JP6906670B1 - 配向液晶フィルムの製造方法 - Google Patents
配向液晶フィルムの製造方法 Download PDFInfo
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- JP6906670B1 JP6906670B1 JP2020160923A JP2020160923A JP6906670B1 JP 6906670 B1 JP6906670 B1 JP 6906670B1 JP 2020160923 A JP2020160923 A JP 2020160923A JP 2020160923 A JP2020160923 A JP 2020160923A JP 6906670 B1 JP6906670 B1 JP 6906670B1
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Abstract
Description
配向液晶層1は、所定方向に配向した液晶分子を含む。例えば、支持基板8上に、液晶化合物を含む液晶性組成物を塗布し、液晶化合物を所定方向に配向させた後、配向状態を固定することにより、図2に示す様に、支持基板8上に配向液晶層1が形成される。
液晶化合物としては、棒状液晶化合物および円盤状液晶化合物等が挙げられる。支持基板の配向規制力によりホモジニアス配向しやすいことから、液晶化合物としては棒状液晶化合物が好ましい。棒状液晶化合物は、主鎖型液晶でも側鎖型液晶でもよい。棒状液晶化合物は、液晶ポリマーでもよく、重合性液晶化合物の重合物でもよい。重合前の液晶化合物(モノマー)が液晶性を示すものであれば、重合後は液晶性を示さないものであってもよい。
液晶性組成物を塗布する支持基板8としては、ガラス板、金属板、金属ベルト、樹脂フィルム基板等が挙げられる。支持基板は第一主面および第二主面を有し、第一主面上に液晶性組成物を塗布する。
液晶化合物がサーモトロピック液晶である場合は、支持基板8の第一主面上に液晶性組成物を塗布し、加熱により液晶化合物を液晶状態として配向させる。
上記の通り、光硬化後の液晶層は、加熱しても相転移を生じないため、未硬化の配向液晶層に比べると熱安定性に優れている。しかし、光硬化後の液晶層を高温環境に長時間暴露すると、光学特性が変化する場合があり、加熱耐久性向上の余地がある。特に、配向液晶層に接着剤を介して他の光学層を貼り合わせた配向液晶フィルムは、長時間の加熱により、レターデーションが上昇する傾向があり、加熱耐久性に課題がある。
樹脂コート層6の樹脂材料としては、非硬化型樹脂が好ましい。非硬化型樹脂とは、樹脂溶液をコーティングした後に、光硬化や熱硬化等の硬化反応を伴わずに樹脂層を形成可能な材料である。非硬化型樹脂は、光硬化性または熱硬化性の反応性基を含まないものであるが、少量の反応性基が残存していてもよい。例えば、反応性官能基当量(1当量の反応性官能基をを含む樹脂の質量)は、3000以上が好ましく、4000以上がより好ましく、5000以上または6000以上であってもよい。
樹脂溶液の有機溶媒は、上記の樹脂材料を溶解可能なものであれば特に限定されない。有機溶媒は、配向液晶層を溶解しないものが好ましい。例えば、配向液晶層が光重合性液晶モノマーの光硬化物を含む場合は、当該硬化物を不溶または難溶である有機溶媒が好ましい。一方、有機溶媒は、光硬化前の液晶性化合物(モノマー)に対する溶解性を示すものであってもよい。有機溶媒は、1種の溶媒でもよく、2種以上の混合溶媒でもよい。
光学層4は特に限定されず、光学フィルムとして一般的に用いられる光学等方性または光学異方性のフィルムを特に制限なく使用できる。光学層4の具体例としては、位相差フィルムや偏光子保護フィルム等の透明フィルム、偏光子、視野角拡大フィルム、視野角制限(覗き見防止)フィルム、輝度向上フィルム等の機能性フィルムが挙げられる。光学層4は、単層でもよく積層体でもよい。光学層4は、配向液晶層であってもよい。例えば、光学層4は、偏光子の一方の面または両面に透明保護フィルムが貼り合わせられた偏光板であってもよい。偏光板が一方の面に透明保護フィルムを備える場合、偏光子と配向液晶層とを貼り合わせてもよく、透明保護フィルムと配向液晶層とを貼り合わせてもよい。
