which the slow axis of the retardation film is expressed in an oblique direction by stretching in an oblique direction (for example, Patent Document 1). However, the conventional oblique stretching method may cause wrinkles in the film during stretching and cannot be wound into a roll.

Japanese Patent No. 4845619

  The present invention has been made in order to solve the above-described conventional problems, and the purpose of the present invention is to prevent the occurrence of wrinkles in a long retardation film having a slow axis in an oblique direction. An object of the present invention is to provide a method that can be manufactured with high manufacturing efficiency. Another object of the present invention is to provide a method capable of producing a circularly polarizing plate having excellent optical properties with high production efficiency.

According to the present invention, a method for producing a retardation film is provided. In the method for producing a retardation film of the present invention, the left and right ends of a film to be stretched are respectively held by variable-pitch left and right clips whose longitudinal clip pitch changes; the film is preheated; And changing the clip pitch of at least one of the left and right clips to obliquely stretch the film; and releasing the clip that holds the film. The clip pitch of the left and right clips is different.
In a preferred embodiment, the oblique stretching is performed by reducing the clip pitch of the other clip to a predetermined pitch while fixing the clip pitch of one of the left and right clips, and then reducing the original clip pitch. Including increasing to.
In a preferred embodiment, the oblique stretching (i) increases the clip pitch of one of the left and right clips and decreases the clip pitch of the other clip; and (ii) the other Increasing the reduced clip pitch of the first clip to the same rate of change as the increased clip pitch of the one clip.
In a preferred embodiment, the clip pitch of the clip having the larger clip pitch when gripping the left and right ends of the film is decreased and then increased.
In a preferred embodiment, the clip pitch ratio (smaller clip pitch / larger clip pitch) of the left and right clips when gripping the left and right ends of the film is 0.5 to 0.95.
According to another aspect of the present invention, a retardation film is provided. This retardation film is obtained by the above-described manufacturing method, has a long shape, and has a slow axis in a direction that forms a predetermined angle with respect to the long direction.
According to another situation of this invention, the manufacturing method of a circularly-polarizing plate is provided. This manufacturing method includes aligning the longitudinal direction and continuously laminating while transporting the retardation film and the long polarizing plate.

  According to the present invention, the right-side end portion and the left-side end portion of the film are gripped at different clip pitches, and at least one of the clip pitches is changed, and the film is stretched obliquely so that the slow axis is inclined in the oblique direction. It is possible to obtain a long retardation film having high production efficiency while preventing generation of wrinkles. Furthermore, according to the present invention, a circularly polarizing plate excellent in optical properties can be obtained with high production efficiency by laminating the retardation film and the polarizing plate thus obtained by so-called roll-to-roll. .

It is a schematic plan view explaining the whole structure of an example of the extending | stretching apparatus which can be used for the manufacturing method of this invention. It is a principal part schematic plan view for demonstrating the link mechanism which changes a clip pitch in the extending | stretching apparatus of FIG. 1, and shows the state where a clip pitch is the minimum. It is a principal part schematic plan view for demonstrating the link mechanism which changes a clip pitch in the extending | stretching apparatus of FIG. 1, and shows a state with the largest clip pitch. It is a schematic diagram explaining one embodiment of diagonal stretch in the manufacturing method of this invention. FIG. 5 is a graph (a) showing the relationship between each zone of the stretching apparatus and the clip pitch in the oblique stretching shown in FIG. 4 and a graph (b) showing the relationship between each zone and the clip pitch change rate. It is a schematic diagram explaining another embodiment of the diagonal stretch in the manufacturing method of this invention. It is the graph (b) which shows the relationship between each zone and clip pitch change rate of each zone of the extending | stretching apparatus in the case of diagonal extending | stretching shown in FIG. 6, and a clip pitch change rate. It is a schematic sectional drawing of the circularly-polarizing plate using the phase difference film obtained by the manufacturing method of this invention. It is the schematic explaining the manufacturing method of the circularly-polarizing plate by one Embodiment of this invention.

  Hereinafter, although preferable embodiment of this invention is described, this invention is not limited to these embodiment.

  In the method for producing a retardation film of the present invention, the left and right end portions of the film to be stretched are each gripped by variable-pitch left and right clips that change the longitudinal clip pitch (gripping step); Preheating (preheating step); changing the clip pitch of at least one of the left and right clips to obliquely stretch the film (stretching step); and if necessary, setting the clip pitch of the left and right clips constant. And heat-treating the film (heat treatment step); and releasing a clip that holds the film (release step). Hereinafter, each step will be described in detail.

A. First, a stretching apparatus that can be used in the manufacturing method of the present invention including this process will be described with reference to FIGS. FIG. 1 is a schematic plan view illustrating the overall configuration of an example of a stretching apparatus that can be used in the production method of the present invention. 2 and 3 are schematic plan views of main parts for explaining a link mechanism for changing the clip pitch in the stretching apparatus of FIG. 1, respectively, FIG. 2 shows a state in which the clip pitch is minimum, and FIG. Indicates the maximum clip pitch. The stretching device 100 has an endless loop 10L and an endless loop 10R having a large number of clips 20 for gripping the film on both the left and right sides in a plan view. In this specification, the left endless loop as viewed from the film entrance side is referred to as the left endless loop 10L, and the right endless loop is referred to as the right endless loop 10R. The clips 20 of the left and right endless loops 10L and 10R are guided by the reference rail 70 and move in a loop. The left endless loop 10R moves in a counterclockwise direction, and the right endless loop 10R moves in a clockwise direction. In the stretching apparatus, a gripping zone A, a preheating zone B, a stretching zone C, a heat treatment zone D, and a release zone E are sequentially provided from the inlet side to the outlet side of the sheet. Each of these zones means a zone where a film to be stretched is substantially gripped, preheated, obliquely stretched, heat treated and released, and does not mean a mechanically and structurally independent section. . It should also be noted that the ratio of the lengths of the respective zones in the stretching apparatus of FIG. 1 is different from the actual ratio of lengths.

