JPWO2009044673A1 - 光学フィルム、その製造方法、偏光板、及び表示装置 - Google Patents
光学フィルム、その製造方法、偏光板、及び表示装置 Download PDFInfo
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- JPWO2009044673A1 JPWO2009044673A1 JP2009536030A JP2009536030A JPWO2009044673A1 JP WO2009044673 A1 JPWO2009044673 A1 JP WO2009044673A1 JP 2009536030 A JP2009536030 A JP 2009536030A JP 2009536030 A JP2009536030 A JP 2009536030A JP WO2009044673 A1 JPWO2009044673 A1 JP WO2009044673A1
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- 125000004079 stearyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
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- CXVGEDCSTKKODG-UHFFFAOYSA-N sulisobenzone Chemical compound C1=C(S(O)(=O)=O)C(OC)=CC(O)=C1C(=O)C1=CC=CC=C1 CXVGEDCSTKKODG-UHFFFAOYSA-N 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 230000002194 synthesizing effect Effects 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- XBFJAVXCNXDMBH-UHFFFAOYSA-N tetracyclo[6.2.1.1(3,6).0(2,7)]dodec-4-ene Chemical compound C1C(C23)C=CC1C3C1CC2CC1 XBFJAVXCNXDMBH-UHFFFAOYSA-N 0.000 description 1
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- 125000001544 thienyl group Chemical group 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- LMYRWZFENFIFIT-UHFFFAOYSA-N toluene-4-sulfonamide Chemical compound CC1=CC=C(S(N)(=O)=O)C=C1 LMYRWZFENFIFIT-UHFFFAOYSA-N 0.000 description 1
- 229910003470 tongbaite Inorganic materials 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 238000005809 transesterification reaction Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000001131 transforming effect Effects 0.000 description 1
- 150000003623 transition metal compounds Chemical class 0.000 description 1
- 229960002622 triacetin Drugs 0.000 description 1
- QORWJWZARLRLPR-UHFFFAOYSA-H tricalcium bis(phosphate) Chemical compound [Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O QORWJWZARLRLPR-UHFFFAOYSA-H 0.000 description 1
- WEAPVABOECTMGR-UHFFFAOYSA-N triethyl 2-acetyloxypropane-1,2,3-tricarboxylate Chemical compound CCOC(=O)CC(C(=O)OCC)(OC(C)=O)CC(=O)OCC WEAPVABOECTMGR-UHFFFAOYSA-N 0.000 description 1
- VOITXYVAKOUIBA-UHFFFAOYSA-N triethylaluminium Chemical compound CC[Al](CC)CC VOITXYVAKOUIBA-UHFFFAOYSA-N 0.000 description 1
- MCULRUJILOGHCJ-UHFFFAOYSA-N triisobutylaluminium Chemical compound CC(C)C[Al](CC(C)C)CC(C)C MCULRUJILOGHCJ-UHFFFAOYSA-N 0.000 description 1
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 1
