KR101984350B1 - Method of producing optical film, optical film and image display device - Google Patents

Method of producing optical film, optical film and image display device Download PDF

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KR101984350B1
KR101984350B1 KR1020157013162A KR20157013162A KR101984350B1 KR 101984350 B1 KR101984350 B1 KR 101984350B1 KR 1020157013162 A KR1020157013162 A KR 1020157013162A KR 20157013162 A KR20157013162 A KR 20157013162A KR 101984350 B1 KR101984350 B1 KR 101984350B1
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film
adhesive composition
pressure
layer
optical film
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KR1020157013162A
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Korean (ko)
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KR20150073201A (en
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마사시 시나가와
류우이치 이노우에
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닛토덴코 가부시키가이샤
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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J5/00—Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2203/00—Applications of adhesives in processes or use of adhesives in the form of films or foils
    • C09J2203/318—Applications of adhesives in processes or use of adhesives in the form of films or foils for the production of liquid crystal displays
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F2202/00—Materials and properties
    • G02F2202/28—Adhesive materials or arrangements

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  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Quality & Reliability (AREA)
  • Polarising Elements (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Liquid Crystal (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

A method for producing an optical film comprising a laminate structure in which at least a first film and a second film are bonded via an adhesive layer or a pressure-sensitive adhesive layer composed of a cured layer of an adhesive composition or a pressure-sensitive adhesive composition, And applying an adhesive composition or a pressure-sensitive adhesive composition to both the concave surface of the first film and the concave surface of the second film to remove foreign matter and / or air bubbles.

Description

Technical Field [0001] The present invention relates to a method of manufacturing an optical film, an optical film,

The present invention relates to an optical film comprising a laminate structure in which at least a first film and a second film are bonded via an adhesive layer or a pressure-sensitive adhesive layer comprising a cured layer of an adhesive composition or a pressure-sensitive adhesive composition, . Further, the present invention relates to an image display device such as a liquid crystal display device, an organic EL display device, or a PDP using the optical film.

2. Description of the Related Art Liquid crystal display devices are rapidly spreading on the market in watches, mobile phones, PDAs, notebook computers, personal computer monitors, DVD players, and TVs. A liquid crystal display device is made by visualizing the polarization state due to the switching of liquid crystal, and a polarizer is used from the principle of display. Particularly in applications such as TVs, higher brightness, higher contrast, and a wider viewing angle are required, and polarizing films are increasingly demanding higher transmittance, higher polarization degree, and higher color reproducibility.

As a polarizer, an iodine-based polarizer having a structure in which iodine is adsorbed to, for example, polyvinyl alcohol (hereinafter simply referred to as " PVA ") in view of high transmittance and high polarization degree is most widely used. In general, a polarizing film has been used in which a transparent protective film is applied to both surfaces of a polarizer by a so-called water-based adhesive in which a polyvinyl alcohol-based material is dissolved in water. However, in recent years, it has become mainstream to use an active energy ray-curable resin composition that does not contain water or an organic solvent because it has the advantages of omitting the drying process and reducing the dimensional change.

In the case of producing an optical film by combining a plurality of films by using an active energy ray-curable resin composition, for example, an adhesive composition is applied only to the concave surface of a transparent protective film, and a polarizer or the like is applied from such an adhered surface side, Is generally produced. However, in the conventional manufacturing method, when foreign substances such as dust or dust adhere to the surface of the polarizer / transparent protective film before application of the adhesive composition or the like, or when the adhesive composition contains minute foreign matters, As a result, appearance defects may occur.

The following Patent Document 1 discloses a method for producing an optical film including a step of applying an optical function layer having a wet coating amount of 10 ml / m 2 or less on a transparent support or a primer layer (undercoat layer) formed on the transparent support There is disclosed a method for producing an optical film comprising a step of removing foreign matter having a height of 10 占 퐉 or more from a transparent support or a subbing layer before applying the optical functional layer.

Japanese Patent Application Laid-Open No. 2008-180905

However, as a result of the investigation by the inventor of the present invention, it has been found that, in the technique described in Patent Document 1, an attempt is made to crush and remove foreign matter by calendering or the like in the state where foreign matter already exists on a transparent support or the like. Precision is not high, and minute foreign matters remain after the removal process. For this reason, the technique described in Patent Document 1 is difficult to apply to a method of manufacturing a thin optical film in which appearance defects are a problem, even when the thickness is thin and minute foreign matter is present.

SUMMARY OF THE INVENTION The present invention has been accomplished as a result of consideration of the above-described circumstances, and an object of the present invention is to provide a method of manufacturing an optical film in which generation of external defects due to foreign substances and / or bubbles is prevented even if the optical film is thin .

As a result of intensive investigations to solve the above problems, the present inventors have found that, when an optical film including a laminate structure in which at least two films are laminated is produced, a specific coating system is employed, Or bubbles and applying the adhesive composition or the pressure-sensitive adhesive composition can be carried out at one time by applying the adhesive composition or the pressure-sensitive adhesive composition to the concave surface of the pressure-sensitive adhesive layer. The present invention is obtained as a result of the study of this example, and has the following constitution.

That is, the present invention provides a method for producing an optical film comprising a laminate structure in which at least a first film and a second film are bonded via an adhesive layer or a pressure-sensitive adhesive layer comprising a cured layer of an adhesive composition or a pressure- And a coating step of removing foreign matter and / or air bubbles by applying the adhesive composition or the pressure-sensitive adhesive composition to both of the concave surface of the first film and the concave surface of the second film using a coating method And a method for producing the optical film.

When two films are laminated to produce an optical film having a laminated structure, it is general to manufacture an optical film by applying an adhesive composition or a pressure-sensitive adhesive composition to a film of a polarizing plate out of the two films, and then sticking another polarizing film thereto Hereinafter also referred to as " single-side coating method "). However, in the present invention, the adhesive composition or the pressure-sensitive adhesive composition is applied to both the cohesive face of the first film and the cohesive face of the second film, and the coating is applied to the foreign substance and / Perform while removing air bubbles. Concretely, by using a post-metering coating method, gels and agglomerates derived from an adhesive composition or a pressure-sensitive adhesive composition are also scraped off while scraping foreign matters such as dust and dust present on both concave surfaces of the two films to be combined, The adhesive composition or the pressure-sensitive adhesive composition is applied to both of the concave surfaces of the two films while scraping from both the concave surfaces of the film. As a result, in the method for producing an optical film according to the present invention, the possibility that foreign matter exists on both of the two side surfaces of the two films becomes very low. As a result, in the method for producing an optical film according to the present invention, it is possible to produce an optical film in which appearance of defects due to foreign substances is prevented.

On the other hand, in the single-sided coating method, foreign substances present on the cohesive surface of the film not coated with the adhesive composition or the pressure-sensitive adhesive composition can not be removed, so that there is a high possibility that foreign matter remains in the adhesive layer (or pressure-sensitive adhesive layer) . Further, in the single-side coating method, the adhesive (or adhesive) -coated surface of the film of the single-layer film is directly adhered to the cohesive surface of the film of another film (without the adhesive composition (or pressure-sensitive adhesive composition)). In this case, since the adhesive composition (or the pressure-sensitive adhesive composition) having a viscosity is in direct contact with the coplanar surface of the film of the other unilamellar bubble, the bubbles tend to get caught in the coaptation. On the other hand, in the method according to the present invention, since the adhesive composition (or the pressure-sensitive adhesive composition) is applied to both the concave surface of the first film and the concave surface of the second film, 2 The adhesive of the film (or the adhesive) is applied in contact with the coated surface. That is, since the adhesive composition (or the pressure-sensitive adhesive composition) having viscosity is superimposed and bonded to each other, the bubbles are less likely to interfere with each other at the time of coalescence, and the bubbles are likely to be released. Therefore, in the method according to the present invention, since the bubble removing effect is superior to the one-side coating method, an optical film in which the occurrence of appearance defects due to bubbles is prevented can be produced.

