JP6401377B2 - 偏光板の製造方法及び脱色溶液 - Google Patents
偏光板の製造方法及び脱色溶液 Download PDFInfo
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- 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
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- 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
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- G02F1/133528—Polarisers
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- 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
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- G03F7/039—Macromolecular compounds which are photodegradable, e.g. positive electron resists
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- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/16—Coating processes; Apparatus therefor
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- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/20—Exposure; Apparatus therefor
- G03F7/2002—Exposure; Apparatus therefor with visible light or UV light, through an original having an opaque pattern on a transparent support, e.g. film printing, projection printing; by reflection of visible or UV light from an original such as a printed image
- G03F7/2004—Exposure; Apparatus therefor with visible light or UV light, through an original having an opaque pattern on a transparent support, e.g. film printing, projection printing; by reflection of visible or UV light from an original such as a printed image characterised by the use of a particular light source, e.g. fluorescent lamps or deep UV light
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- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/20—Exposure; Apparatus therefor
- G03F7/2002—Exposure; Apparatus therefor with visible light or UV light, through an original having an opaque pattern on a transparent support, e.g. film printing, projection printing; by reflection of visible or UV light from an original such as a printed image
- G03F7/2004—Exposure; Apparatus therefor with visible light or UV light, through an original having an opaque pattern on a transparent support, e.g. film printing, projection printing; by reflection of visible or UV light from an original such as a printed image characterised by the use of a particular light source, e.g. fluorescent lamps or deep UV light
- G03F7/2006—Exposure; Apparatus therefor with visible light or UV light, through an original having an opaque pattern on a transparent support, e.g. film printing, projection printing; by reflection of visible or UV light from an original such as a printed image characterised by the use of a particular light source, e.g. fluorescent lamps or deep UV light using coherent light; using polarised light
