KR20200115195A - Method for producing optical laminate - Google Patents

Abstract

The present invention relates to a method of manufacturing an optical laminate, capable of suppressing occurrence of foreign substances derived from a material constituting the optical laminate. According to the present invention, the method of manufacturing an optical laminate includes: an antistatic conveyance step (A) of conveying a base film-attached polymer layer (6) in a longitudinal direction while performing an antistatic function on the base film-attached polymer layer (6); a bonding step (B) of bonding an optical film (1) to a polymer layer (2) through an adhesive or adhesive layer (3) to obtain a base film-attached optical laminate (7); a peeling step (C) of peeling a base film (5) from the base film-attached optical laminate (7) to obtain an optical laminate (4); and a base film antistatic conveyance step (D) of conveying the base film (5) in the longitudinal direction performing the antistatic function on the base film (5).

Description

The manufacturing method of an optical laminated body {METHOD FOR PRODUCING OPTICAL LAMINATE}

The present invention relates to a method for producing an optical laminate.

Conventionally, in the production of various polymer films used in the optical field, the so-called roll-to-roll method, which is a mass production method with good production efficiency, that can continuously process until the final product using a strip-shaped substrate wound in a roll shape. Is widely adopted. For example, Patent Document 1 describes a method of manufacturing an optical film by stretching in the longitudinal direction while transporting a long polymer film. In addition, in Patent Documents 2 and 3, a method of forming a hard coat layer or a metal film on a film conveyed by a roll-to-roll method is described. In these methods, for the purpose of preventing the occurrence of scratches on a film or a layer or film formed on the film, it is described that a step of static electricity elimination is included so that the amount of charge of the film during transport becomes less than or equal to a predetermined value. .

[Patent Document 1] Japanese Patent Application Laid-Open No. 2017-39291 [Patent Document 2] Japanese Patent Application Laid-Open No. 2015-196322 [Patent Document 3] Japanese Patent Application Laid-Open No. 2014-214365

Optical laminates, such as an elliptically polarizing plate, can be manufactured by laminating various optical films, such as a retardation film and a polarizing film. Manufacture of an optical laminate used in such an optical field is usually carried out in a clean room with few foreign matters floating in the air in order to prevent mixing of foreign matters. However, during the lamination process of the optical film, the end of the optical film may be peeled off, and the peeled film piece becomes a foreign material and adheres to the outer surface of the obtained optical laminate, thereby causing defects in the optical laminate obtained. When foreign matter, such as a piece of film, remains in the clean room, there is a possibility that continuous defects may occur in the optical laminate to be manufactured thereafter by the residual foreign matter.

For this reason, in the manufacturing process of an optical laminated body, it is necessary to reduce the residual amount of foreign matters in the clean room as much as possible in addition to preventing the occurrence of scratches on the optical laminate itself during manufacture by foreign matters. On the other hand, with recent thinning of image display devices, optical films such as retardation films including a liquid crystal cured film obtained by coating a polymerizable liquid crystal compound on a substrate or an alignment film and curing in an alignment state have been developed. In an optical film including such a liquid crystal cured film, it has been found that particularly, the end of the liquid crystal cured film is peeled off and is likely to cause foreign matter to be generated.

In addition, in the manufacturing process of a long optical laminate, in order to suppress the occurrence of cross-sectional misalignment when the optical laminate is wound in a roll shape, a slit that cuts off both ends in the width direction of the laminate to match the width of the laminate. There is a case to provide a process. The inventors of the present invention have newly discovered that in the manufacturing process of an optical layered product including such a slit process, foreign matters such as film pieces due to cutting or peeling are more likely to occur, and the occurrence of defects in the optical layered product is more likely to occur. It was discovered, and in the manufacturing process of an optical laminated body including a slit process, it was discovered that it is necessary to suppress the generation|occurrence|production of a foreign matter itself in addition to reducing the residual amount of a foreign matter at the manufacturing site.

The present invention suppresses the generation of foreign matters originating from the material constituting the optical laminate during the manufacturing process of the optical laminate including the slit process, and further reduces the amount of foreign matter remaining at the manufacturing site. It is an object of the present invention to provide a method for producing a sieve.

The present invention is to provide the following suitable aspects.

[1] An optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound are provided, and the polymer layer (2) comprises the optical film (1) and an adhesive or adhesive layer (3). As a method of manufacturing the optical laminate 4 obtained by lamination through,

Attaching a long base film comprising a long base film 5 and the polymer layer 2 laminated on the base film 5, the base film 5 being peelable from the polymer layer 2 The polymer layer with a base film antistatic conveyance process (A) which conveys the polymer layer 6 in the longitudinal direction while antistatic,

With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) A bonding step (B) for obtaining an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2, and

Along with the peeling process (C) of peeling the said base film 5 from the optical laminated body 7 with a base film obtained in said bonding process (B), and obtaining the said optical laminated body 4,

Including a base film static elimination conveyance process (D) conveying in the longitudinal direction while static electricity elimination of the base film 5 after peeling off in the said peeling process (C),

The said polymer layer with base film antistatic conveyance process (A) includes a polymer layer slit process with a base film (SA) which cuts and cuts the end part of the said polymer layer with base film 6 in a conveyance direction, or,

The bonding step (B) includes an optical film slit step (SB1) in which the end portion of the optical film 1 before bonding with the polymer layer 6 with a base film is cut in the conveyance direction and cut out, or

The bonding step (B) cuts the end of the optical layered body 7 with the base film after bonding with the polymer layer 6 with a base film in the conveyance direction, and cuts it out. ), and

The absolute value of the charge amount of the polymer layer with a base film 6 after static elimination in the polymer layer with base film antistatic transfer step (A) is 0.01 kV or more and 6 kV or less, or the base film antistatic transfer step (D ), the absolute value of the charge amount of the base film 5 after antistatic is 0.01 kV or more and 6 kV or less

Method for producing the optical laminate.

[2] An optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound are provided, and the polymer layer (2) comprises the optical film (1) and an adhesive or adhesive layer (3). As a method of manufacturing the optical laminate 4 obtained by lamination through,

Attaching a long base film comprising a long base film 5 and the polymer layer 2 laminated on the base film 5, the base film 5 being peelable from the polymer layer 2 The polymer layer with a base film antistatic conveyance process (A) which conveys the polymer layer 6 in the longitudinal direction while antistatic,

With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) A bonding step (B) for obtaining an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2, and

Along with the peeling process (C) of peeling the said base film 5 from the optical laminated body 7 with a base film obtained in said bonding process (B), and obtaining the said optical laminated body 4,

Including a base film static elimination conveyance process (D) conveying in the longitudinal direction while static electricity elimination of the base film 5 after peeling off in the said peeling process (C),

The said polymer layer with base film antistatic conveyance process (A) includes a polymer layer slit process (SA) with a base film in which an end portion of the polymer layer with base film 6 is cut out in a conveyance direction,

The absolute value of the charge amount of the polymer layer 6 with the base film after static elimination in the antistatic transfer step (A) of the polymer layer with a base film is 0.01 kV or more and 6 kV or less

Method for producing the optical laminate.