In the present invention, the " post-metering coating system " means a system of applying an external force to a liquid film to remove an excess liquid to obtain a predetermined coating film thickness. In the method for producing an optical film according to the present invention, when such external force is given to a liquid film made of an adhesive composition or a pressure-sensitive adhesive composition, foreign matter such as dust or dust existing on the coaptation surface is scratched off. Specific examples of the post-metering coating method include a gravure roll coating method, a forward roll coating method, an air knife coating method, and a rod / bar coating method. However, in view of accuracy of removal of foreign matters and uniformity of coating film thickness , In the present invention, it is preferable that the coating method is a gravure roll coating method using a gravure roll. In the present invention, "removal of foreign matter and / or bubbles" means removal of at least one or both of foreign matter and bubbles.

In the above production method, a post-metering coating method is used in which the adhesive composition or the pressure-sensitive adhesive composition is circulated to be applied, and the foreign matter mixed in the adhesive composition or the pressure-sensitive adhesive composition from the first film and / Is removed from the adhesive composition or the pressure-sensitive adhesive composition. In the post-metering coating method, a coating liquid composed of an adhesive composition or a pressure-sensitive adhesive composition is applied to the laminated surface of the first film and the second film. When such a coating liquid is applied to the laminated surface of the first film and / The possibility that foreign matter is present on the coplanar surface of the first film and the second film after application becomes high. However, when the coating method to be used is provided with a foreign matter removing function for removing foreign matters mixed in the adhesive composition or the pressure-sensitive adhesive composition from the first film and / or the second film by the application, from the adhesive composition or the pressure- It is possible to remarkably reduce the amount of foreign substances in the liquid. Thereby, the possibility that foreign matter exists on the coplanar surface of the first film and the second film after coating can be remarkably reduced.

In the above manufacturing method, it is preferable that the rotational direction of the gravure roll and the advancing direction of the first film and the second film are opposite to each other. In this case, the effect of scraping foreign substances such as dust and dust existing on the coalescence surface of the first film and the coalescence surface of the second film, and further the gel or aggregate derived from the adhesive composition or the pressure-sensitive adhesive composition is effectively increased, The appearance defects of the optical film can be prevented more effectively.

Various patterns can be formed on the surface of the gravure roll, and for example, a honeycomb mesh pattern, a trapezoidal pattern, a grid pattern, a pyramid pattern, or a diagonal pattern can be formed. It is preferable that the pattern formed on the surface of the gravure roll is a honeycomb mesh pattern in order to effectively prevent appearance defects of the finally obtained optical film. In the case of the honeycomb mesh pattern, the cell volume is preferably from 1 to 5 cm 3 / m 2, more preferably from 2 to 3 cm 3 / m 2, in order to improve the surface accuracy of the coated surface after application of the adhesive composition or the pressure-sensitive adhesive composition. Similarly, in order to increase the surface accuracy of the coated surface after application of the adhesive composition or the pressure-sensitive adhesive composition, the number of cell lines per inch of the roll is preferably 200 to 3000 lines / inch. It is preferable that the rotational speed ratio of the gravure roll to the advancing speed of the first film and the second film is 100 to 300%.

However, the thicker the thickness of the adhesive layer (or the pressure-sensitive adhesive layer) or the total thickness of the optical film, the more difficult it is for the foreign substances to be visually observed, and the appearance defects tend to be unlikely to be problematic. On the other hand, the thinner the thickness of the adhesive layer (or the pressure-sensitive adhesive layer), the thinner the total thickness of the optical film, the easier the visibility of the foreign substance becomes, and as a result, the appearance defect becomes a problem in many cases. However, in the method for producing an optical film according to the present invention, an optical film having a very low incidence of foreign matter in the adhesive layer (or the pressure-sensitive adhesive layer) can be produced. Therefore, among the optical films, Specifically, the manufacturing method related to the present invention is particularly useful when the first film is a transparent protective film and the second film is a polarizer. The manufacturing method according to the present invention is advantageous in that even in the case of producing a thin polarizing film in particular, as in the case where the thickness of the polarizer is not more than 10 탆, it is possible to prevent the appearance of defects due to foreign substances or bubbles in the adhesive layer It is possible to produce a thin polarizing film in which generation is prevented.

The present invention also relates to an image display device characterized in that an optical film produced by any one of the above-described manufacturing methods, and further, the optical film described above is used.

In the method for producing an optical film according to the present invention, it is possible to efficiently remove foreign matters present on both of the two adjoining faces of the two films to be laminated and foreign matters present in the adhesive composition or in the pressure-sensitive adhesive composition, It is possible to prevent the occurrence of appearance defects due to foreign substances and / or air bubbles, thereby making it possible to produce an optical film. Therefore, the method for producing an optical film according to the present invention is a method for producing an optical film in which the thickness of the adhesive layer is thin, that is, an optical film having a thin total thickness, particularly a method for producing a thin polarizing film .

1 is an example of a schematic view of a method for producing an optical film according to the present invention.
Fig. 2 is an example of a schematic view of a gravure roll coating system which is a post-metering coating system used in the present invention.

Hereinafter, a method for producing an optical film according to the present invention will be described with reference to the drawings.

A method of producing an optical film according to the present invention is a method of applying an adhesive composition or a pressure-sensitive adhesive composition to both of an adhesion face of a first film and an adhesion face of a second film using a post- Respectively.

Fig. 1 shows an example of a schematic view of a manufacturing method of an optical film related to the present invention. In this embodiment, as an after-coating application method, an example in which an adhesive composition is applied using a gravure roll coating method using a gravure roll . 1, the first film 1 is transported toward the right side in FIG. 1 at the time when the adhesive composition 3 is applied using the gravure roll coating system 10, and on the other hand, The gravure roll provided in the main body 10 rotates clockwise. That is, the rotational direction of the gravure roll and the advancing direction of the first film are opposite to each other. Likewise, in the relationship between the second film 2 and the gravure roll, the direction of rotation of the gravure roll and the direction of advance of the second film 2 are opposite to each other. In this case, the effect of scraping foreign matters such as dust and dust existing on the coplanar surface of the first film 1 and the coplanar surface of the second film 2, as well as the gel or aggregate derived from the adhesive composition, It is possible to more effectively prevent appearance defects of the finally obtained optical film.

In order to more effectively prevent the appearance defects of the finally obtained optical film, the rotation speed of the gravure roll is preferably 100 to 300% with respect to the progress speed of the first film (1) and the second film (2) To 250%.

2 shows an example of a schematic view of a gravure roll coating system which is a post metering coating system used in the present invention. In particular, an adhesive composition (3) is applied to a first film (1) using a gravure coating system . As shown in Fig. 2, when the gravure roll 4 is pressed against the first film 1 and the foreign substance is removed while being brought into contact with the first film 1, foreign matter such as dust and dust present on the concave surface of the first film 1, Further, the gel or aggregate derived from the adhesive composition can be more effectively removed.

As shown in FIG. 2, the gravure coating system 10 includes at least a gravure roll 4. A concavo-convex pattern such as a honeycomb mesh pattern, a trapezoidal pattern, a lattice pattern, a pyramid pattern, or an oblique line pattern is formed on the surface of the gravure roll. In order to increase the surface accuracy of the coated surface after application of the adhesive composition or the pressure-sensitive adhesive composition, it is preferable that a honeycomb-shaped mesh pattern is formed, and the cell volume is preferably 1 to 5 cm3 / m2, more preferably 2 to 3 cm3 / m2 . Similarly, in order to increase the surface accuracy of the coated surface after application of the adhesive composition or the pressure-sensitive adhesive composition, the number of cell lines per inch of the roll is preferably 200 to 3000 lines / inch. The concavo-convex pattern of the gravure roll 4 has a function of applying the adhesive composition 3 to the concave surface of the first film while raising the adhesive composition (coating liquid) 3. In the present invention, in order to prevent foreign matter from being mixed into the adhesive composition (3), it is preferable that the adhesive coating liquid is a closed system which is not exposed to the outside air.