  In the gripping zone A and the preheating zone B, the left and right endless loops 10R and 10L are configured to be substantially parallel to each other at a separation distance corresponding to the initial width of the film to be stretched. In the stretching zone C, the distance between the left and right endless loops 10R and 10L gradually increases from the preheating zone B side toward the heat treatment zone D until it corresponds to the width after stretching of the film. In the heat treatment zone D, the left and right endless loops 10R and 10L are configured to be substantially parallel to each other at a separation distance corresponding to the width of the film after stretching.

  The clip 20L on the left endless loop 10L (left clip) and the clip 20R on the right endless loop 10R (right clip) can each move independently. For example, the driving sprockets 11 and 12 of the left endless loop 10L are rotationally driven counterclockwise by the electric motors 13 and 14, and the driving sprockets 11 and 12 of the right endless loop 10R are clocked by the electric motors 13 and 14. It is driven to rotate around. As a result, traveling force is applied to the clip carrying member 30 of the drive roller (not shown) engaged with the drive sprockets 11 and 12. As a result, the left endless loop 10L cyclically moves in the counterclockwise direction, and the right endless loop 10R cyclically moves in the clockwise direction. By driving the left electric motor and the right electric motor independently of each other, the left endless loop 10L and the right endless loop 10R can be cyclically moved independently.

  Further, the clip (left clip) 20 of the left endless loop 10L and the clip (right clip) 20 of the right endless loop 10R are each of a variable pitch type. That is, the left and right clips 20 and 20 can independently change the clip pitch (distance between clips) in the vertical direction (MD) with movement. The variable pitch type can be realized by any appropriate configuration. Hereinafter, a link mechanism (panda graph mechanism) will be described as an example.

  As shown in FIGS. 2 and 3, an elongated rectangular clip carrying member 30 is provided in the lateral direction in plan view for carrying the clips 20 individually. Although not shown, the clip carrying member 30 is formed into a solid frame structure with a closed cross section by an upper beam, a lower beam, a front wall (wall on the clip side), and a rear wall (wall on the side opposite to the clip). The clip carrying member 30 is provided so as to roll on the traveling road surfaces 81 and 82 by the traveling wheels 38 at both ends thereof. 2 and 3, the traveling wheels on the front wall (the traveling wheels that roll on the traveling road surface 81) are not shown. The traveling road surfaces 81 and 82 are parallel to the reference rail 70 over the entire area. A long hole 31 is formed along the longitudinal direction of the clip carrying member on the rear side (the side opposite to the clip) of the upper and lower beams of the clip carrying member 30, and the slider 32 can slide in the longitudinal direction of the long hole 31. Is engaged. In the vicinity of the end portion of the clip carrying member 30 on the clip 20 side, a single first shaft member 33 is vertically provided so as to penetrate the upper beam and the lower beam. On the other hand, a single second shaft member 34 is vertically provided through the slider 32 of the clip carrying member 30. One end of a main link member 35 is pivotally connected to the first shaft member 33 of each clip carrying member 30. The main link member 35 is pivotally connected to the second shaft member 34 of the adjacent clip carrier member 30 at the other end. In addition to the main link member 35, one end of the sub link member 36 is pivotally connected to the first shaft member 33 of each clip carrying member 30. The sub link member 36 is pivotally connected at the other end to the intermediate portion of the main link member 35 by a pivot shaft 37. As shown in FIG. 2, as the slider 32 moves to the rear side of the clip carrying member 30 (opposite the clip side) by the link mechanism using the main link member 35 and the sub link member 36, the clip carrying members 30 are connected to each other. As the slider 32 moves to the front side (clip side) of the clip carrier member 30 as shown in FIG. 3, the clip pitch increases. . Positioning of the slider 32 is performed by the pitch setting rail 90. As shown in FIGS. 2 and 3, the larger the clip pitch, the smaller the separation distance between the reference rail 70 and the pitch setting rail 90. Since the link mechanism is well known in the art, a more detailed description is omitted.

  By performing oblique stretching of the film using the stretching apparatus as described above, a retardation film having a slow axis in an oblique direction (for example, a direction of 45 ° with respect to the longitudinal direction) can be produced. First, in the gripping zone A (the entrance of the film take-in of the stretching apparatus 100), the left and right endless loops 10R and 10L are gripped by the clips 20 on both sides of the film to be stretched at a constant clip pitch. The film is sent to the preheating zone B by the movement of the endless loops 10 </ b> R and 10 </ b> L (substantially, the movement of each clip holding member 30 guided by the reference rail 70). The ratio of the clip pitches of the left and right clips (smaller clip pitch / larger clip pitch) is preferably 0.5 to 0.95, more preferably 0.6 to 0.90. Further, the larger clip pitch of the different clip pitches can be appropriately set according to the purpose or the like, and can be, for example, 50 mm to 300 mm, preferably 100 mm to 250 mm.