[3] The manufacturing method according to [2], wherein the absolute value of the charge amount of the base film 5 after static elimination in the base film antistatic conveyance step (D) is 0.01 kV or more and 6 kV or less.

[4] The production method according to [2] or [3], wherein the polymer layer (2) is included at an end portion cut out in the polymer layer slit step (SA) with a base film.

[5] An optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound are provided, and the polymer layer (2) comprises the optical film (1) and an adhesive or adhesive layer (3). As a method of manufacturing the optical laminate 4 obtained by lamination through,

Attaching a long base film comprising a long base film 5 and the polymer layer 2 laminated on the base film 5, the base film 5 being peelable from the polymer layer 2 The polymer layer with a base film antistatic conveyance process (A) which conveys the polymer layer 6 in the longitudinal direction while antistatic,

With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) A bonding step (B) for obtaining an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2, and

Along with the peeling process (C) of peeling the said base film 5 from the optical laminated body 7 with a base film obtained in said bonding process (B), and obtaining the said optical laminated body 4,

Including a base film static elimination conveyance process (D) conveying in the longitudinal direction while static electricity elimination of the base film 5 after peeling off in the said peeling process (C),

The bonding step (B) includes an optical film slit step (SB1) in which the end portion of the optical film 1 before bonding with the polymer layer 6 with a base film is cut in the conveyance direction and cut out, or

The bonding step (B) cuts the end of the optical layered body 7 with the base film after bonding with the polymer layer 6 with a base film in the conveyance direction, and cuts it out. ), and

The absolute value of the charge amount of the polymer layer with a base film 6 after static elimination in the polymer layer with base film antistatic transfer step (A) is 0.01 kV or more and 6 kV or less, or the base film antistatic transfer step (D ), the absolute value of the charge amount of the base film 5 after antistatic is 0.01 kV or more and 6 kV or less

Method for producing the optical laminate.

[6] Including the optical laminate slit step (SB2) with the base film,

The manufacturing method according to the above [5], wherein the polymer layer (2) is included in the end portion to be cut in this step (SB2).

[7] Polymer layer with base film In the polymer layer 6 with base film provided in the antistatic transfer step (A), the polymer layer 2 is the base material over the entire width direction of the polymer layer 2 The production method according to any one of [1] to [6], which is provided on the film 5 and has a width of the base film 5 wider than that of the polymer layer 2.

[8] Polymer layer with base film In the polymer layer (6) with base film provided in the antistatic transfer step (A), the polymer layer (2) is provided on the base film (5) through the alignment layer (8). Is laminated, the alignment layer 8 is laminated on the base film 5 over the entire width direction, and the width of the base film 5 is wider than the width of the alignment layer 8 [ The production method according to any one of 1] to [7].

[9] The width of the polymer layer (2) of the polymer layer (6) with a base film provided in the bonding step (B) is the polymer layer (6) with the base film and the optical film (1) in the bonding step (B). The production method according to any one of [1] to [8] above, which is wider than the width of the pressure-sensitive adhesive or adhesive layer (3) formed to bond).

[10] In the polymer layer (6) with a base film provided in the bonding step (B), the polymer layer (2) is laminated on the base film (5) through an orientation layer (8), and the orientation [1] The width of the layer (8) is wider than that of the pressure-sensitive adhesive or adhesive layer (3) formed to bond the polymer layer (6) with the base film and the optical film (1) in this bonding step (B). The production method according to any one of] to [9].

[11] A long base film (5) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound laminated on the base film (5) is provided, and the base film (5) is the polymer As a method of conveying the polymer layer 6 with a long base film which can be peeled off from the layer 2 in the longitudinal direction while being charged,

A polymer layer with a base film slit step (SA) in which an end portion of the polymer layer 6 with a base film is cut and cut in a conveyance direction,

A method of conveying a polymer layer with a base film in which the absolute value of the charge amount of the polymer layer 6 with a base film after antistatic is 0.01 kV or more and 6 kV or less.

[12] A long base film (5), a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound, and a long optical bonded on the polymer layer (2) through an adhesive or an adhesive layer (3) As a method of manufacturing an optical laminate 7 with a long base film including a film 1, wherein the base film 5 is peelable from the polymer layer 2,

A long base film comprising the long base film 5 and the polymer layer 2 laminated on the base film 5, and the base film 5 is peelable from the polymer layer 2 The polymer layer with a base film static elimination conveyance process (A) which conveys the adhesion polymer layer 6 in the longitudinal direction while static electricity, and

With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) Step (B) of providing an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2

Including,

The said polymer layer with base film antistatic conveyance process (A) includes a polymer layer slit process with a base film (SA) which cuts and cuts the end part of the said polymer layer with base film 6 in a conveyance direction, or,

The bonding step (B) includes an optical film slit step (SB1) in which the end portion of the optical film 1 before bonding with the polymer layer 6 with a base film is cut in the conveyance direction and cut out, or

The bonding step (B) cuts the end of the optical layered body 7 with the base film after bonding with the polymer layer 6 with a base film in the conveyance direction, and cuts it out. ), and

The method for producing an optical layered product with a base film, wherein the absolute value of the charge amount of the polymer layer with a base film 6 after static elimination in the polymer layer with base film antistatic transfer step (A) is 0.01 kV or more and 6 kV or less.

[13] A long optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound, wherein the polymer layer (2) comprises the optical film (1) and an adhesive or adhesive layer (3) As a method of manufacturing the optical laminate (4) laminated through),

A long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3), the base material The optical laminated body slit step (SB2) with a base film in which the end of the optical laminate 7 with a long base film capable of being peeled off from the polymer layer 2 is cut in the conveying direction, and the end Along with the peeling step (C) of peeling the said base film 5 from the said optical laminated body 7 with a base film after cutting out, and obtaining the said optical laminated body 4,

A base film static elimination conveyance process (D) which conveys in the longitudinal direction while static electricity elimination of the said base material film 5 after peeling in said peeling process (C) is provided,

The method for producing an optical laminate in which the absolute value of the charge amount of the base film 5 after the static elimination in the base film antistatic conveyance step (D) is 0.01 kV or more and 6 kV or less.

According to the present invention, during the manufacturing process of the optical layered product including the slit process, the generation of foreign matters originating from the material constituting the optical layered product is suppressed, and the amount of residual foreign matters at the manufacturing site is reduced. A method for producing a sieve can be provided.