In the example shown in Fig. 2, the foreign substance present on the coinciding surface of the first film 1, and further the gel product or aggregate derived from the adhesive composition 3 are scraped off by the gravure roll 4 , It is sometimes moved into the container 5 containing the adhesive composition 3 and then applied to the concave surface of the first film by the gravure roll 4 again. Therefore, particularly in the case of a method in which the post-metering application method is applied by circulating the adhesive composition or the pressure-sensitive adhesive composition, as the coating process of the adhesive composition 3 becomes prolonged, the accumulation amount of foreign substances scraped off by the gravure roll 4 Is likely to increase. However, in the case where the gravure coating system 10 has a foreign matter removing function for removing foreign matter mixed in the adhesive composition or the pressure-sensitive adhesive composition from the first film and / or the second film by application, from the adhesive composition or the pressure- , The amount of the foreign substances or the like present in the adhesive composition 3 to be applied is always kept at a trace amount to zero. Therefore, finally, the amount of foreign matter or the like generated on the concave surface of the first film 1 can be significantly reduced. In the present invention, the foreign matters removing function includes a filter, a distillation apparatus, and a centrifugal separator. When the filter is used as the foreign matter removing function, as shown in Fig. 2, for example, the filter 7 can be disposed on the downstream side of the pump function 8. It is also possible to arrange the filter 7 on the upstream side of the pump function 8, and the number of the filters 7 does not matter. The mesh size of the filter 7 can be appropriately changed depending on the material of the first film 1 and the second film or the blend design of the adhesive composition 3 and is preferably 10 m or smaller and more preferably 5 m or smaller Do. The adhesive composition 3 may be circulated by using a tank 6 or the like as shown in Fig. 2, and the adhesive composition 3 after being applied by the gravure roll 4 may be discarded.

After the adhesive composition 3 is applied to both the coplanar surface of the first film 1 and the coplanar surface of the second film 2 by the application method of the metering coating system shown in Fig. 1, for example, The first film 1 and the second film 2 are bonded to each other via the adhesive composition (adhesive layer) using the adhesive composition 9.

In the case of producing the optical film as a continuous line, the line speed of the first film and / or the second film varies depending on the curing time of the adhesive composition (or the pressure-sensitive adhesive composition), but is preferably 1 to 500 m / min, Min, preferably 5 to 300 m / min, more preferably 10 to 100 m / min. When the line speed is too small, it is not possible to produce an optical film which is insufficient in productivity or too large in damage to the first film and / or the second film and can withstand durability tests and the like. If the line speed is excessively large, the curing of the adhesive composition becomes insufficient, and the intended adhesive property may not be obtained.

Next, the optical film produced by the manufacturing method according to the present invention will be described below. Such an optical film includes a laminate structure in which at least a first film and a second film are bonded via an adhesive layer or a pressure-sensitive adhesive layer comprising a cured layer of an adhesive composition or a pressure-sensitive adhesive composition.

≪ Adhesive layer or pressure-sensitive adhesive layer >

When the adhesive layer or the pressure-sensitive adhesive layer is optically transparent, it is not particularly limited, and various types of water-based, solvent-based, hot-melt-based, and radical-curing types are used. In the case of producing a transparent conductive laminate or a polarizing film as an optical film, a transparent curing type adhesive layer is preferable.

≪ Transparent curable adhesive layer >

As the adhesive composition, for example, a radical-curable adhesive is preferably used for forming the transparent curing-type adhesive layer. As the radical curing type adhesive, an active energy ray curing type adhesive such as an electron beam curable type or an ultraviolet ray curable type can be exemplified. In particular, an active energy ray curable type which is curable in a short time is preferable, and further, an ultraviolet curable type adhesive which can be cured with a low energy is preferable.

As ultraviolet curable adhesives, radical curing curable adhesives and cationic curable adhesives can be categorized. In addition, the radical polymerization curing type adhesive can be used as a thermosetting adhesive.

Examples of the curable component of the radical polymerization curable adhesive include a compound having a (meth) acryloyl group and a compound having a vinyl group. These curable components may be either monofunctional or bifunctional or more. These curable components may be used singly or in combination of two or more. As the curing component, for example, a compound having a (meth) acryloyl group is preferable.

Specific examples of the compound having a (meth) acryloyl group include methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) (Meth) acrylate, n-butyl (meth) acrylate, isobutyl (meth) acrylate, s- (Meth) acrylate, n-hexyl (meth) acrylate, cetyl (meth) acrylate, n-hexyl Acrylates such as n-octyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, 4-methyl- ) Acrylic acid (having 1 to 20 carbon atoms) alkyl esters.

Examples of the compound having a (meth) acryloyl group include cycloalkyl (meth) acrylate (for example, cyclohexyl (meth) acrylate, cyclopentyl (meth) 2-norbornylmethyl (meth) acrylate (e.g., benzyl (meth) acrylate, etc.), polycyclic (meth) Acrylate, 5-norbornene-2-yl-methyl (meth) acrylate and 3-methyl- (Meth) acrylate, 2-hydroxypropyl (meth) acrylate and 2,3-dihydroxypropylmethyl-butyl (meth) methacrylate), an alkoxy group or a phenoxy group-containing Methacrylic acid esters such as 2-methoxyethyl (meth) acrylate, 2-ethoxyethyl (meth) acrylate, (Meth) acrylate, 2-methoxymethoxyethyl (meth) acrylate, 3-methoxybutyl (meth) acrylate, ethylcarbitol Methacrylic acid esters such as glycidyl (meth) acrylate, halogen-containing (meth) acrylic esters (such as 2,2,2-trifluoroethyl (meth) acrylate, (Meth) acrylate, hexafluoropropyl (meth) acrylate, octafluoropentyl (meth) acrylate, heptadecafluoro (meth) acrylate, (Meth) acrylate), and alkylaminoalkyl (meth) acrylates (e.g., dimethylaminoethyl (meth) acrylate).

Examples of the compound having a (meth) acryloyl group other than the above include hydroxyethyl acrylamide, N-methylol acrylamide, N-methoxymethylacrylamide, N-ethoxymethylacrylamide, And amide group-containing monomers such as amide. And nitrogen-containing monomers such as acryloylmorpholine.

Examples of the curable component of the radical polymerization curable adhesive include compounds having a plurality of polymerizable double bonds such as (meth) acryloyl groups and vinyl groups, and the compounds are used as crosslinking components in an adhesive component It may be mixed. Examples of the curable component that becomes such a crosslinking component include tripropylene glycol diacrylate, 1,9-nonanediol diacrylate, tricyclodecane dimethanol diacrylate, cyclic trimethylolpropane formal acrylate, di (Manufactured by Kyowa Chemical Industry Co., Ltd.), light acrylate DGE-4A (manufactured by Kyowa Chemical Industry Co., Ltd.), acrylic acid monoacrylate SR-531 (manufactured by Sartomer), CD-536 (manufactured by Sartomer), and the like can be given. If necessary, various epoxy (meth) acrylates, urethane (meth) acrylates, polyester (meth) acrylates and various (meth) acrylate monomers may be cited.

The radical polymerization curing type adhesive contains the above-mentioned curable component. In addition to the above components, a radical polymerization initiator is added according to the curing type. When the adhesive is used in an electron beam hardening type, it is not particularly required to include a radical polymerization initiator in the adhesive, but when it is used in an ultraviolet curing type or a thermosetting type, a radical polymerization initiator is used. The amount of the radical polymerization initiator to be used is usually about 0.1 to 10 parts by weight, preferably 0.5 to 3 parts by weight, per 100 parts by weight of the curing component. In addition, a photo-sensitizer may be added to the radical polymerization curing type adhesive, as needed, such as a carbonyl compound or the like, which increases the curing rate and sensitivity by electron beams. The amount of the photosensitizer is usually about 0.001 to 10 parts by weight, preferably 0.01 to 3 parts by weight, per 100 parts by weight of the curing component.

