JP7170828B2 - マスクフィルムおよびこれを用いた偏光板の製造方法 - Google Patents
マスクフィルムおよびこれを用いた偏光板の製造方法 Download PDFInfo
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Description
[化学式1]
12KOH+6I2→2KIO3+10KI+6H2O
[化学式2]
I5 -+IO3 -+6H+→3I2+3H2O
I3 -→I-+I2
[化学式3]
B(OH)3+3KOH→K3BO3+3H2O
<製造例>
ポリビニルアルコール系フィルム(日本合成社のM3000 grade、厚さ30μm)を25℃の純粋溶液で膨潤工程を15秒間経た後、0.2wt%の濃度および25℃のヨウ素溶液で60秒間染着工程を進行させた。以後、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倍延伸工程を進行させた。また、延伸工程の後、5wt%のKI溶液で補色工程を経た後、60℃のオーブンにて5分間乾燥させることにより、厚さ12μmの偏光子を製造した。以後、偏光子の一面に接着剤を用いてTACフィルムを積層して、一面に保護フィルムを有する偏光板を製造した。
a.共重合体樹脂(A)の製造
窒素ガスが還流し温度調節が容易となるように冷却装置を設けた1L反応器に、全反応物100重量部に対して、ブチルアクリレート94重量部、2-ヒドロキシエチル(メタ)アクリレート1重量部、アクリル酸5重量部を投入した。その後、上記反応器内部の酸素を除去するために窒素ガスを20分間パージング(purging)した後、反応器の温度を60℃に維持した。以後、反応開始剤であるアゾビスイソブチロニトリル0.03重量部を50%の濃度でエチルアセテートに希釈させて注入した。これを8時間反応させた後、最終アクリル系ポリマー(A)を得た。
窒素ガスが還流し温度調節が容易となるように冷却装置を設けた1L反応器に、全反応物100重量部に対して、ブチルアクリレート91重量部、2-ヒドロキシエチル(メタ)アクリレート1重量部、アクリル酸4重量部、メタアクリロイルポリメチルメタアクリレート4重量部からなる単量体混合物を投入し、溶剤としてエチルアセテート100重量部を投入した。その後、反応器内部の酸素を除去するために窒素ガスを20分間パージング(purging)した後、反応器の温度を65℃に維持した。以後、反応開始剤であるアゾビスイソブチロニトリル0.03重量部を50%の濃度でエチルアセテートに希釈させて注入し、8時間反応させてアクリル系ポリマー物質(B)を得た。
上記共重合過程から得たアクリル系共重合体AおよびBを9:1の重量比(A:Bの重量比)で混合した共重合体100重量部に対して、イソシアネート系架橋剤であるトリメチロールプロパンのトリレンジイソシアネート付加物をエチルアセテート溶液に50%に希釈したものを少量投入して粘着剤を製造した。架橋剤の含有量によって、上記粘着剤のモジュラスおよび粘着力の調節が可能である。
a.製造例1
明細書に記載の測定方法により測定された、モジュラスが3000MPa、厚さが80μmのPET保護フィルム上に、モジュラスが0.3MPaのアクリル系粘着剤を80μmの厚さにコーティングして粘着剤層を形成し、上記粘着剤層上に15μmのPET離型フィルムを積層してマスクフィルムを製造した。以後、CO2 laserを用いて10Wの出力、パルス繰り返し率20kHzで上記マスクフィルムに直径3mmのホール(穿孔部)を30cmの間隔で打抜いた。以後、上記打抜かれたマスクフィルムの離型フィルムを除去して、上記製造例で製造した偏光板の保護フィルムがない面に積層し、KOH10wt%、50℃の溶液に15sec浸漬して、上記マスクフィルムのホール(穿孔部)と一致する部分を脱色させた後、洗浄のために、50℃のクエン酸5wt%水溶液に10秒間浸漬して中和させた後、60℃に5分間乾燥した。以後、マスクフィルムを除去し、除去した面に接着剤を用いてTAC保護フィルムを積層して局地的脱色部を有する偏光板を製造した。