1 is a schematic diagram for explaining an embodiment of a method for manufacturing an optical laminate of the present invention.
Fig. 2 is a schematic cross-sectional view showing an example of a layer structure of an optical laminate produced by the method for producing an optical laminate of the present invention.
3 is a schematic cross-sectional view showing an example of the layer structure of a polymer layer with a base film used in the method for manufacturing an optical laminate of the present invention.
4 is a schematic cross-sectional view showing an example of a layer structure of an optical laminate with a base film used in the method for producing an optical laminate of the present invention.
5 is a schematic view showing an example of a slitter device used in the method for manufacturing an optical laminate of the present invention.
Fig. 6 is a schematic diagram showing the overlapping of the upper and lower blades in an example of a slitter device used in the method of manufacturing an optical laminate of the present invention.
Fig. 7 is a schematic diagram showing the width (wrap) of the outer peripheral portion where the upper and lower blades overlap in an example of a slitter device used in the method for manufacturing an optical laminate of the present invention.
Fig. 8 is a schematic cross-sectional view of a polymer layer with a base film, which is an embodiment used in the method for producing an optical laminate of the present invention, cut along the width direction.
Fig. 9 is a schematic cross-sectional view of a polymer layer with a base film, which is an embodiment used in the method of manufacturing an optical laminate of the present invention, cut along the width direction.
Fig. 10 is a schematic cross-sectional view of an optical laminate with a base film, which is an embodiment used in the method for producing an optical laminate of the present invention, cut along the width direction.
Fig. 11 is a schematic cross-sectional view of an optical laminate with a base film, which is an embodiment used in the method for producing an optical laminate of the present invention, cut along the width direction.

Hereinafter, an embodiment of the present invention will be described in detail. In addition, the scope of the present invention is not limited to the embodiments described here, and various changes can be made without impairing the gist of the present invention.

<Method of manufacturing an optical laminate>

The present invention relates to a method for producing an optical laminate comprising a polymer layer composed of a polymer of an optical film and a polymerizable liquid crystal compound laminated through an adhesive or an adhesive layer. For example, referring to Fig. 2 showing an example of a layer structure of a typical optical laminate obtained by the method for producing an optical laminate of the present invention, the optical film 1 is obtained by the method for producing an optical laminate of the present invention. Optical laminate (4) comprising a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound laminated on one side through an adhesive or adhesive layer (3) (hereinafter, also simply referred to as "polymer layer (2)") Can be manufactured. The optical laminated body 4 may have the alignment layer 8 on the side opposite to the pressure-sensitive adhesive or adhesive layer 3 of the polymer layer 2.

1 is a schematic diagram illustrating a representative embodiment of a method for manufacturing an optical laminate of the present invention. Hereinafter, a method of manufacturing the optical laminate of the present invention will be described with reference to FIG. 1.

The manufacturing method of the optical laminate of the present invention comprises a long base film 5 and a polymer layer 2 laminated on the base film 5, and the base film 5 comprises the polymer layer ( The polymer layer with a base film 6 (FIG. 3) which can be peeled off from 2) is conveyed in the longitudinal direction while being charged in the lengthwise direction (hereinafter, referred to simply as "step (A)"). Includes]. In one embodiment of the present invention, the elongated polymer layer 6 with a base film is used in the step (A) in a state wound on a unwinding roll, and a polymer layer with a base film wound in a roll shape on a unwinding roll 1 (11) ( 6) is continuously fed out from the unwinding roll 1 (11) and continuously conveyed in the longitudinal direction by the conveying roller 12.

In the present invention, the base film 5 is not particularly limited as long as it contains a material finally peelable from the polymer layer 2 or the alignment layer 8 laminated on the base film. As the base film 5, a known material used for an optical film can be used, and it is preferable that it is a long film roll containing a resin base material. Examples of the resin constituting the base film 5 including the resin base material include polyolefins such as polyethylene, polypropylene, and norbornene polymer; Polyvinyl alcohol; Polyethylene terephthalate; Polymethacrylic acid ester; Polyacrylic acid ester; Cellulose ester; Polyethylene naphthalate; Polycarbonate; Polysulfone; Polyethersulfone; Polyether ketone; Polyphenylene sulfide; And polyphenylene oxide.

The base film containing such a resin base material is generally an electrically charged resin base film having a property of being easily charged. For example, the polymer layer 6 with the base film wound in a roll shape is sent out from the unwinding roll 1 (11) and conveyed. When the polymer layers 6 with the base film are peeled off from each other, the polymer layer 6 with the base film which has been delivered is brought into contact with the roller 12 for conveyance and peeled off, so that the polymer layer with the base film 6 during conveyance The charge amount of is higher. For example, when the polymer layer 6 with the base film contains a resin base material as the base film 5, the polymer layer 6 with the base film after being sent out has an absolute value exceeding 7 kV when static electricity is not performed. It has a charge amount. Manufacturing an optical laminate with such a high charge amount not only poses a risk to the operator, may cause problems with the machine used, etc., but also dust or dust existing in the air is produced. It causes a defect in the obtained optical laminated body by adhering to or flowing into the laminated body. For this reason, in the present invention, the polymer layer 6 with a base film fed out from the unwinding roll 1 (11) is continuously conveyed in the longitudinal direction while being charged.

The manufacturing method of the optical layered product of the present invention provides a long optical layer through an adhesive or an adhesive layer 3 on the polymer layer 2 side with respect to the polymer layer 6 with a base film conveyed by the above step (A). A long-length optical film (1) bonded to the film (1) through a pressure-sensitive adhesive or adhesive layer (3) on the long base film (5), the polymer layer (2), and the polymer layer (2) A bonding step (B) to obtain a long base film-attached optical laminate 7 (Fig. 4) in which the base film 5 is peelable from the polymer layer 2 (hereinafter, simply “Step (B )”.

In one embodiment of the present invention, in the step (B), the base film 5 side of the polymer layer 2 constituting the polymer layer 6 with a base film continuously conveyed by the step (A) is On the opposite side, a pressure-sensitive adhesive or adhesive layer 3 is continuously formed while conveying the polymer layer 6 with a base film. The pressure-sensitive adhesive or pressure-sensitive adhesive layer 3 can be formed, for example, by applying a pressure-sensitive adhesive or adhesive 3'. The pressure-sensitive adhesive or adhesive may be applied by a conventional method, for example, an adhesive diluted with a solvent, or a non-diluted adhesive with a gravure coater or a die coater. In step (B), the pressure-sensitive adhesive or adhesive is applied to the outermost surface of the layer opposite to the base film 5 constituting the polymer layer 6 with the base film (for example, on the side of the polymer layer 2 in FIG. 3) Although it just needs to be done, you may apply to the side of the optical film 1 bonded to the polymer layer 6 with a base film. Subsequently, while conveying the polymer layer 6 with a base film to which an adhesive or adhesive has been applied, the optical continuously delivered from the unwinding roll 2 14 to the polymer layer 2 side of the polymer layer 6 with a base film Attaching a long base film including an optical film 1 bonded to the base film-attached polymer layer 6 through a pressure-sensitive adhesive or adhesive layer 3 by overlapping the film 1 and pressing it with a nip roll 15 The optical laminate 7 can be obtained continuously.