Examples of the curable component of the cationic polymerization curable adhesive include compounds having an epoxy group and an oxetanyl group. The compound having an epoxy group is not particularly limited as long as it has at least two epoxy groups in the molecule, and various generally known curable epoxy compounds can be used. As a preferable epoxy compound, a compound having at least two epoxy groups and at least one aromatic ring in the molecule, or a compound having at least two epoxy groups in the molecule, at least one of which has two adjacent carbon atoms constituting an alicyclic ring And the like, and the like.

For forming the transparent curing type adhesive layer, for example, a vinyl polymer type, a gelatin type, a vinyl type latex type, a polyurethane type, an isocyanate type, a polyester type, an epoxy type and the like can be cited as an aqueous curing type adhesive. The adhesive layer composed of such an aqueous adhesive can be formed as a coating and drying layer of an aqueous solution. When preparing the aqueous solution, a crosslinking agent, a catalyst such as another additive, or an acid can be added as needed.

As the water-based adhesive, it is preferable to use an adhesive containing a vinyl polymer, and the vinyl polymer is preferably a polyvinyl alcohol-based resin. As the polyvinyl alcohol-based resin, an adhesive containing a polyvinyl alcohol-based resin having an acetoacetyl group is more preferable in terms of improving durability. As the crosslinking agent that can be blended in the polyvinyl alcohol-based resin, a compound having at least two functional groups having reactivity with the polyvinyl alcohol-based resin can be preferably used. For example, boric acid or borax, carboxylic acid compounds, alkyldiamines; Isocyanates; Epoxies; Monoaldehydes; Dialdehydes; Amino-formaldehyde resins; Further, a divalent metal, a salt of a trivalent metal, and an oxide thereof can be mentioned.

The adhesive forming the curable adhesive layer may contain an additive agent as appropriate. Examples of the additive include a coupling agent such as a silane coupling agent and a titanium coupling agent, an adhesion promoter represented by ethylene oxide, an additive for improving wettability with a transparent film, an acryloxy group compound or a hydrocarbon type (natural or synthetic resin) An antistatic agent, a dye, a processing aid, an ion trap agent, an antioxidant, a tackifier, a filler (other than a metal compound filler), a plasticizer, a leveling agent, a foaming inhibitor , Stabilizers such as antistatic agents, heat stabilizers, and moisture stabilizers.

The thickness of the transparent curing adhesive layer is preferably 0.01 to 10 mu m. More preferably 0.1 to 5 占 퐉, and still more preferably 0.3 to 4 占 퐉. In addition, since the height of the appearance defects originating from foreign matter or bubbles between the respective film layers is generally several micrometers (about 2 to 5 占 퐉), if the thickness of the adhesive layer is 2 占 퐉 or less, the problem of appearance defects becomes large . However, the production method of the optical film according to the present invention is particularly useful as a method for producing an optical film in which the thickness of the adhesive layer is not more than 2 占 퐉 because occurrence of appearance defects can be prevented.

The pressure-sensitive adhesive layer is formed of a pressure-sensitive adhesive. As the pressure-sensitive adhesive, various pressure-sensitive adhesives can be used. Examples of the pressure-sensitive adhesive include rubber pressure-sensitive adhesives, acrylic pressure sensitive adhesives, silicone pressure sensitive adhesives, urethane pressure sensitive adhesives, vinyl alkyl ether pressure sensitive adhesives, polyvinyl pyrrolidone pressure sensitive adhesives, polyacrylamide pressure sensitive adhesives, and cellulosic pressure sensitive adhesives . Depending on the type of the pressure-sensitive adhesive, a tacky base polymer is selected. Of the above pressure-sensitive adhesives, an acrylic pressure-sensitive adhesive is preferably used because it has excellent optical transparency, exhibits appropriate wettability, cohesiveness and adhesive property, and is excellent in weather resistance and heat resistance.

The radical polymerization curing type adhesive can be used as an electron beam hardening type or an ultraviolet ray hardening type.

In the electron beam hardening type, the irradiation condition of the electron beam may be any appropriate condition as long as it is a condition capable of curing the radical polymerization hardening type adhesive composition. For example, in the electron beam irradiation, the acceleration voltage is preferably 5 kV to 300 kV, and more preferably 10 kV to 250 kV. If the accelerating voltage is less than 5 kV, the electron beam may not reach the adhesive, resulting in insufficient curing. If the accelerating voltage exceeds 300 kV, the penetration force through the sample is too strong to reduce damage to the transparent protective film or polarizer . The irradiation dose is 5 to 100 kGy, more preferably 10 to 75 kGy. When the irradiation dose is less than 5 kGy, the adhesive becomes insufficient in curing. When the irradiation dose exceeds 100 kGy, the transparent protective film or the polarizer is damaged and mechanical strength is lowered, yellowing occurs, and desired optical characteristics can not be obtained.

The electron beam irradiation is usually carried out in an inert gas atmosphere, and may be carried out under a condition where air or oxygen is slightly introduced, if necessary. Although oxygen depending on the material of the transparent protective film is appropriately introduced, it is possible to prevent damage to the transparent protective film by causing oxygen inhibition on the surface of the transparent protective film which is first contacted with the electron beam, have.

On the other hand, when a transparent protective film imparted with ultraviolet ray absorbing ability is used in the ultraviolet ray curing type, light having a wavelength shorter than 380 nm is absorbed by light of shorter wavelength than 380 nm, and therefore light of shorter wavelength than 380 nm does not reach the active energy ray curable adhesive composition, It does not contribute to the polymerization reaction. Further, the light having a wavelength shorter than 380 nm absorbed by the transparent protective film is converted into heat, and the transparent protective film itself generates heat, which causes defects such as curling and wrinkling of the polarizing film. Therefore, when the ultraviolet curing type is employed in the present invention, it is preferable to use an apparatus which does not emit light having a shorter wavelength than 380 nm as the ultraviolet ray generating apparatus, and more specifically, it has an integrated illuminance of 380 to 440 nm The ratio of the integrated illuminance in the wavelength range of 250 to 370 nm is preferably 100: 0 to 100: 50, more preferably 100: 0 to 100: 40. As the ultraviolet ray satisfying the relationship of the integrated illuminance, a gallium-encapsulated metal halide lamp and an LED light source emitting light in a wavelength range of 380 to 440 nm are preferable. A metal halide lamp, a fluorescent lamp, a tungsten lamp, a gallium lamp, an excimer laser, or solar light as a light source, and a bandpass filter, such as a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, an ultra high pressure mercury lamp, an incandescent lamp, a xenon lamp, a halogen lamp, It is also possible to cut off light of a shorter wavelength than 380 nm by using a filter.

The first film and / or the second film can be used without particular limitation as long as it is a transparent optical film. As described above, the thicker the thickness of the adhesive layer (or the pressure-sensitive adhesive layer) and hence the total thickness of the optical film, the more difficult it is for the foreign substance to be visually recognized, and the appearance defects tend to be unlikely to be problematic. On the other hand, the thinner the thickness of the adhesive layer (or the pressure-sensitive adhesive layer), the thinner the total thickness of the optical film, the easier the visibility of the foreign substance becomes, and as a result, the appearance defect becomes a problem in many cases. However, in the method for producing an optical film according to the present invention, an optical film having a very low incidence of foreign matter in the adhesive layer (or the pressure-sensitive adhesive layer) can be produced. Therefore, among the optical films, Specifically, the manufacturing method related to the present invention is particularly useful when the first film is a transparent protective film and the second film is a polarizer. The manufacturing method according to the present invention is advantageous in that even in the case of producing a thin polarizing film in particular, as in the case where the thickness of the polarizer is not more than 10 탆, it is possible to prevent the appearance of defects due to foreign substances or bubbles in the adhesive layer It is possible to produce a thin polarizing film in which generation is prevented.