上記のように、配向液晶層1の表面に樹脂コート層6を設け、その上に接着剤層3を介して光学層4を貼り合わせることにより、配向液晶フィルム100における配向液晶層1の加熱耐久性を向上できる。
支持基板8上の配向液晶層1の表面に樹脂コート層6が設けられ、樹脂コート層6上に接着剤層3を介して光学層4が貼り合わせられた配向液晶フィルム103は、そのまま光学部材として用いてもよい。この場合、支持基板8が配向液晶フィルム103の一部を構成する。図1に示す配向液晶フィルム100の様に、配向液晶層1から支持基板を剥離してもよい。支持基板の剥離により露出した配向液晶層1の表面には、図5に示す様に、適宜の粘着剤層2を積層してもよい。
配向液晶フィルムは、視認性向上等を目的としたディスプレイ用光学フィルムとして用いることができる。例えば、液晶表示装置では、液晶セルから視認側に射出される光の偏光状態を適宜に変換して、視野角特性を向上させる等の目的で、画像表示セル(液晶セル)と偏光子との間に光学補償フィルムとしての位相差板が配置される場合がある。
図8は画像表示装置の積層構成例を示す断面図であり、画像表示セル50の表面に、粘着剤層2を介して配向液晶層1を備える配向液晶フィルムが貼り合わせられている。配向液晶フィルムは、2層以上の配向液晶層を備えるものであってもよい。画像表示セル50としては、液晶セルや有機ELセル等が挙げられる。
<比較例1>
ネマチック液晶相を示す光重合性液晶化合物(BASF製「Paliocolor LC242」)をシクロペンタノンに溶解して、固形分濃度30重量%の溶液を調製した。この溶液に、界面活性剤(ビック・ケミー製「BYK−360」)および光重合開始剤(IGM Resins製「Omnirad907」)を添加して、液晶性組成物溶液を調製した。レベリング剤および重合開始剤の添加量は、光重合性液晶化合物100重量部に対して、それぞれ、0.01重量部および3重量部とした。
シクロペンタノンと酢酸エチルの混合溶媒に、表1に示す樹脂を固形分濃度3重量%となるように溶解して、樹脂溶液を調製した。比較例1の積層体の配向液晶層の表面に、ワイヤーバー(#10)で樹脂溶液を塗布した後、85℃で加熱して溶媒を除去して、配向液晶層の表面にコーティング樹脂層を形成した。なお、表1において、実施例1〜3のアクリル樹脂は、楠本化成より入手したものであり、実施例4〜6および比較例3のエポキシ樹脂は三菱ケミカルより入手したものである。
比較例1の積層体の配向液晶層の表面に、ワイヤーバー(#10)でシクロペンタノンを塗布した後、85℃で1分間加熱して溶媒を除去した。
シクロペンタノンと酢酸エチルの混合溶媒に、エポキシ当量約190のビスフェノールA型エポキシ樹脂(三菱ケミカル製「jER828」および光カチオン重合開始剤(サンアプロ製「CPI100P」)を、エポキシ樹脂濃度が3重量%となるように溶解して、光硬化性の樹脂組成物(溶液)を調製した。比較例1の積層体の配向液晶層の表面に、ワイヤーバー(#10)で組成物を塗布した後、85℃で加熱して溶媒を除去して、その後、紫外線を照射して、エポキシ樹脂を光硬化した。
厚み20μmの無延伸ノルボルネン系フィルム(日本ゼオン製「ゼオノアフィルム」)の片面に、UV硬化型接着剤を介して厚み5μmのPVA系偏光子が設けられた積層体(片保護偏光板)を準備した。
<外観>
コーティング樹脂層を形成後(比較例2はシクロペンタノンによる表面処理後)のフィルム表面を目視にて観察し、析出物が確認されなかったものをOK、析出物が確認されたものをNGとした。
上記の偏光板の粘着剤層をガラス板に貼り合わせて評価用試料を作製した。位相差計(王子計測機器製「KOBRA21−ADH」)により波長590nmの面内レターデーションを測定した後、評価用試料を85℃の空気循環式恒温オーブンに120時間投入した。オーブンから試料を取り出した後、再度面内レターデーションを測定し、加熱試験前後のレターデーションの変化率を算出した。