The manufacturing method of the optical laminated body of this invention is the polymer layer (6) with a base film, optical film (1), or the optical laminated body (7) with a base film conveyed in the said process (A) and/or process (B). ) (Hereinafter, these are collectively referred to as a "long sheet") and a slit step of cutting the end portion in the width direction in the conveying direction. Specifically,

In the step (A), a polymer layer with a base film slit step (SA) (hereinafter simply referred to as a ``slit step (SA)) in which an end portion of the polymer layer 6 with a base film is cut and cut in the conveyance direction is included. do or,

In the step (B), the optical film slit step (SB1) in which the end portion of the optical film 1 before bonding with the polymer layer 6 with the base film is cut in the conveying direction and cut out (hereinafter simply referred to as "slit step (SB1) ), or

In step (B), the optical laminated body slit process with a base film (SB2) in which the end of the optical laminate 7 with a base film after bonding with the polymer layer 6 with a base film is cut in the conveyance direction and cut out. Hereinafter, it is also simply referred to as "slit process (SB2)"]

Includes. By passing through the said slit process, the edge part in the width direction of the long sheet to be conveyed is cut neatly, and the occurrence of cross-sectional deviation etc. when the obtained laminated body is wound in a roll shape can be suppressed.

The slit process (SA), the slit process (SB1), and the slit process (SB2) are all, for example, using a slitter device conventionally used in the manufacture of optical films, etc., and the end of the long sheet to be conveyed in the conveying direction. It can be done by cutting and cutting. As a slitter device, for example, as shown in FIG. 5, a slitter device using a so-called rotating round blade having a pair of upper and lower annular blades that rotate while making contact with each other at the outer periphery thereof. And the like. In the slitter device shown in FIG. 5, the upper blade 31 is formed in an annular shape, and is clamped and fixed with the holder 36 and the holder 37 after being roundly inserted into the shaft 34. The other end of the shaft 34 on which the annular blade is installed is supported by the bearing 38, and the upper blade 31 fixed by the motor 40 through the reducer 39 is configured to be rotatable. The lower blade 32 is also configured to be rotatable like the upper blade 31, and as shown in FIG. 6, when rotating, the upper blade 31 and the lower blade 32 are arranged to overlap at the outer periphery. The width of the outer circumferential portion (35 in Fig. 7) where the upper blade 31 and the lower blade 32 overlap is called a lap, and is adjusted by the object to be cut, its thickness, and the diameter of the blade. In the method for manufacturing the optical laminate of the present invention, the wrap width can be adjusted in the range of 0.1 to 1.5 mm, for example. Since fluctuations in the wrap width during operation of the slitter device may affect the quality of the cut surface of the long sheet by causing unevenness in the degree of cutting of the rotating round blade, it is centered on the shaft 34 or the tool. It is preferable to use one with high processing precision so that a shift does not occur.

For example, as shown in Fig. 5, a slitter device using a rotating round blade is installed at a desired slit position along the width direction of the long sheet 33 to be conveyed, and the upper blade 31 and the lower blade 32 are By inserting the long sheet 33 along the conveying direction (longitudinal direction) between the included rotary round blades, the conveyed long sheet 33 can be continuously cut along the length direction to a desired width. The position where the slitter device is arranged in the conveyance path of the long sheet in the slit step (SA), the slit step (SB1) and the slit step (SB2) is not particularly limited, and in the steps (A) and (B) It is good to arrange it at a desired point on the path through which the long sheet is conveyed.

In the case of including the slit process as described above, compared with the manufacturing process not including the slit process, the generation of fine chips due to cutting of the long sheet, peeling of the optical film or optical laminate at the end after the slit, etc., There is a tendency that foreign matter originating from the material constituting the optical laminate is more likely to be generated. In addition, in general, in the manufacturing site of an optical laminate that continuously processes while conveying a long sheet, the long sheet tends to meander during the conveyance, and this phenomenon tends to become more remarkable as the long sheet becomes longer. have. When the long sheet is conveyed while meandering, the long sheet has various angles from the longitudinal direction and is inserted through the cutting edge of the slitter device, and the amount of foreign matter caused by the cutting of the long sheet or the peeling of the end is further increased. It causes. In the manufacturing process including the slit process, for example, when the foreign material generated during the manufacturing process enters between the cutting blade and the cutting edge, cracks are generated in the cutting edge of the polymer layer composed of a polymer of a polymerizable liquid crystal compound. There is. Such cracks may cause fracture of the obtained optical laminate or crack in the optical laminate during use of an image display device incorporating the optical laminate.

The manufacturing method of the optical layered product of the present invention includes controlling the amount of charge of the long sheet by performing static electricity elimination in a conveyance path (e.g., step (A)) of a long sheet such as a polymer layer 6 with a base film. do. As a result, it is possible to suppress the meandering of the long sheet during conveyance and to reduce the angle of the long sheet to be inserted into the slitter device (i.e., the long sheet to be inserted parallel to the cutting blade). It is possible to suppress the occurrence of foreign matters caused by this.

Therefore, in step (A), it is preferable to perform static electricity so that the absolute value of the charge amount of the polymer layer 6 with a base film after static electricity is not less than 0.01 kV and not more than 6 kV. In particular, when the amount of charge is more than the above lower limit, the polymer layer 6 with the base film is conveyed while being properly adsorbed to the guide roll formed near the slit process by the charging, thereby suppressing the meandering of the polymer layer 6 with the base film. And it is possible to reduce the angle at the time of insertion into the slitter device. Thereby, the precision of the slit position can be maintained high, and generation|occurrence|production of a foreign matter caused by a slit process can be suppressed effectively. In addition, in the process of transporting the polymer layer 6 with the base film, the material constituting the polymer layer 6 with the base film, especially the end of the polymer layer 2 or the alignment layer 8, etc. Even in the case where this occurs, the foreign matter is easily adhered to the base film 5, and the end portion that is likely to be peeled off is not removed by adsorption by charging and is easily fixed on the base film 5, so that the subsequent In the process, foreign matter can be discharged from the manufacturing site (clean room) 20 together with the base film 5 to be peeled off. Thereby, the residual amount of the foreign matter derived from the material constituting the polymer layer 6 with the base film in the manufacturing site can be reduced.

Conventionally, from the viewpoint of preventing adhesion of dust or dust in the air or preventing abnormal discharge, it is considered that the lower the charge amount of the long sheet conveyed in the roll-to-roll method, the lower (ideally 0 kV) it is preferable. (For example, the above patent document, etc.). However, in the manufacturing method of an optical layered product including a polymer layer or an alignment layer including a polymer of a polymerizable liquid crystal compound as in the present invention, when the charge amount is made as close to 0 kV as possible, dust existing in the air While it becomes difficult to adhere to the long sheet during manufacture, as described above, the long sheet to be conveyed tends to meander, and the slit position is liable to be shifted, making it difficult to maintain the slit position consistently and accurately. . This makes it easier to generate foreign substances during manufacturing, and also makes it difficult to adsorb foreign substances generated during the manufacturing process and originate from the material constituting the target optical laminate itself. Such foreign matter remains in the manufacturing site, and there is a possibility of causing continuous defects in the optical laminate to be manufactured thereafter. In the present invention, the generation of foreign matters themselves resulting from the materials constituting the optical laminate is suppressed, and even if foreign matters are generated, the foreign matters are more effectively adsorbed to the base film 5, and the foreign matters remain in the manufacturing site. From the viewpoint of reducing the amount, the lower limit of the absolute value of the charge amount of the polymer layer 6 with a base film after static elimination in step (A) is more preferably 0.03 kV or more, still more preferably 0.05 kV or more, It is particularly preferably 0.07 kV or more.

