JP7016932B2 - Manufacturing method of optical laminate, liquid crystal laminate, and optical laminate - Google Patents

Description

The present invention relates to a method for manufacturing an optical laminate, a liquid crystal laminate, and an optical laminate.

A member including an optical film such as a polarizing plate and a retardation plate is used in a display device such as a liquid crystal display device or an organic EL display device. As a member containing such an optical film, a liquid crystal composition containing a polymerizable liquid crystal compound is applied onto a base material layer, and then the polymerizable liquid crystal compound is polymerized and cured to form a liquid crystal layer having retardation characteristics. An optical laminate in which a polarizing element is laminated on this liquid crystal layer via an adhesive layer is known (for example, Patent Document 1 and the like).

Japanese Patent Application Laid-Open No. 2015-191142

When the liquid crystal layer of the optical laminated body as described above contains fluorine atoms, it has been found that defects such as wrinkles and bubbles occur in the optical laminated body in which a polarizing element or the like is laminated on the liquid crystal layer via an adhesive layer. Was done. When an optical laminate having such a defect is applied to a display device, the visibility tends to be deteriorated.

It is an object of the present invention to provide a method for manufacturing an optical laminate in which the generation of defects such as wrinkles and bubbles is suppressed, a liquid crystal laminate, and an optical laminate.

The present invention provides the following methods for manufacturing an optical laminate, a liquid crystal laminate, and an optical laminate.
[1] A method for producing an optical laminate in which a first liquid crystal layer obtained by curing a first liquid crystal composition containing a polymerizable liquid crystal compound and a fluorine atom, a laminated layer, and an optical layer are laminated in this order. hand,
A step of performing a surface activation treatment on one surface of the first liquid crystal layer and
A step of forming a coating layer by applying a patch composition to the one surface to which the surface activation treatment has been performed, and a step of forming a coating layer.
The step of laminating the optical layer on the coating layer and
Including the step of forming the bonding layer from the coating layer.
Fluorine atomic weight F1 [atm%] on the one surface before the surface activation treatment and fluorine atomic weight F2 [atm%] on the one surface after the surface activation treatment. ] Is a method for manufacturing an optical laminate that satisfies the relationship of the following formula (I).
0.05 × F1 ≦ F2 ≦ 0.7 × F1 (I)
[2] The method for producing an optical laminate according to [1], wherein the first liquid crystal composition contains a leveling agent.
[3] The method for producing an optical laminate according to [2], wherein the leveling agent contains the fluorine atom.
[4] The method for producing an optical laminate according to any one of [1] to [3], wherein the optical layer is a second liquid crystal layer containing a cured product of a polymerizable liquid crystal compound.
[5] The second liquid crystal layer has a surface that has been subjected to a surface activation treatment.
The step of laminating the second liquid crystal layer is a step of laminating the second liquid crystal layer so that the surface of the second liquid crystal layer subjected to the surface activation treatment is in contact with the coating layer. Method for manufacturing an optical laminate.
[6] Further, a step of laminating a polarizing plate on the side opposite to the bonded layer in one of the first liquid crystal layer and the second liquid crystal layer is included.
The method for producing an optical laminate according to [4] or [5], wherein the polarizing plate has a protective layer on one side or both sides of a linear polarizing element.
[7] The method for producing an optical laminate according to any one of [1] to [3], wherein the optical layer includes a polarizing plate having a protective layer on one side or both sides of a linear polarizing element.
[8] The optical lamination according to [7], further comprising a step of laminating a second'liquid crystal layer containing a cured product of a polymerizable liquid crystal compound on the side of the first liquid crystal layer opposite to the bonded layer. How to make a body.
[9] The method for producing an optical laminate according to any one of [1] to [8], wherein the surface activation treatment applied to the one surface of the first liquid crystal layer is a corona treatment. ..
[10] The method for producing an optical laminate according to [9], wherein in the step of performing the surface activation treatment, the treatment amount of the corona treatment is 1 kJ / m ² or more and 8 kJ / m ² or less.
[11] The method for producing an optical laminate according to any one of [1] to [10], wherein the bonded layer is an adhesive layer.
[12] A liquid crystal laminate in which a first liquid crystal layer containing a cured product of a polymerizable liquid crystal compound and a bonded layer are laminated.
A liquid crystal laminate having a fluorine atomic weight on the surface of the 1'liquid crystal layer on the bonded layer side of 1.5 atm% or more and 4.5 atm% or less.
[13] The liquid crystal laminate according to [12], further having a base material layer on the side of the first'liquid crystal layer opposite to the bonded layer side.
[14] An optical laminate having the liquid crystal laminate according to [12] or [13] and an optical layer.
The optical layer is an optical laminate laminated on the bonded layer side of the liquid crystal laminate.
[15] The optical laminate according to [14], wherein the optical layer is a second liquid crystal layer containing a cured product of a polymerizable liquid crystal compound.
[16] The optical laminate according to [15], wherein the fluorine atomic weight on the surface of the second liquid crystal layer on the bonded layer side is 1.5 atm% or more and 4.5 atm% or less.
[17] The liquid crystal laminate is the liquid crystal laminate according to [12].
The optical laminate further has a polarizing plate on one of the first'liquid crystal layer and the second liquid crystal layer on the side opposite to the bonded layer side.
The optical laminate according to [15] or [16], wherein the polarizing plate includes a polarizing plate having a protective layer on one side or both sides of a linear polarizing element.
[18] The optical laminate according to [14], wherein the optical layer includes a polarizing plate having a protective layer on one side or both sides of a linear polarizing element.
[19] The liquid crystal laminate is the liquid crystal laminate according to claim 12.
The optics according to [18], wherein the optical laminate further has a second'liquid crystal layer containing a cured product of a polymerizable liquid crystal compound on the side of the first'liquid crystal layer opposite to the bonded layer side. Laminated body.
[20]
The optical laminate according to any one of [14] to [19], wherein the bonding layer is an adhesive layer.

According to the present invention, it is possible to provide an optical laminate in which the generation of defects such as wrinkles and bubbles is suppressed.

It is a schematic sectional drawing schematically showing an example of the optical laminated body of this invention. (A) to (c) are schematic cross-sectional views schematically showing an example of a manufacturing process of the optical laminate of the present invention. It is a schematic sectional drawing schematically showing another example of the optical laminated body of this invention. (A) to (d) are schematic cross-sectional views schematically showing another example of the manufacturing process of the optical laminate of the present invention. It is a schematic sectional drawing schematically showing still another example of the optical laminated body of this invention. (A) to (c) are schematic cross-sectional views schematically showing still another example of the manufacturing process of the optical laminate of the present invention. It is a schematic sectional drawing schematically showing an example of the liquid crystal laminate of this invention. It is a schematic sectional drawing schematically showing another example of the liquid crystal laminate of this invention. It is a schematic sectional drawing schematically showing still another example of the optical laminated body of this invention. It is a schematic sectional drawing schematically showing still another example of the optical laminated body of this invention. It is a schematic sectional drawing schematically showing still another example of the optical laminated body of this invention. It is a schematic sectional drawing schematically showing still another example of the optical laminated body of this invention.

Hereinafter, preferred embodiments of the method for producing an optical laminate of the present invention will be described with reference to the drawings. The embodiments shown below and each modification may be arbitrarily combined. In each modification, the same members as those described above are designated by the same reference numerals and the description thereof will be omitted.

<Manufacturing method of optical laminate>
FIG. 1 is a schematic cross-sectional view schematically showing an example of the optical laminate of the present invention. 2 (a) to 2 (c) are schematic cross-sectional views schematically showing an example of a manufacturing process of the optical laminate of the present invention.

As shown in FIG. 1, in the optical laminate 1 obtained by the method for manufacturing an optical laminate of the present embodiment, the first liquid crystal layer 10, the first bonded layer 20 (bonded layer), and the optical layer 30 are arranged in this order. Have. The first liquid crystal layer 10 is a cured product layer obtained by curing a first liquid crystal composition containing a polymerizable liquid crystal compound and a fluorine atom. The first bonding layer 20 is an adhesive layer or an adhesive layer made of a cured product of the adhesive composition, and is preferably an adhesive layer. The optical layer 30 means a layer having optical functions such as transmitting, reflecting, and absorbing light.

The optical laminate 1 may have a first base material layer 11 on the opposite side of the first liquid crystal layer 10 from the first bonded layer 20, and the first alignment layer and the first base material layer 11 may be provided. You may have them in this order. The optical laminate 1 may be a single-wafered body or a long film-like material.