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- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/26—Processing photosensitive materials; Apparatus therefor
- G03F7/30—Imagewise removal using liquid means
- G03F7/32—Liquid compositions therefor, e.g. developers
- G03F7/322—Aqueous alkaline compositions
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- C08J2329/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
- C08J2329/02—Homopolymers or copolymers of unsaturated alcohols
- C08J2329/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
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- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
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- G02—OPTICS
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- 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
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- 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
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Description
ヨウ素及び二色性染料のうち少なくとも一つ以上が染着されたポリビニルアルコール系偏光子を提供するステップ、
前記偏光子の一面に保護フィルムを備えるステップ、
前記偏光子の他面に少なくとも一つ以上の穿孔部を含むマスク層を備えるステップ、及び
前記マスク層が備えられた偏光子の他面に脱色剤を1重量%〜30重量%で含む脱色溶液を局地的に接触させ、400nm〜800nm波長帯域における単体透過率が80%以上の偏光解消領域を形成するステップを含み、
前記脱色溶液の表面張力が50mN/m以下である偏光板の製造方法を提供する。
表示パネル、及び
前記表示パネルの一面または両面に付着された前記偏光板を含む画像表示装置を提供する。
ポリビニルアルコール系フィルム(日本合成社製のM3000 grade 30μm)を25℃の純水溶液で膨潤工程を15秒間経た後、0.2wt%濃度及び25℃のヨウ素溶液で60秒間染着工程を行った。その後、ホウ酸1wt%、45℃の溶液で30秒間洗浄工程を経た後、ホウ酸2.5wt%、52℃の溶液で6倍延伸工程を行った。延伸後、5wt%のヨウ化カリウム(KI)溶液で補色工程を経た後、60℃のオーブンで5秒間乾燥させて12μmの偏光子を製造した。その後、アクリル系保護フィルムを前記ポリビニルアルコール系偏光子の一面に積層し、偏光子の他の一面に直径約4mmの孔(hole)が加工されたマスキングフィルムを積層した後、アクリル系保護フィルムの他の一面(保護フィルムの偏光子に対向する面の反対面)に粘着剤を用いてポリエチレンテレフタレート(PET)を積層した。
前記一面には穿孔されたマスキングフィルムが積層され、他の一面には保護フィルム及びポリエチレンテレフタレート(PET)が積層された偏光子を、界面活性剤(BYK−348、BYK Chemie)が0.2wt%添加された60 KOH 10wt%水溶液に3秒間浸漬して脱色した後、ホウ酸4wt%水溶液に5秒間浸漬して中和した後、60℃のオーブンで30秒間乾燥した後、マスキングフィルムを除去した後、アクリル系保護フィルムを積層した。その後、ポリエチレンテレフタレート(PET)フィルムを除去してアクリル系保護フィルム/ポリビニルアルコール系偏光子/アクリル系保護フィルム構造の偏光板を製造した。
界面活性剤(BYK−348、BYK Chemie)が0.1wt%添加された脱色溶液を用いたことを除いては、実施例1と同様の条件で偏光板を製造した。
イソプロピルアルコール20wt%添加された脱色溶液を用いたことを除いては、実施例1と同様の条件で偏光板を製造した。
イソプロピルアルコール10wt%添加された脱色溶液を用いたことを除いては、実施例1と同様の条件で偏光板を製造した。
イソプロピルアルコール5wt%添加された脱色溶液を用いたことを除いては、実施例1と同様の条件で偏光板を製造した。
イソプロピルアルコール2wt%添加された脱色溶液を用いたことを除いては、実施例1と同様の条件で偏光板を製造した。
イソプロピルアルコール1wt%添加された脱色溶液を用いたことを除いては、実施例1と同様の条件で偏光板を製造した。
添加剤が入っていない脱色溶液を用いたことを除いては、実施例1と同様の条件で偏光板を製造した。