上記の偏光板の粘着剤層をコーニング製の無アルカリガラスに貼り合わせて評価用試料を作製した。評価用試料の無アルカリガラスの下にアルミニウム蒸着ポリエステルフィルム(東レアドバンスドフィルム製「DMS−X42」)を配置し、分光測色計(コニカミノルタ製「CM−2600d」を用いて、偏光板側から光を照射し、SCI方式で反射光の色相(Lab色空間におけるa*およびb*の値)を測定した。その後、評価用試料を85℃の空気循環式恒温オーブンに120時間投入した。オーブンから試料を取り出した後、再度、アルミニウム蒸着ポリエステルフィルム上で反射光の色相を測定し、加熱試験前後での反射光の色相の変化量√{(Δa*)2+(Δb*)2}を算出した。
6 樹脂コート層
8 支持基板
4 光学層(偏光板)
5 光学層(配向液晶層)
3,7 接着剤層
2 粘着剤層
9 セパレーター
50 画像表示セル
Claims (18)
- 液晶分子が配向した配向液晶層上に、接着剤層を介して光学層が貼り合わせられた配向液晶フィルムの製造方法であって、
配向液晶層の第一主面に、非硬化型樹脂と有機溶媒とを含む樹脂溶液を塗布して、非硬化型の樹脂コート層を形成し、
前記樹脂コート層上に接着剤層を介して光学層を貼り合わせる、
配向液晶フィルムの製造方法。 - 前記樹脂コート層のガラス転移温度が20℃以上である、請求項1に記載の配向液晶フィルムの製造方法。
- 前記接着剤層の厚みが0.01〜5μmである、請求項1または2に記載の配向液晶フィルムの製造方法。
- 接着剤を活性エネルギー線により硬化して前記接着剤層を形成する、請求項1〜3のいずれか1項に記載の配向液晶フィルムの製造方法。
- 前記光学層が、偏光子、透明フィルム、または他の配向液晶層である、請求項1〜4のいずれか1項に記載の配向液晶フィルムの製造方法。
- 前記配向液晶層において、液晶分子がホモジニアス配向している、請求項1〜5のいずれか1項に記載の配向液晶フィルムの製造方法。
- 前記光学層が偏光子を含み、
前記配向液晶層における液晶分子の配向方向と、前記偏光子の吸収軸方向とのなす角が10〜80°である、請求項6に記載の配向液晶フィルムの製造方法。 - 前記樹脂コート層の厚みが、0.05〜3μmである、請求項1〜7のいずれか1項に記載の配向液晶フィルムの製造方法。
- 前記非硬化型樹脂の重量平均分子量が2万以上である、請求項1〜8のいずれか1項に記載の配向液晶フィルムの製造方法。
- 前記非硬化型樹脂が、非硬化型のアクリル樹脂または非硬化型のエポキシ樹脂を含む、請求項1〜9のいずれか1項に記載の配向液晶フィルムの製造方法。
- 前記樹脂溶液に、前記配向液晶層を構成する液晶化合物の未硬化物が溶出し、
前記樹脂コート層に、前記未硬化物が含まれる、請求項1〜10のいずれか1項に記載の配向液晶フィルムの製造方法。 - 前記樹脂溶液を塗布した後、前記光学層を貼り合わせる前に、40〜150℃で加熱を行う、請求項1〜11のいずれか1項に記載の配向液晶フィルムの製造。
- 光重合性液晶モノマーを含有する液晶性組成物を支持基板上に塗布し、
前記支持基板上の液晶性組成物を加熱して、液晶モノマーを液晶状態として配向させ、
光照射により前記液晶モノマーを重合または架橋することにより、
前記配向液晶層を形成する、請求項1〜12のいずれか1項に記載の配向液晶フィルムの製造方法。 - 前記支持基板が樹脂フィルムである、請求項13に記載の配向液晶フィルムの製造方法。
- 前記支持基板上に前記配向液晶層が設けられた状態で、前記配向液晶層の前記支持基板と接していない面に、前記樹脂溶液を塗布する、請求項13または14に記載の配向液晶フィルムの製造方法。
- 前記配向液晶層から前記支持基板を剥離し、
支持基板の剥離により露出した配向液晶層の表面に、前記樹脂溶液を塗布する、請求項13または14に記載の配向液晶フィルムの製造方法。 - 前記樹脂溶液の有機溶媒は、前記光重合性液晶モノマーに対する溶解性を有し、かつ前記光重合性液晶モノマーの光硬化物を不溶または難溶である、請求項13〜16のいずれか1項に記載の配向液晶フィルムの製造方法。
- 前記光学層が、透明フィルム、偏光子、または前記配向液晶層とは別の配向液晶層である、請求項1〜17のいずれか1項に記載の配向液晶フィルムの製造方法。
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