Furthermore, the charge amount (absolute value) of the polymer layer 6 with a base film after static elimination in the step (A) is not less than the above lower limit, such as 0.3 kV or more, further 0.5 kV or more, particularly 0.7 kV or more, particularly It is desirable to keep it above 1.0 kV. In particular, in the case of continuously performing the steps (A) and (B), by continuously maintaining the charge amount above a certain value, the meandering of the long sheet throughout the steps (A) and (B) is suppressed, The slit position can be maintained with high precision, and generation and residual of foreign matter can be suppressed more effectively.

From the viewpoint of prevention of abnormal discharge, safety, etc., the upper limit of the absolute value of the charge amount of the polymer layer 6 with the base film after static elimination in step (A) is more preferably 5 kV or less, and 3 kV or less. It is more preferable, and it is especially preferable that it is 2 kV or less, and it is especially preferable that it is 1.5 kV or less.

The amount of charge of the polymer layer 6 with a base film can be controlled, for example, by using a known antistatic device or the like. Examples of the antistatic device include an ion wind antistatic device that generates ion wind, a light irradiation type antistatic device using ultraviolet rays or soft X-rays, a self-discharge type antistatic device, an antistatic brush, an antistatic string, a ground (earth), and the like. , It may be appropriately selected according to the roll-to-roll equipment used. Only one type of antistatic device may be used, or a plurality of antistatic devices may be used in combination. In the present invention, as the antistatic device, since it can perform static electricity quickly and reliably, an ion wind static electricity eliminator and a light irradiation type static electricity eliminator are preferable. According to the present invention, even in the case of using an ion-air static elimination device, the use of an ion-air static elimination device is more preferable since scattering of the peeled film piece by ion wind can be suppressed. In the case of using an ion wind antistatic device, it is preferable to install an ion wind antistatic device along a conveyance path so that ion wind may reach the side of the base film 5 of the polymer layer 6 with a base film.

In step (A), it is preferable that the charge amount is controlled so as to maintain the above range over the entire length of the polymer layer 6 with a base film during transport. For this reason, it is preferable to install the antistatic device 13 immediately after the polymer layer 6 with the base film is delivered from the unwinding roll 1 (11). For example, the conveying roller 12 is liable to increase the amount of charge due to friction. An antistatic device appropriately along the conveying path of the polymer layer 6 with the base film, such as installed on the downstream side of the conveying roller 12 so as to control the amount of charge of the polymer layer 6 with the base film after contact with It is preferable to control the charge amount of the polymer layer 6 with a base film during conveyance by providing. In addition, in the case of including the slit step (SA), by installing an antistatic device 13 on the upstream side of the slitter device 21 used in the slit step (SA) to control the amount of charge, the slitter device 21 It becomes easy to control the conveyance direction of the polymer layer 6 with the base film which is inserted and penetrated, and the precision of a slit position can be improved. On the other hand, the polymer layer 6 with a base film after antistatic may be conveyed without grounding (earth) so that the lower limit of the above-described charging amount (absolute value) can be maintained, and if the base film is a charging resin base film, It may be conveyed as it is without further charging.

In addition, the amount of charge of the polymer layer 6 with a base film can be measured by providing a charge amount measuring device such as a surface potential (electric field) measuring device in the downstream region of the antistatic device.

When the manufacturing method of the optical laminate of the present invention includes a slit step (SB1), similarly to the slit step (SA), an antistatic device 13 is provided on the upstream side of the slitter device 21 used in the slit step (SB1). ) May be disposed, and the amount of charge of the optical film 1 may be controlled. In addition, when the manufacturing method of the optical laminated body of the present invention includes a slit step (SB2), similar to the slit step (SA), an antistatic device is provided on the upstream side of the slitter device 21 used in the slit step (SB2). It is preferable to arrange (13) and to control the charge amount of the optical laminated body 7 with a base film.

The manufacturing method of the optical layered product of the present invention may include only any one of a slit step (SA), a slit step (SB1), and a slit step (SB2), or may include a plurality of slit steps in combination. The manufacturing method of the optical laminate of the present invention that controls the charge amount of a long sheet is the effect of the present invention (in particular, suppression of the occurrence of foreign matter) when the polymer layer 2 is included at the end of the long sheet cut out in the slit process. Effect) remarkably.

For this reason, it is advantageous in the case of determining the slit position so that the polymer layer 2 is included at the end cut in the slit process (SA) and/or the slit process (SB1), and further, the slit process (SA) and the slit process It is advantageous when it contains at least one of (SB2), and is especially advantageous when it includes a slit process (SA) and a slit process (SB2).

In order to suppress meandering during conveyance in step (B), the absolute value of the charge amount of the polymer layer 6 with the base film and the optical laminate 7 with the base film conveyed in the step (B) is preferably Preferably, it is controlled to be 0.01 kV or more, more preferably 0.03 kV or more, even more preferably 0.05 kV or more, and particularly preferably 0.07 kV or more. By controlling the charge amount of the long sheet conveyed in the step (B) to be equal to or greater than the lower limit, the effect of suppressing the occurrence of foreign matter due to the suppression of the meandering of the long sheet can be obtained, and the base film 5 in the step (A) It enables reliable discharge of foreign matter adhered to the outside of the manufacturing site (clean room), and foreign matter originating from the constituent material of the optical laminate 7 with a substrate film that may be newly formed in step (B) is removed from the substrate film ( Attached to 5), it is possible to discharge outside the manufacturing site (clean room). In addition, from the viewpoint of prevention of abnormal discharge, safety, etc., the absolute value of the charge amount of the polymer layer 6 with the base film and the optical laminate 7 with the base film conveyed in the step (B) is preferably It is preferable that it is controlled to 6 kV or less, more preferably 5 kV or less, and still more preferably 3 kV or less. Furthermore, the charge amount (absolute value) of the polymer layer 6 with the base film and the optical laminate 7 with the base film to be conveyed in the step (B) is equal to or greater than the lower limit, and furthermore than 0.5 kV, particularly 1.0 kV or greater. It is desirable to keep it.