B. Preheating process In the preheating zone (preheating process) B, the left and right endless loops 10R and 10L are configured to be parallel to each other at a separation distance corresponding to the initial width of the film to be stretched as described above. Neither stretching nor longitudinal stretching is performed, and only preheating is performed. However, the distance between the left and right clips (distance in the width direction) may be slightly increased in order to avoid problems such as film deflection due to preheating and contact with the nozzles in the oven.

  In the preheating step, the film is heated to a temperature T1 (° C.). It is preferable that temperature T1 is more than the glass transition temperature (Tg) of a film, More preferably, it is Tg + 2 degreeC or more, More preferably, it is Tg + 5 degreeC or more. On the other hand, the heating temperature T1 is preferably Tg + 40 ° C. or lower, more preferably Tg + 30 ° C. or lower. Although it changes with films to be used, temperature T1 is 70 to 190 degreeC, for example, Preferably it is 80 to 180 degreeC.

  The temperature raising time to the temperature T1 and the holding time at the temperature T1 can be appropriately set according to the constituent material of the film and the manufacturing conditions (for example, the film conveyance speed). These temperature raising time and holding time can be controlled by adjusting the moving speed of the clip 20, the length of the preheating zone, the temperature of the preheating zone, and the like.

C. Stretching Step In the stretching zone (stretching step) C, the film is stretched obliquely by changing the clip pitch of at least one of the left and right clips 20. Typically, the clip pitch of at least one clip is changed so that the change rate of the clip pitch of the left and right clips before and after oblique stretching becomes substantially equal. Thereby, the length of a right-and-left end part is substantially equal, and the stretched film by which generation | occurrence | production of wrinkles was suppressed can be obtained. Preferably, the clip pitch of one clip is once decreased and then increased. Thereby, the slow axis can be expressed with high uniaxiality and in-plane orientation while suppressing the generation of wrinkles.

  The oblique stretching can be performed while increasing the distance between the left and right clips (distance in the width direction), for example, as in the illustrated example. This will be specifically described below. In the following description, for convenience, the stretching zone C is described as being divided into an inlet-side stretching zone (first oblique stretching zone) C1 and an outlet-side stretching zone (second oblique stretching zone) C2. The lengths of the first oblique stretching zone C1 and the second oblique stretching zone C2 and the ratio of the lengths to each other can be appropriately set according to the purpose.

In one embodiment, the oblique extension is performed by reducing the clip pitch of the other clip to a predetermined pitch while fixing the clip pitch of one of the left and right clips to the original clip pitch. Including increasing. A representative embodiment will be specifically described with reference to FIGS. 4 and 5. First, in the preheating zone B, the clip pitch of the right clip is P ₁ and the clip pitch of the left clip is P ₂ . P ₁ or P ₂ is a clip pitch when the film is gripped, and P ₁ <P ₂ is satisfied. Next, as soon as the film enters the first oblique stretching zone C1, the reduction of the clip pitch of one (left side in the illustrated example) clip is started. In the first oblique stretching zone C1, it reduces the clip pitch of the left clip to the P _3. On the other hand, the clip pitch of the right clip is maintained at P1 in the _first oblique stretching zone C1. Therefore, the end portion of the first oblique stretching zone C1 in (beginning of the second oblique stretching zone C2), left clip moves the clip pitch P _3, right clip is a moving clip pitches P ₁ ing. Next, as soon as the film enters the second oblique stretching zone C2, the clip pitch of the left clip starts to increase. In the second oblique stretching zone C2, the clip pitch of the left clip is increased to P ₂ (that is, the decreased clip pitch is returned to the original clip pitch). On the other hand, the clip pitch of the right clip is maintained in the P ₁ in the second diagonal stretching zone C2. Therefore, the end portion of the second oblique stretching zone C2 in (end of extension zone C), the left clip and right clips are decided to move in P ₂ and P ₁ is the initial clip pitches. Also, unlike the example shown in the figure, the clip pitch of the clip on the right side (that is, the smaller initial clip pitch) is changed while the clip pitch of the clip on the right side (that is, the smaller initial clip pitch) is changed Also good. According to the oblique stretching, stretching wrinkles and retardation unevenness can be suitably prevented, and a slow axis can be expressed with high uniaxiality and in-plane orientation.

  As described above, the clip pitch can be adjusted by positioning the slider by adjusting the distance between the pitch setting rail of the stretching device and the reference rail.

In the present embodiment, the clip pitch change rate (for example, P ₃ / P ₂ ) in the first oblique stretching zone is preferably 0.3 to 0.9, more preferably 0.4 to 0.8. It is. If the clip pitch change rate is in such a range, wrinkles and phase difference unevenness can be suitably prevented.

In the present embodiment, the oblique stretching may include lateral stretching, and may not include lateral stretching. In other words, the width of the film after oblique stretching may be larger than the initial width of the film, or may be substantially the same as the initial width. Needless to say, the illustrated example shows an embodiment including transverse stretching. When the oblique stretching includes transverse stretching as in the illustrated example, the transverse stretching ratio (ratio between the initial width W ₁ of the film and the width W ₃ of the film after oblique stretching (W ₃ / W ₁ )) is preferably Is 1.0 to 4.0, more preferably 1.3 to 3.0. If the draw ratio is too small, tin-like wrinkles may occur in the resulting retardation film. When the draw ratio is too large, the biaxiality of the obtained retardation film becomes high, and the viewing angle characteristics may be deteriorated when applied to a circularly polarizing plate or the like.