The first film and / or the second film may be subjected to surface modification treatment before applying the active energy ray-curable adhesive composition. Specific examples of the treatment include corona treatment, plasma treatment, and saponification treatment.

Further, in the method for producing an optical film according to the present invention, the first film and the second film are preferably bonded via an adhesive layer formed by the cured layer of the radical polymerization curable adhesive composition, An adhesion-facilitating layer can be formed between the second films. The adhesion facilitating layer can be formed by various resins having a polyester skeleton, a polyether skeleton, a polycarbonate skeleton, a polyurethane skeleton, a silicone, a polyamide skeleton, a polyimide skeleton, and a polyvinyl alcohol skeleton, for example. These polymer resins may be used singly or in combination of two or more. Further, other additives may be added to form the adhesion-facilitating layer. Specifically, stabilizers such as a tackifier, an ultraviolet absorber, an antioxidant, and a heat stabilizer may be used.

The easy-to-adhere layer is formed by applying the forming material of the easy-to-adhere layer onto a film by a known technique and drying it. The forming material of the easy-to-adhere layer is usually adjusted as a solution diluted to an appropriate concentration in consideration of the thickness after drying, the original activity of coating, and the like. The thickness of the ease of adhesion layer after drying is preferably 0.01 to 5 占 퐉, more preferably 0.02 to 2 占 퐉, and still more preferably 0.05 to 1 占 퐉. Also, a plurality of layers can be formed as the easy-to-adhere layer. In this case as well, the total thickness of the easy-to-adhere layer is preferably in the above range.

Hereinafter, a polarizing film will be described as an example of the optical film. 1, a polarizing film including a laminated structure in which at least a first film and a second film are bonded is formed on a first film 1 as a transparent protective film, a transparent protective film or a PET substrate, And a second laminated film (2) in which a polarizer is laminated with an adhesive layer interposed therebetween as needed, via an adhesive layer comprising a cured layer of an adhesive composition. In the present embodiment, the polarizing surface of the second laminated film 2 is set as a coherent surface, and an example of applying the adhesive composition to such a coherent surface is shown.

In the manufacturing method according to the present invention, it is possible to manufacture an optical film in which foreign substances are effectively prevented from being generated in the adhesive layer, so that a particularly thin optical film, It is suitable for manufacturing. Therefore, the thickness of the first film and the second film (in this embodiment, the first film is the protective film and the second film is the laminated film of the PET base + polarizer) is preferably 60 占 퐉 or less, more preferably 40 占 퐉 or less Do. Further, when the total thickness of the polarizing film is 100 m or less, the thickness of the polarizing film is thin, so that appearance defects due to foreign substances in the adhesive layer often become a problem. However, in the manufacturing method according to the present invention, it is possible to produce an optical film in which foreign substances are effectively prevented from being generated in the adhesive layer. Therefore, when a thin polarizing film having a total thickness of 100 m or less is produced, It is preferable in the case of producing a thin polarizing film having a thickness of 탆 or less. In the case of producing a thin polarizing film in the present invention, occurrence of appearance defects can be effectively prevented even when a thin polarizing film including a thin polarizer having a thickness of 10 m or less is produced.

The polarizer is not particularly limited, and various polarizers can be used. As the polarizer, for example, a dichromatic material such as iodine or a dichroic dye is adsorbed on a hydrophilic polymer film such as a polyvinyl alcohol film, a partially porous polyvinyl alcohol film or an ethylene / vinyl acetate copolymerization system partial saponification film A monoaxially stretched film, a dehydrated polyvinyl alcohol or a dehydrochlorinated polyvinyl chloride film, and the like. Among them, a polarizer comprising a polyvinyl alcohol-based film and a dichromatic material such as iodine is preferable. The thickness of these polarizers is not particularly limited, but is generally about 80 占 퐉 or less.

The polarizer obtained by dyeing a polyvinyl alcohol film with iodine and uniaxially stretching can be produced by, for example, dying polyvinyl alcohol in an aqueous solution of iodine and stretching it to 3 to 7 times its original length. If necessary, it may be immersed in an aqueous solution of boric acid, potassium iodide or the like. If necessary, the polyvinyl alcohol film may be dipped in water and washed with water before dyeing. The polyvinyl alcohol film is washed with water to clean the surface of the polyvinyl alcohol film and to prevent unevenness such as uneven dyeing by swelling the polyvinyl alcohol film. The stretching may be carried out after dyeing with iodine, stretching while dyeing, and dyeing with iodine after stretching. It can be stretched in an aqueous solution such as boric acid or potassium iodide or in a water bath.

As the polarizer, a thin polarizer having a thickness of 10 탆 or less can be used. From the viewpoint of thinning, the thickness is preferably 1 to 7 mu m. Such a thin polarizer is preferable because it is excellent in durability because thickness irregularity is small, visibility is excellent, and dimensional change is small, and further thickness and thickness can be achieved as a polarizing film.

Examples of the thin polarizer include a polarizer disclosed in JP-A-51-069644, JP-A 2000-338329, WO2010 / 100917, PCT / JP2010 / 001460, And a thin polarizer described in Japanese Patent Application No. 2010-263692. These thin polarizers can be obtained by a manufacturing method including a step of stretching a layer of a polyvinyl alcohol-based resin (hereinafter also referred to as a PVA-based resin) and a lead resin base material in the form of a laminate, and a step of dyeing. With this method, even if the PVA-based resin layer is thin, it can be stretched without problems such as breakage due to stretching because it is supported on the resin base material for drawing.

As the thin polarizers, WO2010 / 100917 pamphlet and PCT / JP201010 can be used as the thin polarizers in that they can be stretched at a high magnification and can improve the polarization performance even in a process including a step of drawing in a laminate state and a step of dyeing. In Japanese Patent Application No. 2010-269002 or in Japanese Patent Application No. 2010-263692, which is disclosed in Japanese Patent Application No. 2010-269002 And a step of auxiliary drawing publicly before stretching in an aqueous boric acid solution described in the specification or Japanese Patent Application No. 2010-263692.

The thin, high-performance polarizer disclosed in the specification of PCT / JP2010 / 001460 is a thin, highly functional polarizer made of a PVA-based resin in which a dichromatic substance is aligned and formed integrally on a resin substrate and having a thickness of 7 μm or less, A transmittance of 42.0% or more, and a polarization degree of 99.95% or more.

The thin, highly functional polarizer is produced by applying a PVA resin to a resin base material having a thickness of at least 20 탆 and drying the PVA base resin layer, and immersing the resulting PVA resin layer in a dyeing solution of a dichroic substance The PVA resin layer in which the dichromatic material is adsorbed to the PVA resin layer and the dichroic material is adsorbed can be prepared by stretching the PVA resin layer together with the resin base material in the aqueous boric acid solution so that the total draw ratio becomes 5 times or more the original length have.

Also disclosed is a method for producing a laminated film comprising a thin, highly functional polarizer in which a dichroic substance is oriented, comprising the steps of: applying a resinous base material having a thickness of at least 20 mu m and an aqueous solution containing a PVA- And a PVA resin layer formed on one side of the resin base material is immersed in a dyeing solution containing a dichroic substance, A step of adsorbing the dichroic substance to the PVA resin layer contained in the laminate film and a step of forming the laminated film including the PVA resin layer on which the dichroic substance is adsorbed by the adsorption of the dichroic substance in the aqueous boric acid solution And a step of stretching the PVA resin layer in which the dichroic substance is adsorbed so as to be at least 5 times the original length, A laminated film having a thickness of 7 탆 or less, a single-layer transmittance of 42.0% or more, and a polarization degree of 99.95% or more and having a thin-shaped high-performance polarizer formed on the PVA resin layer with a dichroic substance oriented on one side thereof is produced By including the step, the thin, highly functional polarizer can be produced.