The method for manufacturing the optical laminate 1 is as follows.
A step of performing a surface activation treatment on one surface (hereinafter, may be referred to as “first surface”) 10a (FIG. 2A) of the first liquid crystal layer 10.
A step of forming a coating layer 25 (FIG. 2B) by applying a first patching agent composition (bonding agent composition) to a first surface 10a that has been subjected to a surface activation treatment.
The step of laminating the optical layer 30 (FIG. 2 (c)) on the coating layer 25, and
Step of forming the first bonded layer 20 from the coating layer 25,
Including
Fluorine atomic weight F1 [atm%] on the first surface 10a before the surface activation treatment step, and fluorine atomic weight F2 [atm%] on the first surface 10a after the surface activation treatment step. Satisfies the relationship of the following formula (I).
0.05 × F1 ≦ F2 ≦ 0.7 × F1 (I)

The first liquid crystal composition preferably contains a leveling agent. The leveling agent preferably contains the above-mentioned fluorine atom.

When the fluorine atom contained in the first liquid crystal composition is, for example, the fluorine atom contained in the leveling agent, the surface of the first liquid crystal layer 10 formed by curing the first liquid crystal composition containing the leveling agent. The leveling agent tends to collect, and the amount of fluorine atom may increase. As described above, when fluorine atoms are gathered and exist on the surface of the first liquid crystal layer 10, when the first patch composition is applied to this surface, repelling of the first patch composition is likely to occur. , Bubbles and other defects may occur.

In the method for producing the optical laminate 1 of the present embodiment, the surface activation treatment is performed on the first surface 10a of the first liquid crystal layer 10, and the fluorine atomic weights F1 and F2 of the first surface 10a before and after the surface activation treatment are performed. Satisfies the relationship of the above formula (I). By this surface activation treatment, the amount of fluorine atomic weight existing on the first surface 10a of the first liquid crystal layer 10 can be reduced to F2, so that the repelling generated when the first patch composition is applied is suppressed. It is possible to obtain the optical laminate 1 in which the occurrence of the above-mentioned defects is suppressed.

Each layer (first liquid crystal layer, optical layer, first base material layer, etc.) used in the method for producing the optical laminate 1 may be a single-wafer body or a long film-like material. When each of the above layers is a long film, the method for manufacturing the optical laminate 1 is preferably performed by so-called Roll to Roll, in which each step is performed while continuously transporting the film-like material.

Hereinafter, each step of the method for manufacturing the optical laminate 1, other steps that may be included in the method for manufacturing the optical laminate 1, modified examples of the method for manufacturing the optical laminate 1, materials used in each step, and the like will be described. This will be described in detail.

(Step of surface activation treatment)
The method for producing the optical laminate 1 includes a step of performing a surface activation treatment on the first surface 10a of the first liquid crystal layer 10.

For the first liquid crystal layer 10, for example, a first liquid crystal composition containing a leveling agent containing a fluorine atom and a polymerizable liquid crystal compound is applied onto the first base material layer 11 to cure the first liquid crystal composition. Can be formed by. The first liquid crystal composition may be applied so as to be in contact with the first base material layer 11 or may be applied so as to be in contact with the first alignment layer provided on the first base material layer 11. Examples of the method for applying the first liquid crystal composition on the first base material layer 11 include known coating methods used in the optical field, specifically, a spin coating method, an extrusion method, and a gravure method. Examples thereof include a coating method, a die coating method, a slit coating method, a bar coating method, a comma coating method, an applicator method, and a flexographic method. Curing of the first liquid crystal composition is not particularly limited, and can be carried out by a conventionally known method for polymerizing and curing a polymerizable liquid crystal compound.

In the step of performing the surface activation treatment, the surface activation treatment is performed on the first surface 10a of the first liquid crystal layer 10. Examples of the surface activation treatment include a treatment capable of reducing the atomic weight of fluorine on the first surface 10a. Specific examples thereof include corona treatment, plasma treatment, discharge treatment such as glow discharge; flame (frame) treatment; ozone treatment; UV ozone treatment; ultraviolet treatment, ionization active ray treatment such as electron beam treatment, and the like. Of these, corona treatment and plasma treatment are preferable, and corona treatment is more preferable. The surface activation treatment can be performed by one or a combination of two or more of the above-mentioned treatments.

The surface activation treatment is performed so as to satisfy the relationship of the above formula (I). The atomic weight of fluorine F2 is preferably 0.65 × F1 [atm%] or less, more preferably 0.5 × F1 [atm%] or less, and 0.4 × F1 [atm%] or less. It may be 0.3 × F1 [atm%] or less. The fluorine atomic weight F2 may be 0.08 × F1 [atm%] or more, 0.1 × F1 [atm%] or more, or 0.15 × F1 [atm%] or more. May be good. The fluorine atomic weight can be determined by X-ray photoelectron spectroscopy (XPS method) as described in Examples described later.

Since the fluorine atomic weight F2 is within the range of the above formula (I), the fluorine atomic weight on the first surface 10a of the first liquid crystal layer 10 can be sufficiently reduced, so that the first patching agent is applied to the first surface 10a. It is possible to suppress the repelling generated when the composition is applied.

The fluorine atomic weight F1 on the first surface 10a before performing the surface activation treatment is preferably 12 atm% or more, more preferably 14 atm% or more, and may be 16 atm% or more, 18 atm. It may be% or more. The fluorine atomic weight F1 is usually 25 atm% or less, and may be 23 atm% or less.

The fluorine atomic weight F2 on the first surface 10a after the step of performing the surface activation treatment is preferably less than 12 atm%, more preferably 10 atm% or less, and may be 9 atm% or less. It may be 6 atm% or less, or 5 atm% or less. The fluorine atomic weight F2 is usually more than 0 atm%, may be 0.5 atm% or more, or may be 1 atm% or more.

By the step of performing the surface activation treatment, the fluorine atomic weights F1 and F2 satisfy the above formula (I), so that the fluorine atomic weight F1 on the first surface 10a of the first liquid crystal layer 10 has a relatively large value as described above. Even in a certain case, it is possible to suppress the repelling generated when the first patch composition is applied to the first surface 10a.

The amount of the surface activation treatment is not particularly limited as long as it can reduce the amount of fluorine atomic weight on the first surface 10a of the first liquid crystal layer 10 so as to satisfy the relationship of the formula (I). For example, when the surface activation treatment is a corona treatment, the treatment amount of the corona treatment is preferably 1 kJ / m ² or more, more preferably 1.5 kJ / m ² or more, and 1.8 kJ / m ² or more. The above is the most preferable. The corona treatment amount is preferably 8 kJ / m ² or less, more preferably 7 kJ / m ² or less, and may be 6 kJ / m ² or less. When the processing amount of the corona treatment is less than 1 kJ / m ² , it tends to be difficult to adjust the fluorine atomic weight F2 on the first surface 10a to a desired range. When the corona treatment amount exceeds 8 kJ / m ² , problems such as deformation of the first liquid crystal layer 10 may occur due to the heat generated by the corona treatment.

(Step of forming the coating layer 25)
In the step of forming the coating layer 25, the coating layer 25 is formed by applying the first patching agent composition to the first surface 10a of the first liquid crystal layer 10 that has been subjected to the step of performing the surface activation treatment. The first bonding agent composition is a composition for forming the first bonding layer 20, and when the first bonding layer 20 is an adhesive layer, it is an adhesive composition, and the first bonding is performed. When the layer 20 is a pressure-sensitive adhesive layer, it is a pressure-sensitive adhesive composition.

Examples of the method for applying the first patching agent composition include a method exemplified as a method for applying the first liquid crystal composition on the first base material layer 11. As a method for applying the first patching agent composition, a gravure coating method, a die coating method, and a slit coating method are preferable.

The viscosity of the first patch composition at a temperature of 25 ° C. is preferably 1 mPa · sec or more, more preferably 10 mPa · sec or more, and may be 20 mPa · sec or more. The viscosity of the first patch composition at a temperature of 25 ° C. is preferably 150 mPa · sec or less, more preferably 140 mPa · sec or less, and may be 130 mPa · sec or less. According to the method for producing the optical laminate 1, even when the viscosity of the first patch composition is in the above range, cissing is suppressed on the first surface 10a of the first liquid crystal layer 10. 1 The patch composition can be applied. As a result, it is possible to obtain the optical laminate 1 in which the occurrence of the above-mentioned defects is suppressed. The viscosity of the first patch composition can be measured by the method described in Examples described later.

(Step of laminating the optical layer 30)
In the step of laminating the optical layer 30, the optical layer 30 is laminated on the coating layer 25 formed in the step of forming the coating layer 25. As a result, it is possible to obtain an optical laminated body 1 in which the first liquid crystal layer 10 and the optical layer 30 are laminated via the first laminated layer 20.