- TZCXWPBSZLCVFR-UHFFFAOYSA-N tris(2,2,6,6-tetramethyl-1-propylpiperidin-4-yl) phosphate Chemical compound C1C(C)(C)N(CCC)C(C)(C)CC1OP(=O)(OC1CC(C)(C)N(CCC)C(C)(C)C1)OC1CC(C)(C)N(CCC)C(C)(C)C1 TZCXWPBSZLCVFR-UHFFFAOYSA-N 0.000 description 1
- GPRWRDWHHCQROU-UHFFFAOYSA-N tris(2,2,6,6-tetramethyl-1-propylpiperidin-4-yl) phosphite Chemical compound C1C(C)(C)N(CCC)C(C)(C)CC1OP(OC1CC(C)(C)N(CCC)C(C)(C)C1)OC1CC(C)(C)N(CCC)C(C)(C)C1 GPRWRDWHHCQROU-UHFFFAOYSA-N 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 150000004670 unsaturated fatty acids Chemical class 0.000 description 1
- 125000003774 valeryl group Chemical group O=C([*])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 150000003682 vanadium compounds Chemical class 0.000 description 1
- 235000015112 vegetable and seed oil Nutrition 0.000 description 1
- 239000008158 vegetable oil Substances 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 239000011592 zinc chloride Substances 0.000 description 1
- 235000005074 zinc chloride Nutrition 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
- QMBQEXOLIRBNPN-UHFFFAOYSA-L zirconocene dichloride Chemical compound [Cl-].[Cl-].[Zr+4].C=1C=C[CH-]C=1.C=1C=C[CH-]C=1 QMBQEXOLIRBNPN-UHFFFAOYSA-L 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
- B29C55/06—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/91—Heating, e.g. for cross linking
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
- B29C48/9155—Pressure rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/04—Particle-shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/05—Filamentary, e.g. strands
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/69—Filters or screens for the moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/69—Filters or screens for the moulding material
- B29C48/693—Substantially flat filters mounted at the end of an extruder screw perpendicular to the feed axis
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2001/00—Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2001/00—Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
- B29K2001/08—Cellulose derivatives
- B29K2001/12—Cellulose acetate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
- B29K2105/256—Sheets, plates, blanks or films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/0034—Polarising
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2011/00—Optical elements, e.g. lenses, prisms
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Polarising Elements (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Shaping By String And By Release Of Stress In Plastics And The Like (AREA)
Abstract
Description