The amount of charge of the polymer layer 6 with a base film and the optical laminate 7 with a base film in step (B) can be controlled by a method similar to the method in step (A). It is preferable that the electric charge amount of the polymer layer 6 with a base film and the optical laminated body 7 with a base film is controlled in the said range and is maintained over the whole of the process (B). In addition, the polymer layer 6 with the base film and the optical layered body 7 with the base film after antistatic may be conveyed without being grounded so that the lower limit of the charge amount (absolute value) can be maintained, and the base film is charged. As long as it is a resin-based film having a high level, it may be conveyed as it is without further performing antistatic.

In step (B), when forming the pressure-sensitive adhesive or adhesive layer (3) on the polymer layer (2) or on the optical film (1), the pressure-sensitive adhesive or adhesive (3') is equal to the width of the polymer layer (2). It may be applied in width, but when pressing the pressure-sensitive adhesive or adhesive layer 3 and the polymer layer 2, the pressure-sensitive adhesive or adhesive does not easily protrude to the side of the laminate, and the resulting optical laminate is finished cleanly. It is preferable that the width of the polymer layer 2 is wider than that of the pressure-sensitive adhesive or adhesive layer 3 in the optical laminate 7 with a base film obtained by applying the adhesive to a width narrower than the width of the polymer layer 2 . Therefore, in one embodiment of the present invention, the width of the polymer layer 2 of the polymer layer 6 with a base film provided in step (B) is the polymer layer 6 with a base film in the step (B) ) Is wider than the width of the pressure-sensitive adhesive or adhesive layer 3 formed to bond the optical film 1. In addition, in another embodiment, when the polymer layer (2) is laminated on the base film (5) through the orientation layer (8), the width of the orientation layer (8) is the base material in the step (B). It is wider than the width of the pressure-sensitive adhesive or adhesive layer 3 formed to bond the film-attached polymer layer 6 and the optical film 1.

In addition, in the manufacturing method of the optical laminated body of this invention, the peeling process (C) of peeling the base film 5 from the optical laminated body 7 with the base film obtained in process (B) to obtain the optical laminated body 4 ) [Hereinafter, simply referred to as "step (C)"], the base film static elimination conveyance step (D) in which the base film 5 after being peeled off in the step (C) is conveyed in the longitudinal direction while static elimination is carried out (hereinafter, simply Also referred to as "step (D)"] is included. In order to discharge the foreign matter adhered to the base film 5 to the outside of the manufacturing site (clean room) together with the base film 5, the process (C) and the process (D) are usually performed simultaneously. While peeling the base film 5 from the laminate in the step (C), by controlling the charge amount of the base film 5 after peeling in the step (D) to a specific range, while attaching a foreign material to the base film 5 It becomes possible to discharge outside the manufacturing site (clean room).

In one embodiment of the present invention, the optical laminate 7 with a base film obtained in the step (B) is wound in the longitudinal direction, and the side of the base film 5 is wound on a peeling roll 16, and the optical laminate The base film 5 is continuously peeled from the optical laminated body 7 with the base film by continuously conveying the (4) side without being wound up. At this time, as shown in FIGS. 10 and 11, if the width of the polymer layer 2 is wider than the width of the pressure-sensitive adhesive or adhesive layer 3, the polymer layer 2 is adhered to the pressure-sensitive adhesive or adhesive layer 3 There is a region 2a that does not exist, but since this region 2a has low adhesion to the base film 5, the end portion 7a cut out by the slit process (SB2) or an optical laminate with a base film ( It is easy to fall off as a fine peeling piece from the base film 5 after peeling from 7). In addition, when the polymer layer 2 is laminated on the base film 5 via the alignment layer 8, in the relationship between the alignment layer 8 and the base film 5, the polymer layer 2 ) And the same problem as the relationship between the base film 5 and the base film 5 are likely to occur. In addition to preventing the remaining region 2a of the polymer layer 2 from falling off, it is manufactured while adsorbing foreign substances attached to the base film 5 to the base film 5 in steps (A) or (B), etc. From the viewpoint of discharging to the outside of the site (clean room) and reducing the amount of foreign matter remaining in the manufacturing site, the lower limit of the absolute value of the charge amount of the base film 5 after peeling in the step (D) is 0.03 kV or more. It is more preferable that it is 0.05 kV or more, and it is especially preferable that it is 0.07 kV or more. Furthermore, it is preferable that the charge amount (absolute value) of the base film 5 after peeling in the step (D) is not less than the above lower limit, furthermore 0.5 kV or more, particularly 0.6 kV or more, particularly 0.7 kV or more. . In addition, from the viewpoint of prevention of abnormal discharge and safety, the upper limit of the absolute value of the charge amount of the base film 5 after peeling in step (D) is more preferably 5 kV or less, and still more preferably 3 kV or less. And it is particularly preferably 1 kV or less. In addition, the base film 5 may be conveyed without grounding so that the lower limit of the amount of charge (absolute value) can be maintained, and if the base film is a charging resin base film, it may be conveyed as it is.

The charge amount of the polymer layer 6 with the base film in step (A) and the charge amount of the base film 5 after peeling in step (D) are about the same or peeling in step (D) It is preferable that the absolute value of the charge amount of the subsequent base film 5 is larger than the absolute value of the charge amount of the polymer layer 6 with a base film in step (A). If the absolute value of the charge amount of the substrate film 5 after peeling in step (D) is sufficiently large, it can be discharged outside the manufacturing site (clean room) while attaching foreign matter to the peeled substrate film 5 It is possible to effectively reduce the residual amount of foreign matter in the site. In addition, if the charge amount of the laminate (film) during production is controlled and maintained in the range of 0.01 kV or more and 6 kV or less throughout the entire process of the steps (A) to (D), the long sheet is In addition to being easy to suppress meandering and making it difficult to generate foreign matter, foreign matter once attached to the base film 5 does not easily overflow into the manufacturing site and is discharged out of the manufacturing site together with the peeling base film 5 It is preferable because it becomes.

In the step (D), the amount of charge of the base film 5 after peeling can be controlled by using a known antistatic device or the like similarly to the method in step (A). In order that no foreign matter remains in the manufacturing site, in the process (D), the amount of charge of the base film 5 after peeling is controlled in the above range until the base film is discharged out of the manufacturing site (clean room) 20 , It is desirable that it is maintained. In one embodiment of the present invention, in the step (D), the antistatic device 13 can be provided on the downstream side of the peeling roll 16, preferably immediately after, if necessary.

In addition, it is preferable that the absolute value of the charge amount of the base film 5 after peeling in the step (D) is larger than the absolute value of the charge amount of the optical laminate 4 obtained in the step (C). If the charge amount of the base film 5 is larger than the charge amount of the optical laminate 4, the foreign material is liable to adhere by the base film 5, and the foreign material adheres on the obtained optical laminate 4 to prevent defects. The possibility of occurrence can be reduced. In one embodiment of the present invention, with respect to the absolute value of the charge amount of the optical laminate 4 in the step (C), the absolute amount of the charge amount of the base film 5 after peeling in the step (D) The value is preferably larger than 0.02 kV, more preferably larger than 0.05 kV.