(Step of forming the first bonded layer 20)
The coating layer 25 can be used as the first bonding layer 20 as it is, depending on the type of the first bonding agent composition, or the optical layer 30 is provided after the coating layer 25 is formed or on the coating layer 25. After laminating, the first laminated layer 20 can be obtained by performing a drying treatment, a curing treatment, or the like.

The step of forming the first bonded layer 20 is not particularly limited, but for example,
When the coating layer 25 is a layer formed by using the adhesive composition, in order to cure the curable component in the adhesive composition contained in the coating layer 25 after the step of laminating the optical layer 30. A step of forming the first bonded layer 20 by performing the curing treatment step of
When the coating layer 25 is a layer formed by using the pressure-sensitive adhesive composition, drying for drying the coating layer 25 after the step of forming the coating layer 25 or after the step of laminating the optical layer 30. Examples thereof include a step of performing a step to form the first bonded layer 20.

(Other processes)
The method for manufacturing the optical laminate 1 may include other steps other than the above. Other steps include, for example,
A step of forming a first alignment layer on one surface of the first substrate layer 11 and forming a first liquid crystal layer 10 on the side opposite to the first substrate layer 11 of the first alignment layer;
After the step of laminating the optical layer 30, a step of peeling off the first base material layer 11, the first base material layer 11 and the first alignment layer and the like can be mentioned. These steps can be performed by one type or a combination of two or more types.

(Modification 1)
FIG. 3 is a schematic cross-sectional view schematically showing another example of the optical laminate of the present invention. 4 (a) to 4 (d) are schematic cross-sectional views schematically showing another example of the manufacturing process of the optical laminate of the present invention.

In the optical laminate 2 obtained by the method for manufacturing the optical laminate of this modification, the optical layer 30 in the optical laminate 1 shown in FIG. 1 is the second liquid crystal layer 32. As shown in FIG. 3, the optical laminate 2 has a first liquid crystal layer 10, a first bonded layer 20, and a second liquid crystal layer 32 (optical layer) in this order. The second liquid crystal layer 32 is a cured product layer of the polymerizable liquid crystal compound formed by polymerizing and curing the polymerizable liquid crystal compound.

In the optical laminate 2, the second bonded layer 21 and the polarizing plate 35 may be further laminated in this order on the side of the second liquid crystal layer 32 opposite to the first bonded layer 20 (FIG. 3). The bi-alignment layer, the second bonding layer 21, and the polarizing plate 35 may be laminated in this order. Although not shown, in the optical laminated body 2, the second laminated layer and the polarizing plate may be further laminated in this order on the side opposite to the first bonded layer 20 of the first liquid crystal layer 10, and the first The alignment layer, the second bonding layer, and the polarizing plate may be laminated in this order. The polarizing plate 35 has a protective layer on one side or both sides of the linear polarizing element. The second bonding layer is an adhesive layer or an adhesive layer made of a cured product of the adhesive composition.

The optical laminate 2 may further have a second base material layer 31 on the opposite side of the second liquid crystal layer 32 from the first bonded layer 20 (FIG. 4 (c)), and is a second oriented layer. And the second base material layer 31 may be provided in this order. The optical laminate 2 may have the first base material layer 11 on the opposite side of the first liquid crystal layer 10 from the first bonded layer 20 (FIGS. 3, FIG. 4 (c)), and the first. The alignment layer and the first base material layer 11 may be provided in this order.

In the method for manufacturing the optical laminate 2, the second liquid crystal layer 32 can be laminated so that the surface of the second liquid crystal layer 32 that has been subjected to the surface activation treatment is in contact with the coating layer 25 (FIG. 4 (FIG. 4). b)).

The second liquid crystal layer 32 is formed by, for example, applying a second liquid crystal composition containing a polymerizable liquid crystal compound onto the second base material layer 31 (FIG. 4A) and curing the second liquid crystal composition. can do. The second liquid crystal composition may be applied so as to be in contact with the second base material layer 31, or may be applied so as to be in contact with the second alignment layer provided on the second base material layer 31. Examples of the method for applying the second liquid crystal composition include the methods exemplified as the method for applying the first liquid crystal composition. Curing of the second liquid crystal composition is not particularly limited, and can be performed by a conventionally known method for polymerizing and curing a polymerizable liquid crystal compound.

The surface of the second liquid crystal layer 32 that has been subjected to the surface activation treatment is, for example, one surface of the second liquid crystal layer 32 (hereinafter, may be referred to as “second surface 32a”) (FIG. 4A). It can be formed by subjecting it to a surface activation treatment. Examples of the surface activation treatment include the surface activation treatment exemplified in the method for producing the optical laminate 1. The surface activation treatment is preferably corona treatment or plasma treatment, and more preferably corona treatment.

The amount of the surface activation treatment performed on the second surface 32a is not particularly limited, but it is preferably performed so as to improve the adhesiveness (adhesion) between the second surface 32a and the coating layer 25. The amount of reduction in the amount of fluorine atomic weight on the second surface 32a before and after the surface activation treatment performed on the second surface 32a is the surface activation treatment performed in the step of performing the surface activation treatment in the method for producing the optical laminate 1. It may be smaller than the reduction amount of the fluorine atomic weight on the first surface 10a before and after. Although the reason for this is not clear, the first patch composition is applied to the first surface 10a of the first liquid crystal layer 10, whereas the first patch composition is directly applied to the second surface 32a. It is considered that this is because the surface is laminated on the coating layer 25 formed by applying the first patch composition. That is, on the first surface 10a to which the first patch composition is applied, the repelling of the first patch composition tends to be a problem, but on the second surface 32a laminated on the coating layer 25, the first surface is the first. It is presumed that repelling of the patch composition is unlikely to occur.

The fluorine atomic weight on the second surface 32a before the surface activation treatment is F1'[atm%], and the fluorine atomic weight on the second surface 32a after the surface activation treatment is F2'[atm%]. For example, the relationship of the following formula (I') may be satisfied.
0.01 x F1'≤F2'≤0.9 x F1'(I')

The atomic weight of fluorine F2'may be 0.85 x F1'[atm%] or less, may be 0.8 x F1'[atm%] or less, and 0.7 x F1'[atm%]. It may be less than or equal to 0.6 × F1'[atm%] or less. The fluorine atomic weight F2'may be 0.05 x F1'[atm%] or more, or 0.1 x F1'[atm%] or more. The atomic weight of fluorine can be determined by X-ray photoelectron spectroscopy (XPS method).

The fluorine atomic weight F1'on the second surface 32a before the surface activation treatment is the same as the fluorine atomic weight F1 on the first surface 10a before the surface activation treatment on the first surface 10a of the first liquid crystal layer 10. May be different. When the fluorine atomic weight F1'and the fluorine atomic weight F1 are different from each other, the fluorine atomic weight F1'may be larger or smaller than the fluorine atomic weight F1. The fluorine atomic weight F1'is preferably 14 atm% or more, may be 18 atm% or more, or may be 20 atm% or more. The fluorine atomic weight F1'is usually 28 atm% or less, and may be 25 atm% or less.

The fluorine atomic weight F2'on the second surface 32a after the surface activation treatment is the same as the fluorine atomic weight F2 on the first surface 10a after the surface activation treatment on the first surface 10a of the first liquid crystal layer 10. It may or may not be different. When the fluorine atomic weight F2'and the fluorine atomic weight F2 are different from each other, the fluorine atomic weight F2'may be larger or smaller than the fluorine atomic weight F2. The fluorine atomic weight F2'is preferably, for example, 20 atm% or less, more preferably 18 atm% or less, and may be 15 atm% or less. The fluorine atomic weight F2'is usually more than 0 atm%, may be 0.5 atm% or more, or may be 1 atm% or more.

The amount of the surface activation treatment on the second surface 32a is not particularly limited as long as it can be performed so as to improve the adhesiveness (adhesion) between the second surface 32a and the coating layer 25. For example, when the surface activation treatment is a corona treatment, the treatment amount of the corona treatment is preferably 0.5 kJ / m ² or more, more preferably 1 kJ / m ² or more, and 1.5 kJ / m ² or more. The above is the most preferable. The corona treatment amount is preferably 8 kJ / m ² or less, more preferably 7 kJ / m ² or less, and may be 6 kJ / m ² or less.

In the step of laminating the optical layer 30, the second liquid crystal layer is formed on the coating layer 25 formed in the step of forming the coating layer 25 so that the second surface 32a side subjected to the surface activation treatment faces the coating layer 25. 32 are laminated (FIG. 4 (b)). As a result, it is possible to obtain an optical laminate 2 in which the first liquid crystal layer 10 and the second liquid crystal layer 32 are laminated via the first bonded layer 20 (FIG. 4 (c)). As described above, the coating layer 25 can be used as the first bonding layer 20 as it is, depending on the type of the first bonding agent composition, or the coating layer 25 can be first by performing a drying treatment, a curing treatment, or the like. It can be the bonded layer 20.