In another embodiment, oblique stretching comprises (i) increasing the clip pitch of one of the left and right clips and decreasing the clip pitch of the other clip, and (ii) the other Increasing the reduced clip pitch of the first clip to the same rate of change as the increased clip pitch of the one clip. This embodiment will be specifically described with reference to FIGS. 6 and 7. First, in the preheating zone B, the constant clip pitches P ₁ and P ₂ (where P ₁ <P ₂ ) are different from each other. P ₁ and P ₂ are clip pitches when the film is gripped. Next, at the same time when the film enters the first oblique stretching zone C1, the clip pitch of the clip with the smaller initial clip pitch (right side in the illustrated example) starts to increase and the clip with the larger initial clip pitch ( The clip pitch of the clip starts to be reduced. In the first oblique stretching zone C1, it increases the clip pitch of the right clip to the P _3, to reduce the clip pitch of the left clip to P _4. Therefore, the left clip moves at the clip pitch P ₄ and the right clip moves at the clip pitch P ₃ at the end portion of the first oblique stretching zone C 1 (the start portion of the second oblique stretching zone C 2). ing. Next, as soon as the film enters the second oblique stretching zone C2, the clip pitch of the left clip starts to increase. In the second oblique stretching zone C2, it increases the clip pitch of the left clip to the P _5. On the other hand, the clip pitch of the right clip is maintained in the P ₃ in a second oblique stretching zone C2. Therefore, the end portion of the second oblique stretching zone C2 in (end of extension zone C), the left clip moves the clip pitch P _5, right clip is a moving clip pitch P _3. Here, the clip pitch change rate (P ₃ / P ₁ ) with respect to the initial clip pitch of the right clip is equal to the clip pitch change rate (P ₅ / P ₂ ) with respect to the initial clip pitch of the left clip. In the illustrated example, for the sake of simplicity, the clip pitch decrease start position of the left clip and the clip clip increase start position of the right clip are both set as the start portion of the first oblique stretching zone C1, but the position is the stretching zone. Can be set to any suitable position. For example, any one of these may be an intermediate portion of the first oblique stretching zone C1.

In the present embodiment, the clip pitch change rate (P ₃ / P ₁ , P ₅ / P ₂ ) is preferably 1.20 to 1.90, more preferably 1.30 to 1.70. The clip pitch change rate (P ₄ / P ₂ ) is preferably 0.40 to 0.95, more preferably 0.45 to 0.90. If the change rate of the clip pitch is within such a range, the slow axis can be expressed with high uniaxiality and in-plane orientation in a direction of approximately 45 degrees with respect to the longitudinal direction of the film.

In the present embodiment, the draw ratio (W ₂ / W ₁ ) in the width direction of the film in the first oblique stretching zone is preferably 1.1 times to 3.0 times, more preferably 1.2 times to 2 times. 0.5 times, more preferably 1.25 times to 2.0 times. If the draw ratio is less than 1.1 times, tin-shaped wrinkles may occur at the end on the contracted side. Moreover, when the said draw ratio exceeds 3.0 times, the biaxiality of the obtained retardation film will become high, and when applied to a circularly-polarizing plate etc., a viewing angle characteristic may fall. Moreover, the draw ratio (W ₃ / W ₂ ) in the width direction of the film in the second oblique stretching zone is preferably 1.1 to 3.0 times, more preferably 1.2 to 2.5 times, More preferably, it is 1.25 times to 2.0 times.

  The oblique stretching can typically be performed at a temperature T2. The temperature T2 is preferably Tg-20 ° C to Tg + 30 ° C, more preferably Tg-10 ° C to Tg + 20 ° C, and particularly preferably about Tg with respect to the glass transition temperature (Tg) of the resin film. Although it changes with resin films to be used, the temperature T2 is, for example, 70 ° C to 180 ° C, and preferably 80 ° C to 170 ° C. The difference (T1-T2) between the temperature T1 and the temperature T2 is preferably ± 2 ° C. or more, more preferably ± 5 ° C. or more. In one embodiment, T1> T2, and thus the film heated to temperature T1 in the preheating step can be cooled to temperature T2.

D. Heat Treatment Step In the heat treatment zone (heat treatment step) D, the film is heated while being conveyed without changing the clip pitch of the left and right clips 20. The heat treatment step can be performed as necessary.

  The heat treatment can typically be performed at a temperature T3. The temperature T3 varies depending on the stretched film, and may be T2 ≧ T3 or T2 <T3. In general, when the film is an amorphous material, T2 ≧ T3, and when the film is a crystalline material, the crystallization treatment may be performed by setting T2 <T3. In the case of T2 ≧ T3, the difference (T2−T3) between the temperatures T2 and T3 is preferably 0 ° C. to 50 ° C. The heat treatment time is typically 10 seconds to 10 minutes. The heat treatment time can be controlled by adjusting the length of the heat treatment zone and / or the film transport speed.

E. Release process Finally, the clip holding the film is released to obtain a retardation film. In addition, the width W ₃ of the film after oblique stretching corresponds to the width of the obtained retardation film. When the oblique stretching does not include transverse stretching, the width of the obtained retardation film is substantially equal to the initial width of the film.