Conveyance conditions of the long sheet in the manufacturing method of the optical laminate of the present invention may be appropriately selected depending on the type, length, width, thickness, manufacturing equipment, and conveyance speed of the long sheet. In one embodiment of the present invention, the conveyance speed of the long sheet may be, for example, 1 m/min to 50 m/min, and from the viewpoint of suppressing the meandering of the long sheet and suppressing the occurrence of foreign matter, preferably 3 m/min to 35 m/min, more preferably 3 m/min to 30 m/min.

The mean amount of the long sheet is preferably 0 mm to 10 mm, more preferably 0 mm to 5 mm, still more preferably 0 mm to 3 mm, most preferably 0 mm to 2 mm, and the mean amount It is preferable to control the charge amount of the long sheet so that it is within the above range. In addition, in the present invention, the "meaning amount" means the maximum amount that the end portion moved in the width direction before and after the long sheet was conveyed by 1000 m.

The conveyance distance of the elongate sheet is appropriately determined depending on the type and length of the elongate sheet, manufacturing equipment, conveyance speed, etc., but is usually 30 m to 1000 m, preferably 50 m to 500 m. In addition, the length and width of the long sheet may be appropriately set according to the type and use of the long sheet. In one embodiment of the present invention, the length of the long sheet is usually 100 m to 5000 m, for example 500 m to 5000 m. In addition, the width of the long sheet is usually 300 mm to 2000 mm, and may be, for example, 500 mm to 1500 mm.

In one embodiment of the present invention, the polymer layer 6 with a base film before cutting the end by a slit step (SA), that is, the polymer layer 6 with a base film provided in the step (A), comprises: It is provided on the base film 5 over the entire width direction of the polymer layer 2, and the width of the base film 5 is wider than that of the polymer layer 2. In this embodiment, the polymer layer 2 has a region 5a in which the polymer layer 2 is not laminated at one end or both ends of the base film 5 in the width direction, as shown in FIG. 8. Are stacked to do so. In addition, the polymer layer 2 and the base film 5 constituting the optical laminate 7 with a base film before cutting the end by the slit steps (SA) and (SB2) may have the same configuration as described above.

In another embodiment of the present invention, the polymer layer (2) is laminated on the base film (5) through the alignment layer (8), before cutting the end by a slit process (SA), that is, the process The alignment layer 8 constituting the polymer layer 6 with a base film provided in (A) is provided on the base film 5 over the entire width direction of the alignment layer 8, and the base film The width of (5) is wider than that of the alignment layer (8). In this aspect, as shown in FIG. 9, the alignment layer 8 has a region 5a in which the alignment layer 8 is not laminated at one end or both ends of the base film 5 in the width direction. Are stacked to do so. In the polymer layer 6 with a base film, since the polymer layer 2 is usually a layer formed on the alignment layer 8, the width of the polymer layer 2 is the width of the alignment layer 8 It is preferably the same as or narrower. In addition, the optical laminate 7 with a base film before cutting the end by the slit process (SA) and (SB2) may be provided with an alignment layer 8, in this case, the alignment layer 8 and the base material The film 5 may have the same configuration as above.

In the polymer layer 6 with the base film or the optical laminate 7 with the base film having such a layered structure, the border 5b in contact with the ends of the base film 5 and the polymer layer 2 or the alignment layer 8 In the vicinity of ), the polymer layer 2 or the alignment layer 8 is easily peeled from the base film 5, and fine peeling pieces become foreign substances during the manufacturing process and are likely to occur. In the manufacturing method of the optical laminate of the present invention, the charge amount of the polymer layer 6 with the base film or the optical laminate 7 with the base film in step (A), preferably in steps (A) and (B) By controlling, meandering of these long sheets can be suppressed, generation of foreign substances derived from the material constituting the long sheets can be suppressed, and foreign substances generated during manufacturing are adhered to the base film 5 at the manufacturing site (clean room). ) Since it can be discharged to the outside, it is particularly suitable as a method for producing an optical laminate using the polymer layer 6 with a base film or the optical laminate 7 with a base film having the above-described layer configuration. In addition, since regions 5a in which the polymer layer 2 or the alignment layer 8 is not laminated exist at both ends of the base film 5 in the width direction, the polymer layer 2 or the alignment layer 8 to be laminated Fine foreign matters generated by peeling off the ends of the substrate film 5 tend to adhere to the region 5a of the base film 5, and a high reduction effect of the residual amount of foreign matters in the manufacturing site can be expected.

The width of the base film 5 constituting the polymer layer 6 with the base film and the optical laminate 7 with the base film is on the base film 5 in the layer configuration before cutting the end in the slit process. It is preferably 0.5 to 10% wider, more preferably 0.7 to 5% wider than the width of the polymer layer 2 or the alignment layer 8 laminated on the layer.

The optical laminated body 4 obtained by the process (C) can be wound up by the take-up roll 17 located downstream. The obtained optical laminate 4 can be formed into a desired shape by performing external processing such as slit processing, punching, chip cutting, and cross-section polishing, if necessary, and is attached to the side or end of the optical laminate 4 You can remove the foreign matter.

In the manufacturing method of the optical laminate of the present invention, the steps (A) and (B), and the steps (C) and (D) may be performed continuously or independently. For example, in the present invention, the optical laminate 7 with a base film obtained in the step (B) may be continuously conveyed from the step (B) to the step (C) to obtain the optical laminate 4, and the step After winding the optical laminated body 7 with the base film produced in (B) once on a take-up roll, you may perform steps (C) and (D) in a line separate from steps (A) and (B). At this time, including any one of the slit process (SA), the slit process (SB1), and the slit process (SB2), in the process (A) and/or (D), preferably, depending on the process included in the manufacturing method. Throughout the manufacturing process, the charge amount of the long sheet is controlled in a specific range.

Therefore, the present invention,

A method for producing an optical laminate comprising the steps (A) to (D) and the slit step (SA) and controlling the amount of charge of the polymer layer 6 with a base film in the step (A) within a specific range,

Charging of the polymer layer 6 or the base film 5 with a base film in step (A) or (D) including the steps (A) to (D) and the slit step (SB1) or (SB2) A method for manufacturing an optical laminate that controls the amount in a specific range,

The conveyance method of the polymer layer with a base film by the process (A) including the said slit process (SA),

The manufacturing method of the optical laminated body with a base film including the said process (A) and (B) and a slit process (SA), (SB1) or (SB2), and

The manufacturing method of the optical laminated body including the said process (C) and (D), and a slit process (SB2)

Also target. Hereinafter, these methods are collectively referred to as "the method of the present invention". The conditions and the like of each step employed in the manufacturing method and the conveying method are the same as those of the manufacturing method of the optical laminate of the present invention described above.

By continuously performing the steps (A) to (D), it is possible to reduce the possibility that a defect in the optical layered product finally obtained is caused by the foreign material adhering to the base film 5 flowing into the layered product during manufacture.