The thin polarizers disclosed in the specification of Japanese Patent Application No. 2010-269002 and the specification of Japanese Patent Application No. 2010-263692 are polarizers of a continuous web made of a PVA resin in which dichromatic materials are oriented, And the PVA resin layer is stretched by a two-step stretching process comprising air-assisted stretching and boric acid in-water stretching so that the thickness of the laminate is not more than 10 占 퐉. Such a thin polarizer satisfies the condition of P &gt; - (100.929 T - 42.4 - 1) x 100 (where T <42.3) and P ≥99.9 (however, T ≥ 42.3) when the simple transmittance is T and the polarization degree is P Is satisfied.

Specifically, the thin polarizer includes a step of producing a drawn intermediate product comprising a PVA-based resin layer oriented by public high-temperature stretching to a PVA-based resin layer formed on an amorphous ester-based thermoplastic resin base material of a continuous web , A step of producing a colored intermediate product comprising a PVA-based resin layer in which a dichroic substance (preferably a mixture of iodine or iodine and an organic dye) is oriented by adsorption of a dichroic substance to the drawn intermediate product, And a step of producing a polarizer having a thickness of 10 占 퐉 or less and made of a PVA-based resin layer in which a dichroic substance is oriented by stretching boric acid in water on the product.

In this production method, it is preferable that the total draw ratio of the PVA-based resin layer formed on the amorphous ester-based thermoplastic resin base material by public hot drawing and boric acid in water drawing is 5 times or more. Boric acid The liquid temperature of the boric acid aqueous solution for in-water elongation can be 60 占 폚 or higher. It is preferable to carry out the insolubilization treatment with respect to the colored intermediate product before stretching the colored intermediate product in the aqueous solution of boric acid. In this case, the colored intermediate product is preferably immersed in an aqueous boric acid solution having a liquid temperature not exceeding 40 캜 desirable. The amorphous ester thermoplastic resin base material may be a copolymerized polyethylene terephthalate copolymerized with isophthalic acid, a copolymerized polyethylene terephthalate copolymerized with cyclohexane dimethanol, or an amorphous polyethylene terephthalate containing other copolymerized polyethylene terephthalate, The thickness of the PVA-based resin layer is preferably 7 times or more the thickness of the PVA-based resin layer to be formed. The stretching magnification of the air high-temperature stretching is preferably 3.5 times or less, and the stretching temperature of the public high-temperature stretching is preferably not lower than the glass transition temperature of the PVA-based resin, specifically 95 ° C to 150 ° C. When the public high temperature stretching is carried out by free uniaxial stretching, the total stretching ratio of the PVA resin layer formed on the amorphous ester thermoplastic resin base material is preferably 5 times or more and 7.5 times or less. When the public high-temperature stretching is carried out by a fixed single uniaxial stretching, the total stretching ratio of the PVA-based resin layer formed on the amorphous ester-based thermoplastic resin base is preferably 5 times or more and 8.5 times or less.

More specifically, a thin polarizer can be produced by the following method.

A substrate of continuous web of isophthalic acid copolymerized polyethylene terephthalate (amorphous PET) in which 6 mol% of isophthalic acid is copolymerized is prepared. The glass transition temperature of the amorphous PET is 75 캜. A laminate composed of an amorphous PET substrate and a polyvinyl alcohol (PVA) layer of a continuous web is produced as follows. Incidentally, the glass transition temperature of PVA is 80 占 폚.

An amorphous PET substrate having a thickness of 200 탆 and a PVA aqueous solution having a polymerization degree of 1000 or more and a PVA powder having a degree of saponification of 99% or more dissolved in water at a concentration of 4 to 5% are prepared. Next, a PVA aqueous solution is applied to an amorphous PET substrate having a thickness of 200 mu m and dried at a temperature of 50 to 60 DEG C to obtain a laminate having a PVA layer having a thickness of 7 mu m formed on an amorphous PET substrate.

A laminate including a PVA layer having a thickness of 7 占 퐉 is subjected to the following steps including a two-step stretching process of air-assisted stretching and boric acid in-water stretching to produce a thin, highly functional polarizer having a thickness of 3 占 퐉. A laminate including a PVA layer having a thickness of 7 占 퐉 is integrally stretched with an amorphous PET substrate by an air assisted stretching process of the first stage to produce a stretched laminate including a PVA layer having a thickness of 5 占 퐉. Specifically, the stretched laminate was obtained by stretching a laminate including a PVA layer having a thickness of 7 탆 to a stretching apparatus placed in an oven set at a stretching temperature environment of 130 캜, stretching it in a single free- It is. By this stretching treatment, the PVA layer contained in the stretched laminate is changed to a PVA layer having a thickness of 5 탆 in which the PVA molecules are oriented.

Next, a colored layered product in which iodine is adsorbed to a PVA layer having a thickness of 5 占 퐉 in which PVA molecules are oriented is produced by a dyeing step. Specifically, this colored layered product is obtained by laminating the drawn laminate to a dyeing solution containing iodine and potassium iodide at a liquid temperature of 30 占 폚, so that the ultimate transmittance of the PVA layer constituting the highly functional polarizer finally produced is 40 to 44% So that iodine is adsorbed on the PVA layer contained in the stretched laminate. In this step, the dyeing solution is adjusted to have an iodine concentration of 0.12 to 0.30% by weight and a potassium iodide concentration of 0.7 to 2.1% by weight with water as a solvent. The ratio of iodine to potassium iodide is 1 to 7. In addition, potassium iodide is required to dissolve iodine in water. More specifically, the drawn laminate was immersed in a dyeing solution having an iodine concentration of 0.30% by weight and a potassium iodide concentration of 2.1% by weight for 60 seconds to obtain a colored laminate in which iodine was adsorbed on a PVA layer having a thickness of 5 탆 .

In addition, the colored laminate is further stretched integrally with the amorphous PET substrate by a second stage boric acid in-water stretching process to produce an optical film laminate including a PVA layer constituting a highly functional polarizer having a thickness of 3 占 퐉 . Specifically, this optical film laminate was obtained by hanging a colored laminate on a stretching apparatus arranged in a treating apparatus set in a boric acid aqueous solution having a liquid temperature range of 60 to 85 DEG C containing boric acid and potassium iodide to give a draw ratio of 3.3, It is stretched in one axis. More specifically, the liquid temperature of the aqueous solution of boric acid is 65 캜. It also has a boric acid content of 4 parts by weight based on 100 parts by weight of water and a potassium iodide content of 5 parts by weight based on 100 parts by weight of water. In the present step, the colored laminate having the iodine adsorption amount adjusted is first immersed in an aqueous solution of boric acid for 5 to 10 seconds. Then, the colored laminate is passed through a plurality of rolls of different treads, which are the stretching apparatuses arranged in the processing apparatus, and stretched in uniaxial stretching so that the stretching magnification is 3.3 times over 30 to 90 seconds. By this stretching treatment, the PVA layer contained in the colored laminate is changed to a PVA layer having a thickness of 3 탆 which is highly oriented in one direction as adsorbed iodine as a polyiodide ion complex. This PVA layer constitutes a highly functional polarizer of the optical film laminate.

The optical film laminate is taken out from the aqueous solution of boric acid by a washing step and the boric acid adhered to the surface of the 3 mu m thick PVA layer formed on the amorphous PET substrate is treated with potassium iodide It is preferable to wash it with an aqueous solution. Then, the cleaned optical film laminate is dried by a drying process by hot air at 60 캜. The cleaning step is a step for eliminating appearance defects such as boric acid precipitation.