請求の範囲第2項の発明は、請求の範囲第1項に記載の光学フィルムの製造方法であって、MD延伸工程におけるフィルムの延伸方式が、近接して配置された2本の搬送ロール間で行なわれるロール延伸方式であり、フィルムをヒータ加熱により昇温・軟化させて、該フィルムを、実質延伸スパン50mm以上、300mm以下においてMD延伸することを特徴としている。
10μm≦T1−T2≦200μm
請求の範囲第1項の発明によれば、弾性ロールよりなるタッチロールを用いることに加えて、キャストでのウェブの膜厚制御、およびいわゆるヒーター加熱方式によるウェブ(フィルム)のMD延伸を組み合わせているから、中央部厚膜にキャストしたフィルムであっても、最終膜厚形状をフラットにすることができて、平面性の良好な優れた光学特性を有する光学フィルムを製造し得、近年の液晶偏光板用保護フィルムの薄膜化、広幅化、高品質化の要求に、充分に応えることができるという効果を奏する。
2:フィルター
3:スタチックミキサー
4:流延ダイ
5:第1冷却ロール(冷却用第1回転体)
6:タッチロール(押圧用第2回転体)
7:第2冷却ロール(冷却用第3回転体)
8:第3冷却ロール(冷却用第4回転体)
P1:フィルムが最初に第1冷却ロール表面に接触した点
P2:フィルムがタッチロール表面に接触した点
9:剥離ロール
10:フィルム
10a:フィルム中央部
10b:フィルム端部
11:キャスト時のウェブ端部の返り
12:幅延伸装置
13:スリッター
14:エンボスリング
15:バックロール
16:巻取り装置
F:光学フィルム(元巻き)
20:MD延伸ゾーン
21:第1延伸前予熱ロール
22:第2延伸前予熱ロール
23:第3延伸前予熱ロール
24:第4延伸前予熱ロール
25:延伸・予熱ロール
26:ニップロール
27:延伸・冷却ロール
28:ニップロール
29:第1延伸後冷却ロール
30:第2延伸後冷却ロール
31:第3延伸後冷却ロール
32:上部加熱ヒータ
33:下部加熱ヒータ
41:ガイドロール
42:ガイドロール
S:実質延伸スパン
例えば1500mm以上、4000mm以下、好ましくは1500mm以上、2500mm以下の広幅の光学フィルムを、タッチロール方式で製膜するときには、ロールの撓みの影響で、フィルム中央部と端部でフィルムが受ける圧力に差が出てしまい、それが原因で、うまく面矯正ができなくなってしまう。
〔セルロース樹脂〕
本発明の光学フィルムの材料としてセルロース樹脂を用いる場合、そのセルロース樹脂は、セルロースエステルの構造を有し、脂肪酸アシル基、置換もしくは無置換の芳香族アシル基の中から少なくともいずれかの構造を含む、セルロースの単独または混合酸エステル(以下、単に「セルロース樹脂」という)であり、非晶性のものである。「非晶性」とは、不規則な分子配置で結晶とはならずに固体となっている物質を意味しており、原料時の結晶状態を表わしたものである。
−PH−R、−P(−R)2、−PH−O−R、−P(−R)(−O−R)、
−P(−O−R)2、−PH(=O)−R−P(=O)(−R)2、
−PH(=O)−O−R、−P(=O)(−R)(−O−R)、
−P(=O)(−O−R)2、−O−PH(=O)−R、
−O−P(=O)(−R)2−O−PH(=O)−O−R、
−O−P(=O)(−R)(−O−R)、
−O−P(=O)(−O−R)2、−NH−PH(=O)−R、
−NH−P(=O)(−R)(−O−R)、
−NH−P(=O)(−O−R)2、−SiH2−R、−SiH(−R)2、
−Si(−R)3、−O−SiH2−R、−O−SiH(−R)2、
及び−O−Si(−R)3が含まれる。
式(II) 0≦X≦2.5
式(III) 0.3≦Y≦2.5
特に、セルロースアセテートプロピオネートが好ましく用いられる。
〔シクロオレフィンポリマーフィルム〕
本発明に好ましく用いられるシクロオレフィンポリマーフィルムについて説明する。
〔ポリカーボネート系フィルム〕
本発明の光学フィルムを作製するのに用いられるポリカーボネート系樹脂としては、種々があり、化学的性質及び物性の点から芳香族ポリカーボネートが好ましく、特にビスフェノールA系ポリカーボネートが好ましい。その中でもさらに好ましくはビスフェノールAにベンゼン環、シクロヘキサン環、叉は脂肪族炭化水素基などを導入したビスフェノールA誘導体を用いたものが挙げられるが、特に中央炭素に対して非対称にこれらの基が導入された誘導体を用いて得られた、単位分子内の異方性を減少させた構造のポリカーボネートが好ましい。例えばビスフェノールAの中央炭素の2個のメチル基をベンゼン環に置き換えたもの、ビスフェノールAのそれぞれのベンゼン環の一の水素をメチル基やフェニル基などで中央炭素に対し非対称に置換したものを用いて得られるポリカーボネートが好ましい。
可塑剤は、その添加目的のために、セルロース樹脂等の樹脂に対する添加量が他のフィルム構成材料よりも多く、揮発成分の存在は得られるフィルムの品質劣化に大きな影響を与えるためである。なお、熱分解温度Td(1.0)は、市販の示差熱重量分析(TG−DTA)装置で測定することができる。
なお、キャスト時のウェブ10の両端部には、返り11,11が形成されているが、後述するスリッター13,13によりフィルムFが所定の有効幅(製品相当部)にカットされて、ウェブ両端部の返り11,11は除去される。
また、MD延伸ロールの間隔は、フィルムがロールに保持されていない区間は短いほど幅収縮が抑えられる。ここで、ロールの中心同士の間の距離が、400mm以下、好ましくは300mm以下である。
本発明によれば、弾性ロールよりなるタッチロール6を用いることに加えて、キャストでのウェブの膜厚制御、およびいわゆるヒーター加熱方式によるウェブ(フィルム)のMD延伸を組み合わせているから、例えば図4aに示すように、中央部厚膜にキャストしたフィルムであっても、最終膜厚形状を、例えば図4bに示すように、フラットにすることができて、平面性の良好な優れた光学特性を有する光学フィルムを製造し得るものである。