In the method for manufacturing the optical laminate 2, in addition to the above steps, in one of the first liquid crystal layer 10 and the second liquid crystal layer 32, the polarizing plate 35 (FIG. 3) is on the opposite side of the bonded layer 20. May include a step of laminating.

When the step of laminating the polarizing plate 35 is performed, after the step of laminating the optical layer 30, a step of peeling off the first base material layer 11 or the second base material layer 31 is performed (FIG. 4 (d)), and the first step is performed. The polarizing plate 35 may be laminated on the exposed surface exposed by peeling off the base material layer 11 or the second base material layer 31. FIG. 4D shows a case where the second base material layer 31 is peeled off. When the first base material layer 11 is peeled off, the first alignment layer may be peeled off together with the first base material layer 11, and when the second base material layer 31 is peeled off, the second orientation layer is peeled off together with the second base material layer 31. The layer may be peeled off.

When the exposed surface is formed as described above, in the step of laminating the polarizing plate 35, the polarizing plate 35 can be laminated on the exposed surface described above, for example, via the second bonding layer 21 (FIG. 3). .. The composition layer of the second laminating agent composition for forming the second laminating layer 21 may be formed on the first liquid crystal layer 10 or the second liquid crystal layer 32 side, or may be formed on the polarizing plate 35 side. You may.

(Modification 2)
FIG. 5 is a schematic cross-sectional view schematically showing still another example of the optical laminate of the present invention. 6 (a) to 6 (c) are schematic cross-sectional views schematically showing still another example of the manufacturing process of the optical laminate of the present invention.

In the optical laminate 3 obtained by the method for manufacturing the optical laminate of this modification, the optical layer 30 in the optical laminate 1 shown in FIG. 1 is a polarizing plate 35'. As shown in FIG. 5, the optical laminate 3 has a first liquid crystal layer 10, a first bonded layer 20, and a polarizing plate 35'(optical layer) in this order.

The optical laminate 3 may further have a second'liquid crystal layer 32'on the opposite side of the first liquid crystal layer 10 from the first bonded layer 20, and the third bonded layer 22 and the second'. The liquid crystal layer 32'may be provided in this order (FIG. 5). Further, the optical laminate 3 may further have a second base material layer 31 on the side opposite to the third bonded layer 22 of the second'liquid crystal layer 32'(FIG. 6 (c)). The two alignment layer and the second base material layer 31 may be provided in this order. The optical laminate 3 may further have a first alignment layer between the first liquid crystal layer 10 and the third bonded layer 22. The second'liquid crystal layer 32'can be a cured product layer of the polymerizable liquid crystal compound formed by polymerizing and curing the polymerizable liquid crystal compound, as in the case of the second liquid crystal layer 32, for example. The third bonding layer 22 is an adhesive layer or an adhesive layer made of a cured product of the adhesive composition.

The method for manufacturing the optical laminate 3 is the same as the method for manufacturing the optical laminate 1 except that the optical layer 30 is a polarizing plate 35', and the first base material layer 11, the first liquid crystal layer 10, and the first patch are attached. A laminated body in which the laminated layer 20 and the polarizing plate 35'are laminated in this order is manufactured (FIG. 6 (a)). Further, except that the second liquid crystal layer 32 is the second'liquid crystal layer 32', the method for producing the optical laminate 2 is the same as the formation of the second liquid crystal layer 32 and the surface activation treatment of the second surface 32a. Then, the formation of the second'liquid crystal layer 32'and the surface activation treatment on the surface of the second'liquid crystal layer 32'on the opposite side of the second base material layer 31 are performed. Next, the first base material layer 11, the first base material layer 11 and the first alignment layer are peeled off (FIG. 6 (b)), and the exposed surface exposed by this peeling is subjected to surface activation treatment. Examples of the surface activating treatment performed on the exposed surface include the surface activating treatment described above.

After that, the second liquid crystal layer 32'is laminated on the exposed surface with the surface activation treatment side of the second'liquid crystal layer 32' facing each other via the third bonded layer 22 (FIG. 6 (c). )). The composition layer of the third patch composition for forming the third patch layer 22 may be formed on the exposed surface side, and the surface of the second liquid crystal layer 32'that has been subjected to the surface activation treatment. It may be formed on the side. The composition layer can be used as it is as the third bonding layer 22 depending on the type of the third bonding agent composition, or can be combined with the third bonding layer 22 by performing a drying treatment, a curing treatment, or the like. can do. After laminating the second liquid crystal layer 32', the second base material layer 31, or the second base material layer 31 and the second alignment layer may be peeled off, if necessary.

<LCD laminate>
7 and 8 are schematic cross-sectional views schematically showing an example of the liquid crystal laminate of the present invention. In the liquid crystal laminate 8 of the present embodiment, as shown in FIG. 7, a first'liquid crystal layer 10'containing a cured product of a polymerizable liquid crystal compound and a first laminated layer (bonded layer) 20 are laminated. It is a thing. As shown in FIG. 8, the liquid crystal laminate 9 of the present embodiment further has a first base material layer 11 (base material layer) on the side opposite to the first bonded layer 20 side of the first'liquid crystal layer 10'. May have the first alignment layer and the first base material layer 11 in this order. The liquid crystal laminates 8 and 9 may be a single-wafered body or a long film-like material.

The 1'liquid crystal layer 10'may be a cured product layer obtained by curing a first liquid crystal composition containing a polymerizable liquid crystal compound and a fluorine atom. The description of the first liquid crystal composition is as described above.

The fluorine atomic weight in the surface 10b of the first'liquid crystal layer 10'on the first bonded layer 20 side (hereinafter, may be referred to as "first'surface") is 1.5 atm% or more, and 2.0 atm%. It may be more than 2.5 atm% or more. The fluorine atomic weight on the 1st'surface 10b of the 1st'liquid crystal layer 10'is 4.5 atm% or less, may be 4.0 atm% or less, or may be 3.8 atm% or less. It may be 5 atm% or less.

When the amount of fluorine atomic weight is within the above range, it is possible to suppress repelling generated when the first patch composition for forming the first patch layer 20 is applied on the first'surface 10b. can. Therefore, it is possible to obtain the liquid crystal layer laminates 8 and 9 in which defects such as bubbles are suppressed from being generated in the first bonded layer 20.

The description of the first bonded layer 20 is as described above. The liquid crystal layer laminates 8 and 9 can be manufactured according to, for example, the manufacturing method of the optical laminate 1 described with reference to FIG.

<Optical laminate>
9 to 12 are schematic cross-sectional views schematically showing another example of the optical laminate of the present invention. The optical laminate 4 shown in FIG. 9 has an optical layer 30 laminated on the first bonded layer 20 side of the liquid crystal laminate 8 shown in FIG. 7. The optical laminate 5 shown in FIG. 10 has an optical layer 30 laminated on the first bonded layer 20 side of the liquid crystal laminate 9 shown in FIG. The description of the optical layer 30 is as described above. Since the optical laminates 4 and 5 include the liquid crystal laminates 8 and 9, respectively, it is possible to suppress the generation of defects such as bubbles in the optical laminates 4 and 5. The optical laminates 4 and 5 shown in FIGS. 9 and 10 can be manufactured according to, for example, the manufacturing method of the optical laminate 1 described with reference to FIG.

In the optical laminate 6 shown in FIG. 11, the optical layer 30 is the second liquid crystal layer 32 (optical layer) in the optical laminate 4 shown in FIG. 9 or the optical laminate 5 shown in FIG. As shown in FIG. 11, the optical laminate 6 is further laminated with the second bonded layer 21 and the polarizing plate 35 on the opposite side of the second liquid crystal layer 32 from the first bonded layer 20 in this order. good. Alternatively, instead of laminating the second laminated layer 21 and the polarizing plate 35, the optical laminated body 6 has a second base material layer 31 on the opposite side of the second liquid crystal layer 32 from the first bonded layer 20. May have the second alignment layer and the second base material layer 31 in this order. The description of the second liquid crystal layer 32, the second bonded layer 21, and the polarizing plate 35 is as described above. The optical laminate 6 shown in FIG. 11 can be manufactured according to, for example, the manufacturing method of the optical laminate 2 described with reference to FIG.