Claims (27)
- ヨウ素及び二色性染料のうち少なくとも一つ以上が染着されたポリビニルアルコール系偏光子を提供するステップ、
前記偏光子の一面に保護フィルムを備えるステップ、
前記偏光子の他面に少なくとも一つ以上の穿孔部を含むマスク層を備えるステップ、及び
前記マスク層が備えられた偏光子の他面に脱色剤を1重量%〜30重量%で含む脱色溶液を局地的に接触させ、400nm〜800nm波長帯域における単体透過率が80%以上の偏光解消領域を形成するステップを含み、
前記脱色溶液の表面張力が50mN/m以下である偏光板の製造方法。 - 前記脱色溶液の表面張力が30mN/m以下である、請求項1に記載の偏光板の製造方法。
- 前記脱色溶液と前記偏光子の接触角が30度以下である、請求項1に記載の偏光板の製造方法。
- 前記脱色溶液と前記偏光子の接触角が10度以下である、請求項1に記載の偏光板の製造方法。
- 前記脱色溶液は、前記脱色溶液の全体重量に対して1重量%〜50重量%のアルコール系溶媒をさらに含む、請求項1に記載の偏光板の製造方法。
- 前記脱色溶液は、前記脱色溶液の全体重量に対して0.01重量%〜0.5重量%の界面活性剤をさらに含む、請求項1に記載の偏光板の製造方法。
- 前記偏光解消領域を形成するステップ前に、保護フィルムの偏光子に対向する反対面に離型フィルムを備えるステップをさらに含む、請求項1に記載の偏光板の製造方法。
- 前記偏光解消領域を形成するステップ後に、前記離型フィルムを除去するステップをさらに含む、請求項7に記載の偏光板の製造方法。
- 前記マスク層を備えるステップが、
マスクフィルムに穿孔部を形成するステップ、及び
前記マスクフィルムを前記偏光子の他面に付着するステップを含む、請求項1に記載の偏光板の製造方法。 - 前記マスクフィルムは、ポリエチレン(PolyEthylene、PE)フィルム、ポリプロピレン(PolyPropylene、PP)フィルム、ポリエチレンテレフタレート(PolyEthyleneTerephtalate、PET)フィルム、エチレンビニルアセテート(Ethylene Vinyl Acetate、EVA)フィルムまたはポリビニルアセテート(PolyVinyl Acetate)フィルムである、請求項9に記載の偏光板の製造方法。
- 前記穿孔部を形成するステップはレーザ加工によって行われる、請求項9に記載の偏光板の製造方法。
- 前記マスク層を備えるステップが、
前記偏光子の他面にコーティング層を形成するステップ、及び
前記コーティング層の一部領域を選択的に除去して穿孔部を形成するステップを含む、請求項1に記載の偏光板の製造方法。 - 前記コーティング層は、高分子樹脂組成物または感光性樹脂組成物を用いて形成される、請求項12に記載の偏光板の製造方法。
- 前記穿孔部を形成するステップはレーザ加工によって行われる、請求項12に記載の偏光板の製造方法。
- 前記脱色剤は、水酸化ナトリウム(NaOH)、硫化水素ナトリウム(NaSH)、アジ化ナトリウム(NaN3)、水酸化カリウム(KOH)、硫化水素カリウム(KSH)及びチオ硫酸カリウム(K2S2O3)からなる群より選択された1種以上を含む、請求項1に記載の偏光板の製造方法。
- 前記脱色溶液のpHが11〜14である、請求項1に記載の偏光板の製造方法。
- 前記脱色溶液の粘度が1cP〜2,000cPである、請求項1に記載の偏光板の製造方法。
- 前記脱色溶液が増粘剤をさらに含む、請求項1に記載の偏光板の製造方法。
- 前記増粘剤は、ポリビニルアルコール系樹脂、ポリビニルアセトアセテート系樹脂、アセトアセチル基変性ポリビニルアルコール系樹脂、ブテンジオールビニルアルコール系樹脂、ポリエチレングリコール系樹脂及びポリアクリルアミド系樹脂からなる群より選択された1種以上を含む、請求項18に記載の偏光板の製造方法。
- 前記偏光解消領域を形成するステップ後に、マスク層を除去するステップをさらに含む、請求項1に記載の偏光板の製造方法。
- 前記偏光解消領域を形成するステップ後に、偏光子を架橋処理するステップをさらに含む、請求項1に記載の偏光板の製造方法。
- 前記偏光解消領域を形成するステップ後に、偏光子を洗浄及び乾燥するステップをさらに含む、請求項1に記載の偏光板の製造方法。
- 前記洗浄及び乾燥するステップにおいて、前記乾燥は直径が100Φ〜500Φの加熱ロール(heating roll)を用いて行われる、請求項22に記載の偏光板の製造方法。
- 前記加熱ロールの温度は30℃〜150℃である、請求項23に記載の偏光板の製造方法。
- 前記偏光解消領域を形成するステップ後に、前記偏光子の少なくとも一面に光学層を形成するステップをさらに含む、請求項1に記載の偏光板の製造方法。
- 前記光学層は、保護フィルム、位相差フィルム、輝度向上フィルム、ハードコーティング層、反射防止層、粘着層またはこれらの組み合わせである、請求項25に記載の偏光板の製造方法。
- 脱色剤と水と界面活性剤とからなる脱色溶液であって、
前記脱色剤は、水酸化ナトリウム(NaOH)、硫化水素ナトリウム(NaSH)、アジ化ナトリウム(NaN 3 )、水酸化カリウム(KOH)、硫化水素カリウム(KSH)及びチオ硫酸カリウム(K 2 S 2 O 3 )からなる群より選択された1種以上を含み、
前記脱色剤の含量は、前記脱色溶液の全体重量に対して1重量%〜30重量%であり、
前記界面活性剤の含量は、前記脱色溶液の全体重量に対して0.01重量%〜0.5重量%であり、
前記脱色溶液は、50mN/m以下の表面張力を有し、
前記脱色溶液は、ヨウ素及び二色性染料のうち少なくとも一つ以上が染着されたポリビニルアルコール系偏光子用である、脱色溶液。
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