(幅方向の延伸倍率)>(流延方向の延伸倍率)
の条件を満たすことが必要である。
(液晶表示装置)
本発明の光学フィルムによって構成される位相差フィルムを含む偏光板は、通常の偏光板と比較して高い表示品質を発現させることができ、特にマルチドメイン型の液晶表示装置、より好ましくは複屈折モードによってマルチドメイン型の液晶表示装置への使用に適している。
(樹脂混合物)
セルロースアセテートプロピオネート 89重量%
(アセチル基置換度1.4、プロピオニル基置換度1.35、
数平均分子量60000)
トリメチロールプロパントリベンゾエート 9重量%
(可塑剤、融点85℃)
酸化防止剤(IRGANOX XP 420/FD) 0.25重量%
(チバスペシャルティケミカルズ社製)
紫外線吸収剤 1.6重量%
(TINUVIN 928、チバスペシャルティケミカルズ社製、
融点115℃)
マット剤(シリカ微粒子) 0.15重量%
(シーホスターKEP−30:日本触媒株式会社製、平均粒径0.3μm)
なお、セルロースアセテートプロピオネートのアセチル基、プロピオニル基、ブチリル基等のアシル基の置換度の測定は、ASTM−D817−96に規定の方法に準じて測定した。
比較例1〜5
比較のために、上記実施例1〜6で作製したロール状のセルロースアセテートプロピオネート未延伸フィルムを繰り出し、MD延伸ゾーン20においてMD延伸を行なうが、MD延伸の条件を、下記の表2に示すように、いずれかの延伸条件を、本発明の範囲外のものとなるように変更して、セルロースアセテートプロピオネート未延伸フィルムのMD延伸を、上記実施例1〜6の場合と同様に、行なった。
つぎに、実施例1〜6及び比較例1〜5においてMD延伸したセルロースアセテートプロピオネートフィルムについて、延伸後の幅収縮量(mm)の結果を、下記の表2に示した。
△:一部ムラっぽいが、許容レベルであるフィルム
×:光漏れがあるフィルム
(a)偏光膜の作製
けん化度99.95モル%、重合度2400のポリビニルアルコール(以下PVAと略す)100重量部に、グリセリン10重量部、及び水170重量部を含浸させたものを溶融混練し、脱泡後、Tダイから金属ロール上に溶融押出し、製膜した。その後、乾燥・熱処理してPVAフィルムを得た。得られたPVAフィルムは平均厚みが40μm、水分率が4.4%、フィルム幅が3mであった。
(b)偏光板の作製
ついで、下記工程1〜5に従って、偏光膜フィルムと偏光板用保護フィルムとを貼り合わせて本発明の偏光板、及び比較例の偏光板を作製した。
(視認性評価)
上記のようにして得られた本発明の液晶パネル、及び比較例の液晶パネルを、床から80cmの高さの机上に配置し、床から3mの高さの天井部に昼色光直管蛍光灯(FLR40S・D/M−X 松下電器産業株式会社製)40W×2本を1セットとして1.5m間隔で10セット配置した。このとき、評価者が液晶パネル表示面正面にいるときに、評価者の頭上より後方に向けて天井部に前記蛍光灯がくるように配置した。液晶パネルは机に対する垂直方向から25°傾けて蛍光灯が写り込むようにして、画面の見易さ(視認性)を下記のようにランク分けして、評価した。
B:近くの蛍光灯の写りこみはやや気になるが、遠くは気にならず、フォントの大きさ8以下の文字もなんとかと読める
C:遠くの蛍光灯の写りこみも気になり、フォントの大きさ8以下の文字を読むのは困難である
D:蛍光灯の写り込みがかなり気になり、写り込みの部分はフォントの大きさ8以下の文字を読むことはできない
評価の結果、本発明の実施例1〜6で作製した光学フィルムを用いた偏光板を組み込んだ液晶パネルは、何れもランクB以上の評価結果であり、良好であった。これに対し、比較例1〜5で作製した光学フィルムを用いた偏光板を組み込んだ液晶パネルは、何れもランクC以下の評価結果であった。
Claims (7)
- 熱可塑性樹脂を主成分とする溶融物を流延ダイから膜状に押し出す押出工程と、押し出された膜状溶融物(ウェブ)を、冷却ロールとタッチロールとで挟圧する挟圧工程と、挟圧後の未延伸フィルムを長手方向に延伸するMD延伸工程とを含む溶融流延製膜法による光学フィルムの製造方法であって、
前記MD延伸工程において、
挟圧後の未延伸フィルムを、同フィルムの搬送方向(MD方向)に、1.1倍以上3.0倍以下に延伸し、かつ、
前記押し出し工程において、
押出しウェブの幅手方向中央部の膜厚:T1(μm)と、同ウェブの幅手方向両端部の膜厚:T2(μm)との間に、下記の関係式が成り立つことを特徴とする、光学フィルムの製造方法。
10μm≦T1−T2≦200μm - MD延伸工程におけるフィルムの延伸方式が、近接して配置された2本の搬送ロール間で行なわれるロール延伸方式であり、フィルムをヒータ加熱により昇温・軟化させて、該フィルムを、実質延伸スパン50mm以上、300mm以下においてMD延伸することを特徴とする、請求の範囲第1項に記載の光学フィルムの製造方法。
- 挟圧工程において、タッチロールが、周面に金属薄板が被覆された弾性ロールよりなるものであることを特徴とする、請求の範囲第1項または第2項に記載の光学フィルムの製造方法。
- 熱可塑性樹脂が、セルロースエステルであることを特徴とする、請求の範囲第1項乃至第3項のうちのいずれか一項に記載の光学フィルムの製造方法。
- 請求の範囲第1項乃至第4項のうちのいずれか一項に記載の光学フィルムの製造方法によって製造されたことを特徴とする、光学フィルム。
- 請求の範囲第5項に記載の光学フィルムを一方の面に用いたことを特徴とする、偏光板。
- 請求の範囲第6項に記載の偏光板を用いたことを特徴とする、表示装置。
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