In the optical laminate 6 shown in FIG. 11, the surface of the second liquid crystal layer 32 on the side of the first bonded layer 20 (hereinafter, may be referred to as “second'surface”) 32b has a fluorine atomic weight of 1.5 atm%. It is preferably 2.0 atm% or more, 2.5 atm% or more, preferably 4.5 atm% or less, and 4.0 atm% or less. Is more preferable, and may be 3.8 atm% or less, or may be 3.5 atm% or less. The fluorine atomic weight of the 2'surface 32b may be the same as or different from the fluorine atomic weight of the second surface 10b of the 1'liquid crystal layer 10'. When the fluorine atomic weight of the second surface 32b and the fluorine atomic weight of the second surface 10b are different from each other, the fluorine atomic weight of the second surface 32b may be larger or smaller than the fluorine atomic weight of the second surface 10b. .. When the fluorine atomic weight of the 2'surface 32b is within the above range, it is possible to further suppress the occurrence of defects such as wrinkles and bubbles in the optical laminate 6.

In the optical laminate 7 shown in FIG. 12, the optical layer 30 is a polarizing plate 35'(optical layer) in the optical laminate 4 shown in FIG. 9 or the optical laminate 5 shown in FIG. As shown in FIG. 12, the optical laminate 7 may further have a second'liquid crystal layer 32'on the side opposite to the first bonded layer 20 of the first'liquid crystal layer 10'. 3 The laminated layer 22 and the second'liquid crystal layer 32'may be provided in this order. Further, the optical laminate 7 may further have a second base material layer 31 on the side opposite to the third bonded layer 22 of the second'liquid crystal layer 32', and the second alignment layer and the second group. The material layer 31 may be provided in this order. The description of the polarizing plate 35', the second'liquid crystal layer 32', the third bonded layer 22, and the second base material layer 31 is as described above. The optical laminate 7 shown in FIG. 12 can be manufactured according to, for example, the manufacturing method of the optical laminate 3 described with reference to FIG.

(Optical laminate)
The optical laminates 1 to 3 are not particularly limited as long as the first liquid crystal layer 10, the first bonded layer 20, and the optical layer 30 are laminated in this order, and the optical laminates 4 to 7 are the first. The'liquid crystal layer 10', the first laminated layer 20, and the optical layer 30 are not particularly limited as long as they are laminated in this order. The optical laminates 1 to 7 may be circular polarizing plates. When the optical laminates 1 to 7 are circular polarizing plates, it is preferable to include a polarizing plate and a 1/4 wave plate (including a case of reverse wavelength dispersibility). When the optical laminates 1 to 7 are circular polarizing plates, [a] polarizing plate, 1/2 wave plate, and 1/4 wave plate are included in this order, or [b] polarizing plate, 1 of reverse wavelength dispersibility. It is preferable to include the / 4 wave plate and the positive C plate in this order, or to include the polarizing plate, the positive C plate, and the 1/4 wave plate having the reverse wavelength dispersibility in this order. In this case, the 1/2 wave plate, the 1/4 wave plate (including the case of reverse wavelength dispersibility), and the positive C plate are the first liquid crystal layer 10, the first'liquid crystal layer 10', and the second liquid crystal. It is preferably either the layer 32 or the second'liquid crystal layer 32'. The optical layer 30 may be a polarizing plate, a 1/2 wave plate, a 1/4 wave plate (including a case of reverse wavelength dispersibility), or a positive C plate. Two or more of these may be laminated.

For example, when the optical laminates 1, 4 and 5 shown in FIGS. 1, 9 and 10 are circular polarizing plates, the optical layer 30 is a polarizing plate, and the first liquid crystal layer 10 or the first'liquid crystal layer 10 is used. 'Is preferably a 1/4 wave plate (including the case of reverse wavelength dispersibility). When the optical laminates 2 and 6 shown in FIG. 3 or FIG. 11 are circular polarizing plates, the second liquid crystal layer 32 (optical layer 30) and the first liquid crystal layer 10 or the first'liquid crystal layer 10'are 1/2. It is preferably a wave plate and a 1/4 wave plate, or a 1/4 wave plate and a positive C plate having a reverse wavelength dispersibility. In this case, the phase difference characteristics of the first liquid crystal layer 10 or the first'liquid crystal layer 10'and the second liquid crystal layer 32 may be selected according to the stacking position of the polarizing plate 35. When the optical laminates 3 and 7 shown in FIGS. 5 or 12 are circular polarizing plates, the optical layer 30 is a polarizing plate 35', and the first liquid crystal layer 10 or the first'liquid crystal layer 10'and the second. The'liquid crystal layer 32'is preferably a 1/2 wave plate and a 1/4 wave plate, respectively, or a 1/4 wave plate and a positive C plate having opposite wavelength dispersibility.

Hereinafter, the materials and the like used in the optical laminates 1 to 7 and the liquid crystal laminates 8 and 9 described above will be specifically described.

(1st liquid crystal layer, 1st'liquid crystal layer)
The first liquid crystal layer 10 is not particularly limited as long as it contains a cured product of a fluorine atom and a polymerizable liquid crystal compound, but is preferably a retardation layer having retardation characteristics. The first'liquid crystal layer 10'contains a cured product of a fluorine atom and a polymerizable liquid crystal compound, and the fluorine concentration on the surface of the first'liquid crystal layer 10 on the first bonded layer 20 side is within a specific range. There is no particular limitation as long as it is present.

The thicknesses of the first liquid crystal layer 10 and the first'liquid crystal layer 10'are not particularly limited, but may be independently 20 μm or less, 15 μm or less, 13 μm or less, or 10 μm. It may be less than or equal to, 5 μm or less, usually 0.1 μm or more, and may be 0.3 μm or more.

The first liquid crystal layer 10 can be formed by using a first liquid crystal composition containing a fluorine atom and a polymerizable liquid crystal compound. The 1'liquid crystal layer 10'can be formed by using a 1'liquid crystal composition containing a fluorine atom and a polymerizable liquid crystal compound. The first liquid crystal composition and the first'liquid crystal composition preferably contain a leveling agent, and more preferably the above-mentioned leveling agent (F) containing a fluorine atom.

The leveling agent (F) includes "Megafuck (registered trademark) R-08", "R-30", "R-90", "F-410", "F-411", and "F-411". "F-443", "F-445", "F-470", "F-471", "F-477", "F-479", "F-482", "F" -483 "and" F-556 "(DIC Co., Ltd.);" Surflon (registered trademark) S-381 "," S-382 "," S-383 "," S-393 ", "SC-101", "SC-105", "KH-40", and "SA-100" (AGC Seimi Chemical Co., Ltd.); "E1830", "E5844" (Daikin Fine Chemical Laboratory Co., Ltd.) ); "Ftop EF301", "Ftop EF303", "Ftop EF351", "Ftop EF352" (Mitsubishi Materials Electronics Chemical Co., Ltd.) and the like can be mentioned.

The polymerizable liquid crystal compound is a compound having a polymerizable reactive group and exhibiting liquid crystallinity. The polymerizable reactive group is a group involved in the polymerization reaction, and is preferably a photopolymerizable reactive group. The photopolymerizable reactive group refers to a group that can participate in the polymerization reaction by an active radical, an acid, or the like generated from the photopolymerization initiator. Examples of the photopolymerizable functional group include a vinyl group, a vinyloxy group, a 1-chlorovinyl group, an isopropenyl group, a 4-vinylphenyl group, an acryloyloxy group, a methacryloyloxy group, an oxylanyl group, an oxetanyl group and the like. Of these, an acryloyloxy group, a methacryloyloxy group, a vinyloxy group, an oxylanyl group and an oxetanyl group are preferable, and an acryloyloxy group is more preferable. The type of the polymerizable liquid crystal compound is not particularly limited, and a rod-shaped liquid crystal compound, a disk-shaped liquid crystal compound, and a mixture thereof can be used. The liquid crystal property of the polymerizable liquid crystal compound may be a thermotropic liquid crystal or a lyotropic liquid crystal, and the phase-ordered structure may be a nematic liquid crystal or a smectic liquid crystal.

The leveling agent (F) contained in the first liquid crystal composition is preferably 0.01 part by mass or more, more preferably 0.05 part by mass or more with respect to 100 parts by mass of the polymerizable liquid crystal compound. Further, it is preferably 5 parts by mass or less, and more preferably 3 parts by mass or less.

The first liquid crystal composition and the first'liquid crystal composition may further contain a polymerization initiator, a photosensitizer, a polymerization inhibitor, a solvent, a leveling agent other than the leveling agent (F), and the like.

(2nd liquid crystal layer, 2nd'liquid crystal layer)
The second liquid crystal layer 32 and the second'liquid crystal layer 32'are not particularly limited as long as they contain a cured product of the polymerizable liquid crystal compound, but are preferably retardation layers having retardation characteristics.

The thicknesses of the second liquid crystal layer 32 and the second'liquid crystal layer 32'are not particularly limited, but may be independently 20 μm or less, 15 μm or less, or 13 μm or less. It may be 10 μm or less, 5 μm or less, usually 0.1 μm or more, and 0.3 μm or more.