F. Film to be stretched and retardation film obtained by stretching As a film suitably used in the production method of the present invention (substantially, the stretching method described in the above items A to E), it is used as a retardation film. Any suitable film obtained may be mentioned. Examples of the material constituting the film include polycarbonate resin, polyvinyl acetal resin, cycloolefin resin, acrylic resin, cellulose ester resin, cellulose resin, polyester resin, polyester carbonate resin, olefin resin, and polyurethane resin. Examples thereof include resins. Polycarbonate resins, polyvinyl acetal resins, cellulose ester resins, polyester resins, and polyester carbonate resins are preferable. This is because with these resins, a retardation film showing the wavelength dependence of reverse dispersion can be obtained. These resins may be used alone or in combination according to desired properties.

  Any appropriate polycarbonate resin is used as the polycarbonate resin. For example, a polycarbonate resin containing a structural unit derived from a dihydroxy compound is preferable. Specific examples of the dihydroxy compound include 9,9-bis (4-hydroxyphenyl) fluorene, 9,9-bis (4-hydroxy-3-methylphenyl) fluorene, 9,9-bis (4-hydroxy-3- Ethylphenyl) fluorene, 9,9-bis (4-hydroxy-3-n-propylphenyl) fluorene, 9,9-bis (4-hydroxy-3-isopropylphenyl) fluorene, 9,9-bis (4-hydroxy) -3-n-butylphenyl) fluorene, 9,9-bis (4-hydroxy-3-sec-butylphenyl) fluorene, 9,9-bis (4-hydroxy-3-tert-butylphenyl) fluorene, 9, 9-bis (4-hydroxy-3-cyclohexylphenyl) fluorene, 9,9-bis (4-hydroxy-3-phenyl) Enyl) fluorene, 9,9-bis (4- (2-hydroxyethoxy) phenyl) fluorene, 9,9-bis (4- (2-hydroxyethoxy) -3-methylphenyl) fluorene, 9,9-bis ( 4- (2-hydroxyethoxy) -3-isopropylphenyl) fluorene, 9,9-bis (4- (2-hydroxyethoxy) -3-isobutylphenyl) fluorene, 9,9-bis (4- (2-hydroxy Ethoxy) -3-tert-butylphenyl) fluorene, 9,9-bis (4- (2-hydroxyethoxy) -3-cyclohexylphenyl) fluorene, 9,9-bis (4- (2-hydroxyethoxy) -3 -Phenylphenyl) fluorene, 9,9-bis (4- (2-hydroxyethoxy) -3,5-dimethylphenyl) fluorene 9,9-bis (4- (2-hydroxyethoxy) -3-tert-butyl-6-methylphenyl) fluorene, 9,9-bis (4- (3-hydroxy-2,2-dimethylpropoxy) phenyl ) Fluorene and the like. The polycarbonate resin contains structural units derived from dihydroxy compounds such as isosorbide, isomannide, isoidet, spiroglycol, dioxane glycol, diethylene glycol, triethylene glycol, polyethylene glycol, and bisphenols in addition to the structural units derived from the dihydroxy compound. You may go out.

  Details of the polycarbonate resin as described above are described in, for example, Japanese Patent Application Laid-Open No. 2012-67300 and Japanese Patent No. 3325560. The description of the patent document is incorporated herein by reference.

  The glass transition temperature of the polycarbonate resin is preferably 110 ° C. or higher and 250 ° C. or lower, more preferably 120 ° C. or higher and 230 ° C. or lower. If the glass transition temperature is excessively low, the heat resistance tends to deteriorate, and there is a possibility of causing a dimensional change after film formation. If the glass transition temperature is excessively high, the molding stability at the time of film molding may deteriorate, and the transparency of the film may be impaired. The glass transition temperature is determined according to JIS K 7121 (1987).

  Any appropriate polyvinyl acetal resin can be used as the polyvinyl acetal resin. Typically, the polyvinyl acetal resin can be obtained by a condensation reaction of at least two types of aldehyde compounds and / or ketone compounds and a polyvinyl alcohol resin. Specific examples and detailed production methods of the polyvinyl acetal resin are described, for example, in JP-A-2007-161994. The description is incorporated herein by reference.

  The retardation film obtained by stretching the film to be stretched preferably has a refractive index characteristic of nx> ny. The retardation film preferably has high in-plane orientation. For example, the birefringence Δn (Δn = nx−ny) measured at a wavelength of 550 nm is preferably 0.0005 to 0.012, more preferably 0. 0.001 to 0.005. Further, the retardation film can preferably function as a λ / 4 plate. The in-plane retardation Re (550) of the retardation film is preferably 100 nm to 180 nm, more preferably 135 nm to 155 nm. In the present specification, nx is the refractive index in the direction in which the in-plane refractive index is maximum (that is, the slow axis direction), and ny is the direction orthogonal to the slow axis in the plane (that is, the fast phase). (Axial direction) and nz is the refractive index in the thickness direction. Re (λ) is an in-plane retardation of the film measured with light having a wavelength of λ nm at 23 ° C. Therefore, Re (550) is the in-plane retardation of the film measured with light having a wavelength of 550 nm at 23 ° C. Re (λ) is determined by the formula: Re (λ) = (nx−ny) × d, where d (nm) is the thickness of the film.