Likewise, although it is not necessarily an essential step in the production of an optical film laminate, an adhesive is applied to the surface of a 3 占 퐉 -thick PVA layer formed on an amorphous PET substrate by an adhesion and / or a transfer process, Of triacetylcellulose film, and then the amorphous PET substrate is peeled off to transfer the PVA layer having a thickness of 3 占 퐉 to the triacetylcellulose film having a thickness of 80 占 퐉.

[Other processes]

The manufacturing method of the above-described thin polarizer may include other processes in addition to the above processes. Examples of the other steps include an insolubilization step, a crosslinking step, and a drying step (controlling the water content). Other processes can be carried out at any appropriate timing. The above-mentioned insolubilization step is typically performed by immersing a PVA-based resin layer in an aqueous solution of boric acid. By carrying out the insolubilization treatment, it is possible to impart water resistance to the PVA-based resin layer. The concentration of the boric acid aqueous solution is preferably 1 to 4 parts by weight based on 100 parts by weight of water. The liquid temperature of the insoluble body (aqueous solution of boric acid) is preferably 20 ° C to 50 ° C. Preferably, the insolubilization step is carried out after the laminate is produced, before the dyeing step or the underwater stretching step. Typically, the crosslinking step is carried out by immersing the PVA resin layer in an aqueous solution of boric acid. By carrying out the crosslinking treatment, it is possible to impart water resistance to the PVA-based resin layer. The concentration of the boric acid aqueous solution is preferably 1 to 4 parts by weight based on 100 parts by weight of water. Further, in the case of performing the crosslinking step after the dyeing step, it is preferable to further add iodide. By combining iodide, the elution of iodine adsorbed to the PVA-based resin layer can be suppressed. The blending amount of iodide is preferably 1 part by weight to 5 parts by weight based on 100 parts by weight of water. Specific examples of the iodide are as described above. The liquid temperature of the crosslinking bath (boric acid aqueous solution) is preferably 20 ° C to 50 ° C. Preferably, the crosslinking step is carried out in the second boric acid aqueous solution before the stretching step. In a preferred embodiment, the dyeing step, the crosslinking step and the second boric acid in water step are carried out in this order.

As a material for forming the transparent protective film formed on one side or both sides of the polarizer, it is preferable that the material is excellent in transparency, mechanical strength, thermal stability, moisture barrier property, isotropy and the like. For example, a polyester polymer such as polyethylene terephthalate or polyethylene naphthalate, a cellulose polymer such as diacetylcellulose or triacetylcellulose, an acryl polymer such as polymethyl methacrylate, a polystyrene or an acrylonitrile / styrene copolymer (AS resin), and polycarbonate-based polymers. Examples of the polymer include polyolefin polymers such as polyethylene, polypropylene, cycloolefin or norbornene structure, polyolefin polymers such as ethylene / propylene copolymer, vinyl chloride polymers, amide polymers such as nylon and aromatic polyamide, imide polymers, Based polymers, polyether sulfone-based polymers, polyetheretherketone-based polymers, polyphenylene sulfide-based polymers, vinyl alcohol-based polymers, vinylidene chloride-based polymers, vinyl butyral-based polymers, arylate- An epoxy-based polymer, or a blend of the above polymer may be mentioned as an example of the polymer forming the transparent protective film. The transparent protective film may contain one or more optional additives. Examples of the additive include an ultraviolet absorber, an antioxidant, a lubricant, a plasticizer, a release agent, a coloring inhibitor, a flame retardant, a nucleating agent, an antistatic agent, a pigment and a colorant. The content of the thermoplastic resin in the transparent protective film is preferably 50 to 100% by weight, more preferably 50 to 99% by weight, still more preferably 60 to 98% by weight, particularly preferably 70 to 97% by weight . When the content of the thermoplastic resin in the transparent protective film is 50 wt% or less, there is a fear that the transparency inherently possessed by the thermoplastic resin can not be sufficiently expressed.

Examples of the transparent protective film include a polymer film described in Japanese Patent Application Laid-Open No. 2001-343529 (WO01 / 37007), for example, a thermoplastic resin having a substituted and / or unsubstituted imide group in the side chain (A) And a thermoplastic resin having a substituted and / or unsubstituted phenyl and nitrile groups in the side chain of the resin (B). Specific examples include films of resin compositions containing an alternating copolymer of isobutylene and N-methylmaleimide and an acrylonitrile / styrene copolymer. The film may be a film comprising a mixed extruded product of the resin composition or the like. Since these films have a small retardation and a small photoelastic coefficient, problems such as non-uniformity due to deformation of the polarizing film can be solved, and the moisture permeability is small, and thus the durability against humidification is excellent.

Though the thickness of the transparent protective film can be suitably determined, it generally ranges from 1 to 500 占 퐉 in terms of workability such as strength and handling properties, and thin layer properties. Particularly preferably 20 to 80 mu m, and more preferably 30 to 60 mu m.

When a transparent protective film is formed on both sides of the polarizer, a transparent protective film made of the same polymer material may be used for the front and back sides, or a transparent protective film made of a different polymer material or the like may be used.

On the surface of the transparent protective film on which the polarizer is not adhered, a functional layer such as a hard coat layer, an antireflection layer, a sticking prevention layer, a diffusion layer, or an antiglare layer can be formed. The functional layer such as the hard coat layer, the antireflection layer, the anti-sticking layer, the diffusion layer, and the antiglare layer may be formed on the transparent protective film itself or may be formed separately from the transparent protective film have.

The polarizing film of the present invention can be used as an optical film laminated with another optical layer in practical use. The optical layer is not particularly limited. For example, a liquid crystal display device such as a reflection plate, a semitransmissive plate, a retardation plate (including a wave plate of 1/2 or 1/4) One or more optical layers that may be used may be used. In particular, a reflection type polarizing film or a semi-transmission type polarizing film in which a reflection plate or a transflective reflection plate is further laminated on the polarizing film of the present invention, an elliptically polarizing film or a circularly polarizing film laminated with a retardation film in addition to the polarizing film, A polarizing film in which a time compensating film is further laminated, or a polarizing film in which a luminance improving film is laminated in addition to a polarizing film.

The optical film obtained by laminating the optical layers on the polarizing film may be formed by sequentially laminating them separately in the process of manufacturing a liquid crystal display or the like. And the like are advantageous in that the manufacturing process of the liquid crystal display device and the like can be improved. Appropriate adhesion means such as a pressure-sensitive adhesive layer can be used for the lamination. When the above polarizing film or other optical film is adhered, the optical axis thereof can be set at an appropriate arrangement angle in accordance with the objective retardation property and the like.

A pressure-sensitive adhesive layer for bonding to another member such as a liquid crystal cell can be formed on the above-mentioned polarizing film or an optical film in which at least one polarizing film is laminated. The pressure-sensitive adhesive for forming the pressure-sensitive adhesive layer is not particularly limited. For example, a polymer such as an acrylic polymer, a silicone polymer, a polyester, a polyurethane, a polyamide, a polyether, have. Particularly, an acrylic pressure-sensitive adhesive which is excellent in optical transparency, exhibits appropriate wettability, cohesiveness and adhesive property, and is excellent in weather resistance and heat resistance can be preferably used.

The pressure-sensitive adhesive layer may be formed on one side or both sides of a polarizing film or an optical film as a superposition layer of a different composition or kind. Further, in the case of forming on both sides, a pressure-sensitive adhesive layer of different composition, kind, thickness, etc. may be formed on the front and back of the polarizing film or the optical film. The thickness of the pressure-sensitive adhesive layer can be appropriately determined depending on the purpose of use and the adhesive force, and is generally 1 to 500 占 퐉, preferably 1 to 200 占 퐉, particularly preferably 1 to 100 占 퐉.