The second liquid crystal layer 32 and the second'liquid crystal layer 32'can be formed by using a second liquid crystal composition containing a polymerizable liquid crystal compound. As the polymerizable liquid crystal compound, the compound described in the first liquid crystal layer 10 can be used. The second liquid crystal composition contains, in addition to the polymerizable liquid crystal compound, a polymerization initiator, a photosensitizer, a polymerization inhibitor, a solvent, a leveling agent (F), a leveling agent other than the leveling agent (F), and the like. May be good.

(1st base material layer, 2nd base material layer)
It is preferable that the first base material layer 11 and the second base material layer 31 are films independently formed of a resin material. As the resin material, for example, it is preferable to use a resin material having excellent transparency, mechanical strength, thermal stability and the like. The resin material is preferably a thermoplastic resin, for example, a cellulose resin such as triacetyl cellulose; a polyester resin such as polyethylene terephthalate and polyethylene naphthalate; a polyether sulfone resin; a polysulfone resin; a polycarbonate resin; Polyamide-based resin such as nylon and aromatic polyamide; polyimide-based resin; polyolefin-based resin such as polyethylene, polypropylene, ethylene / propylene copolymer; cyclic polyolefin-based resin having cyclo-based and norbornene structure; (meth) acrylic-based resin ; Polyarylate-based resin; Polystyrene-based resin; Polyvinyl alcohol-based resin and the like can be mentioned. The first base material layer 11 and the second base material layer 31 may be independently of each other and may have a single-layer structure or a multi-layer structure. In the case of a multi-layer structure, each layer is made of the same resin material. It may be formed or may be made of a different resin material.

From the viewpoint of strength and processability, the thickness of the first base material layer 11 and the second base material layer 31 is preferably 5 to 300 μm, and more preferably 10 to 200 μm, respectively.

(1st alignment layer, 2nd alignment layer)
The first alignment layer and the second alignment layer have an orientation regulating force that orients the polymerizable liquid crystal compound in a desired direction. The first alignment layer and the second alignment layer have solvent resistance that does not dissolve due to application of the first liquid crystal composition and the second liquid crystal composition, respectively, and are heated for removing the solvent and orienting the polymerizable liquid crystal compound. Those having heat resistance in the treatment are preferable. Examples of the first alignment layer and the second alignment layer include an alignment layer containing an orientation polymer, a photo-alignment layer, and a grub alignment layer in which an uneven pattern or a plurality of grooves are formed and oriented on the surface.

(Optical layer)
The optical layer 30 is a layer having optical functions such as transmitting, reflecting, and absorbing light, and may be a resin film or a liquid crystal layer. The optical layer 30 may have a single-layer structure, or may have a laminated structure of two or more layers laminated via a bonded layer or the like.

The optical layer 30 includes a linear polarizing element; a polarizing plate having a protective layer laminated on one side or both sides of the linear polarizing element; a polarizing plate with a protective film having a protective film laminated on one side of the polarizing plate; a reflective film; semi-transmissive. Reflective film; brightness improving film; optical compensation film; antiglare function film; retardation film, retardation layer and the like can be mentioned.

(Polarizer)
The optical laminate may include a polarizing plate as an optical layer, or may include a polarizing plate separately from the optical layer. The polarizing plate is one in which a protective layer is laminated on one side or both sides of a linear polarizing element. When the polarizing plate has a protective layer laminated on only one side, it is preferable that the protective layer is provided on the side opposite to the first liquid crystal layer 10 and the second liquid crystal layer 32 of the linear polarizing element in the optical laminated body.

It is preferable that the linear polarizing element and the protective layer are bonded to each other via an adhesive layer or an adhesive layer. Examples of the adhesive composition for forming the adhesive layer and the pressure-sensitive adhesive composition for forming the pressure-sensitive adhesive layer include the adhesive composition and the pressure-sensitive adhesive composition described later. Examples of the protective layer include films formed by using the resin materials exemplified in the first base material layer 11 and the second base material layer 31.

The thickness of the polarizing plate may be, for example, 200 μm or less, 120 μm or less, 100 μm or less, 50 μm or less, 30 μm or less, and usually 10 μm or more. It may be 15 μm or more, or 20 μm or more.

(Linear deflector)
Examples of the linear polarizing element include a PVA polarizing layer in which a dichroic dye is adsorbed and oriented on a polyvinyl alcohol-based resin film, and a liquid crystal polarizing layer in which the dichroic dye is oriented in a cured layer of a polymerizable liquid crystal compound. Be done.

The polyvinyl alcohol-based resin constituting the polyvinyl alcohol-based resin film can be obtained by saponifying the polyvinyl acetate-based resin. Examples of the polyvinyl acetate-based resin include polyvinyl acetate, which is a homopolymer of vinyl acetate, and a copolymer of a monomer copolymerizable with vinyl acetate and vinyl acetate. Examples of the monomer copolymerizable with vinyl acetate include unsaturated carboxylic acid, olefin, vinyl ether, unsaturated sulfonic acid, and (meth) acrylamide having an ammonium group.

The saponification degree of the polyvinyl alcohol-based resin is usually 85 to 100 mol%, preferably 98 mol% or more. The polyvinyl alcohol-based resin may be modified, and for example, polyvinyl formal or polyvinyl acetal modified with aldehydes may be used. The average degree of polymerization of the polyvinyl alcohol-based resin is usually 1000 to 10000, preferably 1500 to 5000. The average degree of polymerization of the polyvinyl alcohol-based resin can be determined in accordance with JIS K 6726.

Usually, a film made of a polyvinyl alcohol-based resin is used as the raw film of the PVA polarizing layer. The polyvinyl alcohol-based resin can be formed into a film by a known method. The thickness of the raw film is usually 1 to 150 μm, and is preferably 10 μm or more in consideration of ease of stretching and the like.

The PVA polarizing layer is, for example, a step of uniaxially stretching the raw film, a step of dyeing the film with a dichroic dye and adsorbing the dichroic dye, a step of treating the film with a boric acid aqueous solution, and a step of treating the film with a boric acid aqueous solution. , The film is washed with water and finally dried to produce. The thickness of the PVA polarizing layer may be 20 μm or less, 15 μm or less, 10 μm or less, usually 3 μm or more, and 5 μm or more.

As the PVA polarizing layer, [i] a single film of a polyvinyl alcohol-based resin film is used as a raw film, and this film is subjected to a uniaxial stretching treatment and a bicolor dye dyeing treatment, as well as a [ii] base material. A coating liquid (aqueous solution, etc.) containing a polyvinyl alcohol-based resin is applied to the film and dried to obtain a base film having a polyvinyl alcohol-based resin layer, which is uniaxially stretched together with the base film, and after stretching. It can also be obtained by subjecting the polyvinyl alcohol-based resin layer of the above to a dyeing treatment of a bicolor dye and then peeling off the base film. Examples of the base film include films formed by using the resin materials described in the first base material layer 11 and the second base material layer 31.

As the polymerizable liquid crystal compound used for forming the liquid crystal polarizing layer, the polymerizable liquid crystal compound having a polymerizable reactive group exemplified in the first liquid crystal composition and the second liquid crystal composition can be used. As the liquid crystal polarizing layer, [iii], for example, a composition for forming a polarizing layer containing a polymerizable liquid crystal compound and a dichroic dye is applied onto an alignment layer formed on a base film, and the polymerizable liquid crystal compound is polymerized. It can be formed by a method of curing, a method of applying a composition for forming a polarizing layer on a [iv] base film to form a coating film, and then stretching the coating film together with the base film. Examples of the base film include the base film used in the above [ii]. The thickness of the liquid crystal polarizing layer may be 20 μm or less, 15 μm or less, 13 μm or less, 10 μm or less, 5 μm or less, and is usually 0. It is 1 μm or more, and may be 0.3 μm or more.

(1st bonding layer, 2nd bonding layer, 3rd bonding layer)
The first bonded layer 20, the second bonded layer 21, and the third bonded layer 22 (hereinafter, may be referred to as "first to third bonded layers 20 to 22") are cured of the adhesive composition. It is an adhesive layer or an adhesive layer which is a thing. The 1st to 3rd bonding layers 20 to 22 can be formed by using the 1st to 3rd bonding agent compositions, respectively. The first to third bonding agent compositions are adhesive compositions when the first to third bonding layers 20 to 22 are adhesive layers, and the first to third bonding layers 20 to 22 are adhesive layers. If it is, it is a pressure-sensitive adhesive composition.

The adhesive composition contains a curable resin component as a curable component, and is an adhesive other than the pressure-sensitive adhesive (adhesive) described later. Examples of the adhesive composition include a water-based adhesive in which a curable resin component is dissolved or dispersed in water, an active energy ray-curable adhesive containing an active energy ray-curable compound, a thermosetting adhesive, and the like. ..