  The retardation film exhibits any suitable refractive index ellipsoid as long as it has a relationship of nx> ny. Preferably, the refractive index ellipsoid of the retardation film exhibits a relationship of nx> ny ≧ nz. The Nz coefficient of the retardation film is preferably 1-1.40, more preferably 1-1.35, and still more preferably 1-1.30. The Nz coefficient is obtained by Nz = Rth (λ) / Re (λ). Here, Rth (λ) is a retardation in the thickness direction of the film measured with light of wavelength λnm at 23 ° C., and is obtained by the formula: Rth (λ) = (nx−nz) × d.

  The retardation film preferably exhibits the so-called reverse dispersion wavelength dependency. Specifically, the in-plane retardation satisfies the relationship Re (450) <Re (550) <Re (650). Re (450) / Re (550) is preferably 0.8 or more and less than 1.0, and more preferably 0.8 to 0.95. Re (550) / Re (650) is preferably 0.8 or more and less than 1.0, and more preferably 0.8 to 0.97.

The absolute value of the photoelastic coefficient of the retardation film is preferably 2 × 10 ⁻¹² (m ² / N) to 100 × 10 ⁻¹² (m ² / N), more preferably 2 × 10 ^−12. (M ² / N) to 50 × 10 ⁻¹² (m ² / N).

G. Circularly polarizing plate and method of manufacturing circularly polarizing plate The retardation film obtained by the above-described manufacturing method of the present invention can typically be suitably used for a circularly polarizing plate. FIG. 8 is a schematic cross-sectional view of an example of such a circularly polarizing plate. The circularly polarizing plate 300 in the illustrated example includes a polarizer 310, a first protective film 320 disposed on one side of the polarizer 310, a second protective film 330 disposed on the other side of the polarizer 310, And a retardation film 340 disposed outside the two protective films 330. The retardation film 340 is a retardation film obtained by the production method of the present invention. The second protective film 330 may be omitted. In that case, the retardation film 340 can function as a protective film for the polarizer. The angle formed by the absorption axis of the polarizer 310 and the slow axis of the retardation film 340 is preferably 30 ° to 60 °, more preferably 38 ° to 52 °, still more preferably 43 to 47 °, and particularly preferably 45. It is about °. In addition, since the structure of a polarizer and a protective film is well-known in the industry, detailed description is abbreviate | omitted.

  The circularly polarizing plate may further include any appropriate optical member or optical function layer at any appropriate position depending on the purpose. For example, the outer surface of the first protective film 320 may be subjected to surface treatment such as hard coat treatment, antireflection treatment, antisticking treatment, antiglare treatment, and light diffusion treatment. Further, another retardation film showing any appropriate refractive index ellipsoid may be arranged on at least one side of the retardation film 340 according to the purpose. Furthermore, an optical member such as a front substrate (for example, a transparent protective substrate or a touch panel) may be disposed outside the first protective film 320.

  The retardation film obtained by the production method of the present invention is very suitable for producing a circularly polarizing plate. Details are as follows. This retardation film is long and has a slow axis in an oblique direction (as described above, for example, a direction of 45 ° with respect to the long direction). In many cases, a long polarizer has an absorption axis in the longitudinal direction or the width direction, so if the retardation film obtained by the production method of the present invention is used, a so-called roll-to-roll can be used. A circularly polarizing plate can be produced with extremely excellent production efficiency. In addition, the retardation film obtained by the production method of the present invention described above has small retardation unevenness, and further can be improved in uniaxiality and in-plane orientation, so that circularly polarized light having very excellent optical characteristics. A board can be obtained. The roll-to-roll refers to a method of continuously laminating long films while aligning their long directions while roll-feeding them.

  With reference to FIG. 9, the manufacturing method of the circularly-polarizing plate by one Embodiment of this invention is demonstrated easily. In FIG. 9, reference numerals 811 and 812 are rolls for winding the polarizing plate and the retardation film, respectively, and reference numeral 822 is a transport roll. In the illustrated example, a polarizing plate (first protective film 320 / polarizer 310 / second protective film 330) and a retardation film 340 are sent out in the direction of the arrows, and are bonded together with their respective longitudinal directions aligned. In that case, it bonds together so that the 2nd protective film 330 of a polarizing plate and the phase difference film 340 may adjoin. In this way, a circularly polarizing plate 300 as shown in FIG. 8 can be obtained. Although not illustrated, for example, a polarizing plate (first protective film 320 / polarizer 310) and a retardation film 340 are bonded so that the polarizer 310 and the retardation film 340 are adjacent to each other, and the retardation film 340 is formed. A circularly polarizing plate that functions as a protective film can also be produced.

  EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited by these Examples. In addition, the measurement and evaluation method in an Example are as follows.