The exposed surface of the pressure-sensitive adhesive layer is covered with a separator for the purpose of preventing contamination during practical use. This makes it possible to prevent contact with the pressure-sensitive adhesive layer in a conventional handling state. As the separator, a suitable thin film such as a plastic film, a rubber sheet, a paper, a cloth, a nonwoven fabric, a net, a foam sheet, a metal foil and a laminate thereof may be used, And a material obtained by coating with an appropriate stripping agent such as an alkyl-based, fluorine-based or molybdenum sulfide, may be used.

The polarizing film or optical film of the present invention can be suitably used for the formation of various devices such as a liquid crystal display device. The formation of the liquid crystal display device can be carried out conventionally. That is, the liquid crystal display device is generally formed by appropriately assembling components such as a liquid crystal cell, a polarizing film or an optical film, and an illumination system as needed, and mounting a driving circuit. However, in the present invention, There is no particular limitation except for the use of a polarizing film or an optical film produced by a conventional method. As for the liquid crystal cell, any type of TN type, STN type, or π type, for example, can be used.

A suitable liquid crystal display device such as a liquid crystal display device in which a polarizing film or an optical film is disposed on one side or both sides of the liquid crystal cell and a backlight or a reflector is used in the illumination system can be formed. In this case, the polarizing film or the optical film according to the present invention can be provided on one side or both sides of the liquid crystal cell. When polarizing films or optical films are formed on both sides, they may be the same or different. In forming a liquid crystal display device, a suitable part such as a diffusion plate, an anti-glare layer, an antireflection film, a protective plate, a prism array, a lens array sheet, a light diffusion plate, a backlight, Or more.

Example

Hereinafter, embodiments of the present invention will be described, but the embodiments of the present invention are not limited thereto. The &quot; parts by weight &quot; in the composition means the number of parts when the total amount of the composition is 100 parts by weight.

(1) Adjustment of adhesive composition

&Lt; Preparation of active energy ray-curable adhesive composition &gt;

, 38.5 parts by weight of HEAA (hydroxyethyl acrylamide) (Kyogin Kasei), 20.0 parts by weight of Aronix M-220 (tripropylene glycol diacrylate) [manufactured by Toa Synthetic Chemical Industry], ACMO (acryloylmorpholine) 38.5 parts by weight of KAYACURE DETX-S (diethylthioxanthone) [manufactured by Nippon Kayaku Co., Ltd.], 1.5 parts by weight of IRGACURE 907 (2-methyl-1- (4-methylthiophenyl) 1-one) [manufactured by BASF Co., Ltd.] were mixed and stirred at 50 ° C for 1 hour to obtain an active energy ray curable adhesive.

&Lt; Adjustment of polyvinyl alcohol-based adhesive composition &gt;

50 parts of methylol melamine was added to 100 parts of a polyvinyl alcohol-based resin (average degree of polymerization: 1200, saponification degree: 98.5 mol%, acetoacetylation degree: 5 mol%) containing an acetoacetyl group in pure water To prepare an aqueous solution adjusted to have a solid content concentration of 3.7%. 18 parts of an alumina colloid aqueous solution (average particle diameter of 15 nm, solid content concentration of 10%, static electricity) was added to 100 parts of the aqueous solution to prepare an aqueous adhesive solution.

&Lt; Organic solvent-based adhesive composition &gt;

CEMEDINE 198L (manufactured by CEMEDA INC.) Was used.

(2) Fabrication of a thin polarizer

In order to manufacture a thin polarizer, first, a laminate having a PVA layer with a thickness of 24 占 퐉 formed on an amorphous PET substrate was subjected to air-assisted stretching at a stretching temperature of 130 占 폚 to produce a stretched laminate, The colored layered product was further subjected to stretching in boric acid water at a stretching temperature of 65 ° C to give a total stretch ratio of 5.94, and a layer of PVA 10 μm thick integrally stretched with the amorphous PET substrate To thereby produce an optical film laminate. In such a two-stage stretching, the PVA molecules of the PVA layer formed on the amorphous PET substrate are oriented at a high degree, and the iodine adsorbed by the dyeing constitutes a thin polarizer in which the poly iodide ion complex is highly oriented in one direction. An optical film laminate (second film (total thickness 40 占 퐉)) including the PVA layer having a thickness of 5 占 퐉 could be produced.

As the first film, a transparent protective film (thickness: 40 mu m) made of a (meth) acrylic resin having a lactone ring structure was used.

Example 1

In the line shown in Figs. 1 and 2, a gravure roll coating system 10 (MCD coater (manufactured by Fuji Machinery Co., Ltd.) (cell shape: honeycomb mesh pattern, number of cell lines of gravure roll: 1000 The adhesive composition 3 is applied to both the coplanar surface of the first film 1 and the coplanar surface of the second film 2 by using the extruder 1 and the extruder 2 in the same manner as in Example 1, The adhesive composition (3) was applied onto the second film (2) composed of the PET base material and the thin polarizer so that the thin polarizing film surface was a cohesive surface. The adhesive composition (3) And applied to the first film and the second film so that the thickness of the adhesive layer was 1 占 퐉. The gravure roll coating method (10) used was a method of using a foreign substance removing function (a foreign substance removing method using a filter) Respectively.

<Active energy ray>

(A gallium-encapsulated metal halide lamp) irradiation apparatus: Light HAMMER 10 manufactured by Fusion UV Systems, Inc., valve: V-valve, peak illuminance: 1600 mW / cm 2, The optical film was prepared by curing the adhesive composition (3) using an integrated irradiation amount: 1000 / mJ / cm 2 (wavelength: 380 to 440 nm). The illuminance of the ultraviolet ray was measured using a Sola-Check system manufactured by Solatell.

Examples 2 to 9 and Comparative Examples 1 to 6

The types of the adhesive composition for bonding the first film and the second film, the presence or absence of application of the adhesive composition to the first film and / or the second film, the type of the post-metering application method, and the formation pattern of the gravure roll surface are shown in Table 1 The optical film was produced in the same manner as in Example 1, In the bar coater application method and the air knife application method, a commercially available coating device was used.

&Lt; Method of counting the number of foreign substances in the adhesive layer &gt;

The number of appearance defects (number of external defects originating from foreign matters and appearance defects originating from (bonded) bubbles (number / m 2)) in the adhesive layer of the polarizing film was counted by visual inspection and reflection inspection using an automatic inspection apparatus. The results are shown in Table 1.

Figure 112015047987498-pct00001

Claims (10)

A method for producing an optical film comprising a laminate structure in which at least a first film and a second film are bonded via an adhesive layer or a pressure-sensitive adhesive layer comprising a cured layer of an adhesive composition or a pressure-
And a coating step of removing foreign matter and / or air bubbles by applying the adhesive composition or the pressure-sensitive adhesive composition to both of the concave surface of the first film and the concave surface of the second film by using a post-metering coating method Wherein the optical film has a thickness of 10 to 100 nm. The method according to claim 1,
The adhesive composition or the pressure-sensitive adhesive composition is applied by circulating the adhesive composition or the pressure-sensitive adhesive composition in a subsequent metering application method, and the adhesive composition or the pressure-sensitive adhesive composition is applied to the adhesive composition or the pressure-sensitive adhesive composition from the first film and / And removing the foreign substance from the pressure-sensitive adhesive composition. The method according to claim 1,
Wherein the coating method is a gravure roll coating method using a gravure roll. The method of claim 3,
Wherein the rotating direction of the gravure roll and the traveling direction of the first film and the second film are opposite to each other. The method of claim 3,
Wherein the pattern formed on the surface of the gravure roll is a honeycomb pattern. The method of claim 3,
Wherein the rotating speed ratio of the gravure roll to the advancing speed of the first film and the second film is 100 to 300%. 7. The method according to any one of claims 1 to 6,
Wherein the first film is a transparent protective film and the second film is a polarizer. 8. The method of claim 7,
Wherein the thickness of the polarizer is 10 占 퐉 or less. An optical film produced by the manufacturing method according to any one of claims 1 to 6. An image display apparatus characterized by using the optical film according to claim 9.
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