モジュラスが3000MPa、厚さが80μmのPET保護フィルム上に、モジュラスが0.3MPaの粘着剤をそれぞれ30μm、15μm、3μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスがそれぞれ2000MPa、厚さが80μmのPET保護フィルムと、モジュラスが5MPaの粘着剤をそれぞれ80μm、30μm、15μm、3μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスがそれぞれ3000MPa、厚さが20μmのPET保護フィルムと、モジュラスが0.3MPaの粘着剤をそれぞれ20μm、5μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスがそれぞれ2000MPa、厚さが20μmのPET保護フィルムと、モジュラスが5MPaの粘着剤をそれぞれ20μm、5μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスがそれぞれ3000MPa、厚さが20μmのPET保護フィルム上に、モジュラスが0.1MPaの粘着剤をそれぞれ80μm、50μm、30μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスがそれぞれ3000MPa、厚さが250μmのPET保護フィルム上に、モジュラスが0.1MPaの粘着剤をそれぞれ3μm、5μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスがそれぞれ1000MPa、厚さが20μmのPET保護フィルム上に、モジュラスが10MPaの粘着剤をそれぞれ80μm、50μm、30μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスがそれぞれ1000MPa、厚さが250μmのPET保護フィルム上に、モジュラスが10MPaの粘着剤をそれぞれ3μm、5μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスが3000MPa、厚さが20μmのPET保護フィルム上に、モジュラスが0.3MPaの粘着剤を80μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスが2000MPa、厚さが20μmのPET保護フィルム上に、モジュラスが5MPaの粘着剤を80μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスが3000MPa、厚さが80μmのPET保護フィルム上に、モジュラスが0.1MPaの粘着剤を80μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
モジュラスが1000MPa、厚さが80μmのPET保護フィルム上に、モジュラスが10MPaの粘着剤を80μmの厚さにコーティングして粘着剤層を形成することを除いて、製造例1と同様の方法で局地的脱色領域を有する偏光板を製造した。
製造例1~26に相当する偏光板の脱色部の任意の点において各2度ごとに引いた線における円外最大Differenceと円内最大Differenceとの合計を計算してエッジラフネス(Edge Roughness)を測定した。
Claims (8)
- 保護フィルムと、
前記保護フィルムの一面に備えられた粘着剤層とを有し、
前記保護フィルムの厚さ(a)と前記粘着剤層の厚さ(b)との比率(a/b)が1~30であり、
前記保護フィルムのモジュラス(c)と前記粘着剤層の粘着剤のモジュラス(d)との比率(c/d)が200~17,000であり、
前記保護フィルムおよび前記粘着剤層を一体に貫通する穿孔部を有し、
前記粘着剤層の厚さ(b)が3μm以上である、マスクフィルム。 - 前記粘着剤層と分離可能に付着した離型フィルムを追加的に有する、請求項1に記載のマスクフィルム。
- 前記穿孔部は、前記保護フィルム、前記粘着剤層、および前記離型フィルムを一体に貫通するものである、請求項2に記載のマスクフィルム。
- 偏光子の一面に前記マスクフィルムを積層させた後、前記穿孔部に対応する部分を処理して脱色部を形成するのに用いられる、請求項1~請求項3のいずれか一項に記載のマスクフィルム。
- 偏光子の一面に、請求項1~請求項4のいずれか一項に記載のマスクフィルムを積層するステップと、
前記マスクフィルムの穿孔部に対応する部分を脱色するステップと、
前記マスクフィルムを除去するステップとを含む非偏光部を有する偏光板の製造方法。 - 前記マスクフィルムの除去された面に前記偏光子の保護フィルムを積層するステップをさらに含む、請求項5に記載の非偏光部を有する偏光板の製造方法。
- 前記非偏光部のエッジラフネスが30μm以下である、請求項5または請求項6に記載の偏光板の製造方法。
- 請求項5~請求項7のいずれか一項に記載の製造方法により製造された偏光板を表示パネルの一面または両面に付着させることを含む、画像表示装置の製造方法。
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