(1) Orientation angle (expression direction of slow axis)
Samples were prepared by cutting out the retardation films obtained in Examples and Comparative Examples into a square shape having a width of 50 mm and a length of 50 mm so that one side was parallel to the width direction of the film. This sample was measured using a Mueller matrix polarimeter (product name “Axoscan” manufactured by Axometrics), and the orientation angle θ at a wavelength of 550 nm and 23 ° C. was measured. The orientation angle θ was measured with a sample placed in parallel on a measurement table.
(2) In-plane retardation Re
In the same manner as in the above (1), measurement was performed at a wavelength of 550 nm and 23 ° C. using a product name “Axoscan” manufactured by Axometrics.
(3) Thickness direction retardation Rth
In the same manner as in the above (1), measurement was performed at a wavelength of 550 nm and 23 ° C. using a product name “Axoscan” manufactured by Axometrics.
(4) Nz coefficient It calculated from a formula: Nz = Rth / Re.
(5) Wrinkle The state of the retardation film obtained in the examples and comparative examples was visually confirmed. The criteria are as follows:
○ ・ ・ ・ Wrinkles and undulations are not observed throughout the film △ ・ ・ ・ Width direction end of the film is crumpled and wrinkled, but the central part is undulated The wrinkles are in, and the film is wavy.
(6) Thickness It measured using the micro gauge type thickness meter (made by Mitutoyo Corporation).
(7) Birefringence (Δn)
The Re value obtained with the product name “Axoscan” manufactured by Axometrics was divided by the film thickness obtained from the micro gauge thickness gauge (manufactured by Mitutoyo Corporation).

<Example 1>
Polymerization was carried out using a batch polymerization apparatus comprising two vertical reactors equipped with a stirring blade and a reflux condenser controlled at 100 ° C. 9,9- [4- (2-Hydroxyethoxy) phenyl] fluorene (BHEPF), isosorbide (ISB), DEG (diethylene glycol), diphenyl carbonate (DPC), and magnesium acetate tetrahydrate in a molar ratio of BHEPF / ISB / DEG / DPC / magnesium acetate = 0.348 / 0.490 / 0.162 / 1.005 / 1.00 × 10 ⁻⁵ was charged. After sufficiently replacing the inside of the reactor with nitrogen (oxygen concentration 0.0005 to 0.001 vol%), heating was performed with a heating medium, and stirring was started when the internal temperature reached 100 ° C. After 40 minutes from the start of temperature increase, the internal temperature was reached to 220 ° C., and control was performed so as to maintain this temperature. The phenol vapor produced as a by-product with the polymerization reaction was led to a reflux condenser at 100 ° C., and a monomer component contained in a small amount in the phenol vapor was returned to the reactor, and the phenol vapor not condensed was led to a condenser at 45 ° C. and recovered.

  Nitrogen was introduced into the first reactor and the pressure was once restored to atmospheric pressure, and then the oligomerized reaction liquid in the first reactor was transferred to the second reactor. Subsequently, the temperature increase and pressure reduction in the second reactor were started, and the internal temperature was 240 ° C. and the pressure was 0.2 kPa in 50 minutes. Thereafter, polymerization was allowed to proceed until a predetermined stirring power was obtained. When a predetermined power is reached, nitrogen is introduced into the reactor, the pressure is restored, the reaction solution is withdrawn in the form of a strand, pelletized with a rotary cutter, and BHEPF / ISB / DEG = 34.8 / 49.0 / A polycarbonate resin A having a copolymer composition of 16.2 [mol%] was obtained. This polycarbonate resin had a reduced viscosity of 0.430 dL / g and a glass transition temperature of 128 ° C.

  The obtained polycarbonate resin was vacuum-dried at 80 ° C. for 5 hours, and then a single-screw extruder (manufactured by Isuzu Chemical Industries, screw diameter 25 mm, cylinder set temperature: 220 ° C.), T-die (width 900 mm, set temperature: 220). ° C.), a chill roll (set temperature: 120 to 130 ° C.), and a film forming apparatus equipped with a winder, a 140 μm thick polycarbonate resin film was produced.

(Preheating and oblique stretching process)
The polycarbonate resin film obtained as described above is subjected to pre-heat treatment and oblique stretching treatment with a clip pitch profile as shown in FIG. 7 using an apparatus as shown in FIGS. Got. Specifically, the polycarbonate resin film (thickness 140 μm, width (W ₁ ) 765 mm) was preheated to 145 ° C. in the preheating zone of the stretching apparatus. In the preheating zone, the clip pitch (P ₁ ) of the right clip was 150 mm, and the clip pitch (P ₂ ) of the left clip was 225 mm.
Next, at the same time as the film entered the first oblique stretching zone C, it started to increase the clip pitch of the right clip and decrease the clip pitch of the left clip. The rate of change of the clip pitch (P ₃ / P ₁ ) of the right clip at the end of the first diagonally extending zone C is 1.42, and the rate of change of the clip pitch of the left clip (P ₄ / P ₂ ) is 0. .6. The first oblique stretching was performed at 138 ° C. The TD stretch ratio (W ₂ / W ₁ ) after the first oblique stretching was 1.45 times.
Next, as soon as the film entered the second oblique stretching zone C2, the clip pitch of the left clip started to increase and increased from P ₄ to P ₅ (where P ₅ is P ₅ / P ₂ = The clip pitch is 1.42.) The rate of change (P ₅ / P ₄ ) in the clip pitch of the left clip in the second oblique stretching zone C2 was 2.37. On the other hand, the clip pitch of the right clip was maintained at P ₃ in a second oblique stretching zone C2. The second oblique stretching was performed at 138 ° C. Moreover, the draw ratio (W ₃ / W ₁ ) in the width direction in the oblique drawing step was 1.9 times.

(Heat treatment and release process)
Next, heat treatment was performed by holding the film at 125 ° C. for 60 seconds in the heat treatment zone. After the heat-treated film was cooled to 100 ° C., the left and right clips were released.