Examples of the resin component contained in the water-based adhesive include polyvinyl alcohol-based resin and urethane-based resin.

Examples of the active energy ray-curable adhesive include compositions that are cured by irradiation with active energy rays such as ultraviolet rays, visible light, electron beams, and X-rays. Of these, an ultraviolet curable resin composition that is cured by irradiation with ultraviolet rays is preferable. The active energy ray-curable adhesive preferably contains an epoxy compound as a curable component, and more preferably contains an alicyclic epoxy compound. The active energy ray-curable adhesive may contain a (meth) acrylic compound or the like together with the epoxy compound. "(Meta) acrylic" means at least one selected from the group consisting of acrylic and methacrylic.

Examples of the thermosetting adhesive include those containing an epoxy resin, a silicone resin, a phenol resin, a melamine resin and the like as a main component. In addition to the curable component, the adhesive composition comprises a solvent, a sensitizer, a polymerization accelerator, an ion trapping agent, an antioxidant, a chain transfer agent, a tackifier, a thermoplastic resin, a filler, a flow conditioner, and a plasticizer. It may contain additives such as an agent, a defoaming agent, an antistatic agent, and a leveling agent.

In the pressure-sensitive adhesive composition, the pressure-sensitive adhesive containing the pressure-sensitive adhesive exhibits adhesiveness by attaching itself to the adherend, and is a so-called pressure-sensitive adhesive. Examples of the pressure-sensitive adhesive include those containing a polymer such as a (meth) acrylic polymer, a silicone polymer, a polyester polymer, a polyurethane polymer, a polyether polymer, or a rubber polymer as a main component. In the present specification, the main component means a component containing 50% by mass or more of the total solid content of the pressure-sensitive adhesive. The pressure-sensitive adhesive may be an active energy ray-curable type or a thermosetting type, and the degree of cross-linking and the adhesive strength may be adjusted by irradiation with active energy rays or heating.

The first bonding layer 20 is preferably an adhesive layer. In this case, the first patch composition is an adhesive composition, preferably an active energy ray-curable resin composition, and preferably an ultraviolet-curable resin composition that is cured by irradiation with ultraviolet rays. ..

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples, but the present invention is not limited to these examples.

[Calculation of fluorine atomic weight]
The fluorine atom content was calculated by the following procedure by X-ray photoelectron spectroscopy using an X-ray photoelectron spectroscope (K-Alpha, manufactured by Thermo Scientific Co., Ltd.).

First, a wide scan spectrum was acquired at the measurement spot on the surface of the first liquid crystal layer, and narrow scan spectra were acquired for all the elements detected in the wide scan spectrum. Next, the peak area of the narrow scan spectrum of all the elements was obtained, the elemental composition ratio [atom%] at each measurement spot was calculated, and the elemental amount of the fluorine atom at the measurement spot was calculated. The measurement conditions are as follows.
(Measurement condition)
-X-ray source: Al-Kα monochrome (1486.7 eV)
-X-ray spot size (measurement spot diameter): 400 μm
-Wide scan analysis (Survey scan);
Measurement range: -10 to 1350 eV, path energy: 200 eV,
Duel time: 25 msec, step: 1.0 eV, number of integrations: 5 times ・ Narrow scan analysis (Snap scan);
Pass energy: 150 eV, capture time: 1 second, total number of times: 10 times

[Measurement of viscosity of patch composition]
The viscosity at a temperature of 25 ° C. and 10 rpm was measured using an E-type viscometer (“TVE-25” manufactured by Toki Sangyo Co., Ltd.).

[Production Example 1: Fabrication of a laminated body A having a liquid crystal layer formed on a base material layer]
(Preparation of composition for forming an alignment layer)
A 2% by mass aqueous solution of polyvinyl alcohol (polyvinyl alcohol 1000 completely saponified type, manufactured by Wako Pure Chemical Industries, Ltd.) was used as a composition for forming an oriented layer.

(Preparation of composition for forming liquid crystal layer)
2.0 parts of a leveling agent (F-556; manufactured by DIC Corporation) was added to a mixture of the polymerizable liquid crystal compound A and the polymerizable liquid crystal compound B shown below at a mass ratio of 90:10, and polymerization was started. Six parts of the agent 2-dimethylamino-2-benzyl-1- (4-morpholinophenyl) butane-1-one (“Irgacure 369 (Irg369)”, manufactured by BASF Japan KK) were added. Further, N-methyl-2-pyrrolidone (NMP) was added so that the solid content concentration became 13%, and the mixture was stirred at 80 ° C. for 1 hour to obtain a liquid crystal layer forming composition.

＜重合性液晶化合物Ｂ＞

The polymerizable liquid crystal compound A was produced by the method described in JP-A-2010-31223. Further, the polymerizable liquid crystal compound B was produced according to the method described in JP-A-2009-173893. The molecular structure of each is shown below.
<Polymerizable liquid crystal compound A>

<Polymerizable liquid crystal compound B>

(Preparation of laminated body A)
After corona treatment is performed on a cycloolefin-based film [trade name "ZF-14-50" manufactured by Nippon Zeon Corporation] having a thickness of 50 μm as a base material layer, the composition for forming an alignment layer is applied with a die coater. Then, it was dried at 60 ° C. for 1 minute and further at 80 ° C. for 3 minutes to form a film having a thickness of 89 nm. Subsequently, the surface of the obtained film was subjected to a rubbing treatment to form an oriented layer. The rubbing process uses a semi-automatic rubbing device (trade name: LQ-008 type, manufactured by Joyo Engineering Co., Ltd.) and a cloth (trade name: YA-20-RW, manufactured by Yoshikawa Kako Co., Ltd.) with a pushing amount of 0.15 mm. The procedure was carried out under the conditions of a rotation speed of 500 rpm and 16.7 mm / s. The direction of the rubbing process was set to be 45 ° counterclockwise when viewed from the visual recognition side with respect to the direction of the absorption axis of the linear polarizing element when it was attached to the linear splitter.

Next, the composition for forming a liquid crystal layer was applied onto the alignment layer using a die coater, dried at 120 ° C. for 1 minute, and then a high-pressure mercury lamp [Ushio, Inc. trade name: "UNICURE VB-15201BY-". A ”] is used to irradiate ultraviolet rays (integrated light intensity at a wavelength of 365 nm under a nitrogen atmosphere: 500 mJ / cm ² ) to form a liquid crystal layer, and the base material layer, the alignment layer, and the liquid crystal layer are laminated in this order. The obtained laminated body A was obtained. When the fluorine atomic weight on the surface of the liquid crystal layer of the laminated body A was measured by the above method, it was 18.5 atm%.

[Manufacturing Example 2: Fabrication of Laminated Body B Having a Liquid Crystal Layer Formed on a Base Material Layer]
The surface of the liquid crystal layer of the laminated body A was subjected to corona treatment at a corona treatment amount of 1.5 kJ / m ² to obtain a laminated body B. The fluorine atomic weight on the surface of the liquid crystal layer of the laminated body B was measured by the above method and found to be 11.5 atm%. No defects such as deformation were confirmed in the laminated body B.

[Production Example 3: Production of Laminated Body C Having a Liquid Crystal Layer Formed on a Base Material Layer]
The surface of the liquid crystal layer of the laminated body A was subjected to corona treatment with a corona treatment amount of 2.3 kJ / m ² to obtain a laminated body C. When the fluorine atomic weight on the surface of the liquid crystal layer of the laminated body C was measured by the above method, it was 8.3 atm%. No defects such as deformation were confirmed in the laminated body C.

[Production Example 4: Production of Laminated Body D Having a Liquid Crystal Layer Formed on a Base Material Layer]
The surface of the liquid crystal layer of the laminated body A was subjected to corona treatment with a corona treatment amount of 3.6 kJ / m ² to obtain a laminated body D. When the fluorine atomic weight on the surface of the liquid crystal layer of the laminated body D was measured by the above method, it was 4.4 atm%. No defects such as deformation were confirmed in the laminated body D.

[Production Example 5: Preparation of a laminated body E having a liquid crystal layer formed on a base material layer]
The surface of the liquid crystal layer of the laminated body A was subjected to corona treatment with a corona treatment amount of 4.5 kJ / m ² to obtain a laminated body E. When the fluorine atomic weight on the surface of the liquid crystal layer of the laminated body E was measured by the above method, it was 3.3 atm%. No defects such as deformation were confirmed in the laminated body E.