  As described above, a retardation film (thickness: 58 μm) was obtained. The obtained retardation film was subjected to the evaluations (1) to (7) above. The results are shown in Table 1.

<Example 2>
The polycarbonate resin film (thickness 155 μm, width 765 mm) obtained in the same manner as in Example 1 was used, and the clip pitch (P ₁ ) of the right clip was 125 mm and the clip pitch (P ₂ ) of the left clip in the preheating zone. 187.5 mm, the change rate (P ₄ / P ₂ ) of the clip pitch of the left clip at the terminal end of the first oblique stretching zone C1 was 0.72, and the width direction in the oblique stretching step A retardation film was obtained in the same manner as in Example 1 except that the draw ratios (W ₂ / W ₁ ) and (W ₃ / W ₁ ) were 1.35 times and 1.7 times, respectively. The obtained retardation film was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Example 3>
The polycarbonate resin film obtained in the same manner as in Example 1 was subjected to pre-heat treatment and oblique stretching with a clip pitch profile as shown in FIG. 5 using an apparatus as shown in FIGS. A film was obtained. Specifically, the polycarbonate resin film (thickness 125 μm, width (W ₁ ) 695 mm) was preheated to 145 ° C. in the preheating zone of the stretching apparatus. In the preheating zone, the clip pitch of the right clip was 200 mm, and the clip pitch of the left clip was 300 mm.
Next, at the same time that the film entered the first diagonal stretching zone C1, the reduction of the clip pitch of the left clip was started and decreased from 300 mm to 135 mm in the first diagonal stretching zone C1. The clip pitch change rate (P ₃ / P ₂ ) was 0.45. In the first oblique stretching zone C1, the clip pitch of the right clip was maintained at a clip pitch of 200 mm in the preheating zone. The TD stretch ratio (W ₂ / W ₁ ) after the first oblique stretching was 1.5 times.
Next, as soon as the film entered the second oblique stretching zone C2, the clip pitch of the left clip started to increase and increased from 135 mm to 300 mm in the second oblique stretching zone C2. On the other hand, the clip pitch of the right clip was maintained at 200 mm in the second oblique stretching zone C2. The draw ratio (W ₃ / W ₁ ) in the width direction in the oblique stretching process was twice. The oblique stretching was performed at 138 ° C.

(Heat treatment and release process)
Next, heat treatment was performed by holding the film at 125 ° C. for 60 seconds in the heat treatment zone. After the heat-treated film was cooled to 100 ° C., the left and right clips were released.

  As described above, a retardation film (thickness: 65 μm) was obtained. The obtained retardation film was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Comparative Example 1>
A retardation film was obtained in the same manner as in Example 1 except that the initial clip pitches (P ₁ , P ₂ ) of the left and right clips were both 150 mm. The obtained retardation film was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Comparative example 2>
A retardation film was obtained in the same manner as in Example 2 except that the initial clip pitches (P ₁ , P ₂ ) of the left and right clips were both 125 mm. The obtained retardation film was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Comparative Example 3>
A retardation film was obtained in the same manner as in Example 3 except that the initial clip pitches (P ₁ , P ₂ ) of the left and right clips were both 200 mm. The obtained retardation film was subjected to the same evaluation as in Example 1. The results are shown in Table 1.

<Evaluation>
As shown in the above table, wrinkles were prevented from occurring in the long retardation film obtained by the production method of the present invention. Further, since it has a slow axis in the direction of about 45 degrees with respect to the long direction and an in-plane retardation of about 140 nm, it is a long polarizer having an absorption axis in the long direction or the width direction. And a circular to polarizing plate can be formed with high production efficiency.

  The retardation film obtained by the production method of the present invention is suitably used for a circularly polarizing plate, and as a result, is suitably used for an image display device such as a liquid crystal display device (LCD) or an organic electroluminescence display device (OLED). .

10L endless loop 10R endless loop 20 clip 30 clip carrying member 70 reference rail 90 pitch setting rail 100 stretching device 300 circularly polarizing plate 310 polarizer 320 first protective film 330 second protective film 340 retardation film

Claims (4)

The left and right ends of the film to be stretched are respectively gripped by the left and right clips of variable pitch type in which the vertical clip pitch changes,
Preheating the film;
Changing the clip pitch of at least one of the left and right clips to obliquely stretch the film, and releasing the clip holding the film;
Ri right clip clip pitch Do different in the time of gripping the left and right end portions of the film,
The oblique stretching is
(I) increasing the clip pitch of one of the left and right clips while decreasing the clip pitch of the other clip; and
(Ii) Increasing the reduced clip pitch of the other clip to the same rate of change as the increased clip pitch of the one clip.
A method for producing a retardation film. The method for producing a retardation film according to claim 1 , wherein the clip pitch of a clip having a larger clip pitch when gripping the left and right ends of the film is decreased and then increased. The right and left clip clip pitch ratio of the time of gripping the left and right end portions of the film (the smaller clip pitch / larger clip pitch of) is 0.5 to 0.95, to claim 1 or 2 The manufacturing method of retardation film of description. A long retardation film is obtained by the method for producing a retardation film according to any one of claims 1 to 3, and
While conveying the the elongated retardation film and longer polarizing plate, comprising bonding continuously aligned its longitudinal direction, the manufacturing method of the circularly polarizing plate.