[Production Example 6: Preparation of patch composition]
3,4-Epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate [Product name "Selokiside 2021P" manufactured by Daicel Co., Ltd.] 1,4-butanediol diglycidyl ether [Nagasechem] with respect to 75 parts by mass. By adding 25 parts by mass of the product name "EX-214L" manufactured by TEX Co., Ltd. and 5.0 parts by mass of the photopolymerization initiator [trade name "CPI-100P" manufactured by Sun Apro Co., Ltd.] and mixing them. , A patch composition (adhesive composition) was prepared. The viscosity of the prepared patch composition was 112 mPa · sec.

[Example 1]
Two laminates B (width 1000 mm, length 100 m) are prepared, and the binder composition prepared in Production Example 6 is applied to the surface of the liquid crystal layer of one laminate B, and the other laminate B is used. After bonding to the surface side of the liquid crystal layer, it is irradiated with ultraviolet rays (integrated light amount 400 mJ / cm ² (UV-B)) to cure the bonding agent composition to form a bonding layer (adhesive layer), and optics. The laminated body (1) was obtained. At this time, the transport time from applying the patching agent composition to one laminated body B to bonding with the other laminated body B was 30 seconds. The total length of the optical laminate (1) was visually inspected using a 10-fold loupe, and the average number of bubbles having a diameter of the circumscribed circle of 50 μm or ^more in a plan view was measured. Met.

[Example 2]
The patching agent composition prepared in Production Example 6 is applied to the surface of the liquid crystal layer of the laminate C (width 400 mm, length 100 m) with a gravure coater, and is attached to the surface of the liquid crystal layer of the laminate B produced in Production Example 2. An optical laminated body (2) was obtained in the same procedure as in Example 1 except that they were combined. A region of the optical laminate (2) having a length of 10 m was visually inspected using a 10-fold loupe, and the average number of bubbles having a diameter of the circumscribed circle of 50 μm or more in a plan view was measured. It was 15 pieces / m ² .

[Example 3]
The binder composition prepared in Production Example 6 was applied to the surface of the liquid crystal layer of the laminate D (width 400 mm, length 100 m) and bonded to the surface of the liquid crystal layer B of the laminate B produced in Production Example 2. An optical laminate (3) was obtained in the same procedure as in Example 1 except for the above. A region of the optical laminate (3) having a length of 10 m was visually inspected using a 10-fold loupe, and the average number of bubbles having a diameter of the circumscribed circle of 50 μm or more in a plan view was measured. It was 04 pieces / m ² .

[Example 4]
The binder composition prepared in Production Example 6 was applied to the surface of the liquid crystal layer of the laminate E (width 400 mm, length 100 m) and bonded to the surface of the liquid crystal layer B of the laminate B produced in Production Example 2. An optical laminate (4) was obtained in the same procedure as in Example 1 except for the above. A region of the optical laminate (4) having a length of 10 m was visually inspected using a 10-fold loupe, and the average number of bubbles having a diameter of the circumscribed circle of 50 μm or more in a plan view was measured. It was 01 pieces / m ² .

[Comparative Example 1]
The binder composition prepared in Production Example 6 was applied to the surface of the liquid crystal layer of the laminate A (width 400 mm, length 100 m) and bonded to the surface of the liquid crystal layer B of the laminate B produced in Production Example 2. An optical laminate (5) was obtained in the same procedure as in Example 1 except for the above. When a region of the optical laminate (5) having a length of 10 m was visually inspected using a 10-fold loupe, a large number of bubbles were confirmed, and the average number of bubbles having a diameter of the circumscribed circle of 50 μm or more in a plan view was confirmed. Could not be measured.

1 to 7 optical laminate, 8, 9 liquid crystal laminate, 10 first liquid crystal layer, 10'first' liquid crystal layer, 10a first surface, 10b first'surface, 11 first substrate layer, 20 first sticking Laminated layer (bonded layer), 21 2nd bonded layer, 22 3rd bonded layer, 25 coated layer, 30 optical layer, 31 2nd base material layer, 32 2nd liquid crystal layer (optical layer), 32'first 2'liquid crystal layer, 32a second surface, 32b second'surface, 35 polarizing plate, 35'polarizing plate (optical layer).

Claims (20)

A method for producing an optical laminate in which a first liquid crystal layer obtained by curing a first liquid crystal composition containing a polymerizable liquid crystal compound and a fluorine atom, a laminated layer, and an optical layer are laminated in this order.
A step of performing a surface activation treatment on one surface of the first liquid crystal layer and
A step of forming a coating layer by applying a patch composition to the one surface to which the surface activation treatment has been performed, and a step of forming a coating layer.
The step of laminating the optical layer on the coating layer and
Including the step of forming the bonding layer from the coating layer.
Fluorine atomic weight F1 [atm%] on the one surface before the surface activation treatment and fluorine atomic weight F2 [atm%] on the one surface after the surface activation treatment. ] Means the relationship of the following formula (I),
The fluorine atomic weight F1 is 12 atm% or more and 25 atm% or less.
A method for producing an optical laminate , wherein the viscosity of the patch composition at a temperature of 25 ° C. is 1 mPa · sec or more and 150 mPa · sec or less .
0.05 × F1 ≦ F2 ≦ 0.5 × F1 (I) The method for producing an optical laminate according to claim 1, wherein the first liquid crystal composition contains a leveling agent. The method for producing an optical laminate according to claim 2, wherein the leveling agent contains the fluorine atom. The method for producing an optical laminate according to any one of claims 1 to 3, wherein the optical layer is a second liquid crystal layer containing a cured product of a polymerizable liquid crystal compound. The second liquid crystal layer has a surface that has been subjected to a surface activation treatment, and has a surface that has been subjected to a surface activation treatment.
The step according to claim 4, wherein the laminating step is a step of laminating the second liquid crystal layer so that the surface of the second liquid crystal layer subjected to the surface activation treatment is in contact with the coating layer. How to manufacture an optical laminate. Further, a step of laminating a polarizing plate on the side opposite to the bonded layer in one of the first liquid crystal layer and the second liquid crystal layer is included.
The method for manufacturing an optical laminate according to claim 4 or 5, wherein the polarizing plate has a protective layer on one side or both sides of a linear polarizing element. The method for producing an optical laminate according to any one of claims 1 to 3, wherein the optical layer includes a polarizing plate having a protective layer on one side or both sides of a linear polarizing element. The method for producing an optical laminate according to claim 7, further comprising a step of laminating a second'liquid crystal layer containing a cured product of a polymerizable liquid crystal compound on the side of the first liquid crystal layer opposite to the bonded layer. .. The method for producing an optical laminate according to any one of claims 1 to 8, wherein the surface activation treatment applied to the one surface of the first liquid crystal layer is a corona treatment. The method for producing an optical laminate according to claim 9, wherein in the step of performing the surface activation treatment, the treatment amount of the corona treatment is 1 kJ / m ² or more and 8 kJ / m ² or less. The method for manufacturing an optical laminate according to any one of claims 1 to 10, wherein the bonded layer is an adhesive layer. A liquid crystal laminate in which a first'liquid crystal layer containing a cured product of a polymerizable liquid crystal compound and a laminated layer are laminated.
A liquid crystal laminate having a fluorine atomic weight on the surface of the 1'liquid crystal layer on the bonded layer side of 1.5 atm% or more and 4.5 atm% or less. The liquid crystal laminate according to claim 12, further comprising a base material layer on the side of the first'liquid crystal layer opposite to the bonded layer side. An optical laminate having the liquid crystal laminate according to claim 12 or 13 and an optical layer.
The optical layer is an optical laminate laminated on the bonded layer side of the liquid crystal laminate. The optical laminate according to claim 14, wherein the optical layer is a second liquid crystal layer containing a cured product of a polymerizable liquid crystal compound. The optical laminate according to claim 15, wherein the fluorine atomic weight on the surface of the second liquid crystal layer on the bonded layer side is 1.5 atm% or more and 4.5 atm% or less. The liquid crystal laminate is the liquid crystal laminate according to claim 12.
The optical laminate further has a polarizing plate on one of the first'liquid crystal layer and the second liquid crystal layer on the side opposite to the bonded layer side.
The optical laminate according to claim 15 or 16, wherein the polarizing plate includes a polarizing plate having a protective layer on one side or both sides of a linear polarizing element. The optical laminate according to claim 14, wherein the optical layer includes a polarizing plate having a protective layer on one side or both sides of a linear polarizing element. The liquid crystal laminate is the liquid crystal laminate according to claim 12.
18. The optics according to claim 18, wherein the optical laminate further has a second'liquid crystal layer containing a cured product of a polymerizable liquid crystal compound on the side of the first'liquid crystal layer opposite to the bonded layer side. Laminated body. The optical laminate according to any one of claims 14 to 19, wherein the bonding layer is an adhesive layer.

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