The method of the present invention is a method for producing various optical laminates having a polymer layer or an alignment layer composed of a polymer of a polymerizable liquid crystal compound, which is easily peeled off at an end during a manufacturing process, particularly in a slit process, to generate foreign matter. Suitable. Therefore, as long as the method of the present invention uses a laminate having a polymer layer composed of a polymer of a polymerizable liquid crystal compound, components of each layer constituting the laminate are not particularly limited, and conventionally known components and materials, etc. You can use

Hereinafter, examples of components, materials, etc. that can constitute each layer included in the polymer layer 6 with a base film and the optical laminate 7 with a base film used in the method of the present invention are given.

In the method of the present invention, the polymerizable liquid crystal compound constituting the polymer layer 2 is not particularly limited, but it is preferable to exhibit optical anisotropy by coating and aligning on a base film or an alignment layer. Here, in the present invention, the polymerizable liquid crystal compound means a liquid crystal compound having a polymerizable functional group, particularly a photopolymerizable functional group. The photopolymerizable functional group refers to a group capable of participating in the polymerization reaction by an active radical or acid generated from a photopolymerization initiator. Examples of the photopolymerizable functional group include vinyl group, vinyloxy group, 1-chlorovinyl group, isopropenyl group, 4-vinylphenyl group, acryloyloxy group, methacryloyloxy group, oxiranyl group, oxetanyl group, and the like. have. Among them, an acryloyloxy group, a methacryloyloxy group, a vinyloxy group, an oxiranyl group, and an oxetanyl group are preferable, and an acryloyloxy group is more preferable. The liquid crystal property may be a thermotropic liquid crystal or a lyotropic liquid crystal, but a thermotropic liquid crystal is preferred from the viewpoint of enabling precise film thickness control. Moreover, a nematic liquid crystal may be sufficient as a good-order structure in a thermotropic liquid crystal, and a smectic liquid crystal may be sufficient.

As the polymerizable liquid crystal compound used in the method of the present invention, for example, a compound having a structure represented by the following formula (I) may be mentioned.

In formula (I), Ar represents a divalent aromatic group, and at least one or more of a nitrogen atom, an oxygen atom, and a sulfur atom is contained in the divalent aromatic group.

G ¹ and G ² each independently represent a divalent aromatic group or a divalent alicyclic hydrocarbon group. Here, the hydrogen atom contained in the divalent aromatic group or the divalent alicyclic hydrocarbon group is a halogen atom, an alkyl group having 1 to 4 carbon atoms, a fluoroalkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cyano group, or It may be substituted with a nitro group, and the carbon atom constituting the divalent aromatic group or the divalent alicyclic hydrocarbon group may be substituted with an oxygen atom, a sulfur atom, or a nitrogen atom.

L ¹ , L ² , B ¹ and B ² are each independently a single bond or a divalent linking group.

Each of k and l independently represents an integer of 0 to 3, and satisfies the relationship of 1≦k+l. Here, when 2≤k+l, B ¹ and B ² , G ¹ and G ² may be the same or different from each other.

E ¹ and E ² each independently represent an alkanediyl group having 1 to 17 carbon atoms, wherein the hydrogen atom contained in the alkanediyl group may be substituted with a halogen atom, and -CH ₂ -contained in the alkanediyl group May be substituted with -O- or -Si-.

P ¹ and P ² each independently represent a polymerizable group or a hydrogen atom, and at least one is a polymerizable group.

G ¹ and G ² are each independently preferably a 1,4-phenyl group, a halogen atom and a C 1 to C 4 group, which may be substituted with at least one substituent selected from the group consisting of a halogen atom and an alkyl group having 1 to 4 carbon atoms. It is a 1,4-cyclohexyl group which may be substituted with at least one substituent selected from the group consisting of alkyl groups, more preferably a 1,4-phenyl group substituted with a methyl group, an unsubstituted 1,4-phenyl group, or no It is a substituted 1,4-trans-cyclohexyl group, Especially preferably, it is an unsubstituted 1,4-phenyl group or an unsubstituted 1,4-trans-cyclohexyl group.

In addition, at least one of the plurality of G ¹ and G ² is preferably a divalent alicyclic hydrocarbon group, and further, at least one of G ¹ and G ² bonded to L ¹ or L ² is a divalent alicyclic hydrocarbon group. More preferable.

L ¹ and L ² are each independently preferably a single bond, -O-, -CH ₂ CH ₂ -, -CH ₂ O-, -COO-, -OCO-, -N=N-, -CR ^a = CR ^b -, or -C≡C-. Here, R ^a and R ^b represent a C 1 to C 4 alkyl group or a hydrogen atom. L ¹ and L ² are each independently more preferably a single bond, -O-, -CH ₂ CH ₂ -, -COO-, or -OCO-.

B ¹ and B ² are each independently preferably a single bond, -O-, -S-, -CH ₂ O-, -COO-, or -OCO-, more preferably a single bond, -O- , -COO-, or -OCO-.

From the viewpoint of expression of reverse wavelength dispersion, k and l are preferably in the range of 2≦k+l≦6, preferably k+l=4, and more preferably k=2 and l=2. Since k=2 also has a symmetrical structure of l=2, it is preferable.

E ¹ and E ² are each independently preferably an alkanediyl group having 1 to 17 carbon atoms, more preferably an alkanediyl group having 4 to 12 carbon atoms.

Examples of the polymerizable group represented by P ¹ or P ² include epoxy group, vinyl group, vinyloxy group, 1-chlorovinyl group, isopropenyl group, 4-vinylphenyl group, acryloyloxy group, methacryloyloxy group, oxira And an oxetanyl group.

Among them, an acryloyloxy group, a methacryloyloxy group, a vinyloxy group, an oxiranyl group, and an oxetanyl group are preferable, and an acryloyloxy group is more preferable.

Ar preferably has an aromatic heterocycle. Examples of the aromatic heterocycle include furan ring, benzofuran ring, pyrrole ring, thiophene ring, pyridine ring, thiazole ring, benzothiazole ring, thienothiazole ring, oxazole ring, benzoxazole ring, and phenanthrol Lean rings, etc. are mentioned. Among them, those having a thiazole ring, a benzothiazole ring, or a benzofuran ring are preferred, and those having a benzothiazole group are more preferred. In addition, when Ar contains a nitrogen atom, it is preferable that the nitrogen atom has π electrons.

In formula (I), the total number N _π of π electrons contained in the divalent aromatic group represented by Ar is preferably 10 or more, more preferably 14 or more, and still more preferably 18 or more. Further, it is preferably 30 or less, more preferably 26 or less, and still more preferably 24 or less.

As an aromatic group represented by Ar, the following groups are mentioned, for example.

In formulas (Ar-1) to (Ar-22), * represents a linking portion, and Z ⁰ , Z ¹ and Z ² are each independently a hydrogen atom, a halogen atom, an alkyl group having 1 to 12 carbon atoms, a cyano group, Nitro group, C1-C12 alkylsulfinyl group, C1-C12 alkylsulfonyl group, carboxyl group, C1-C12 fluoroalkyl group, C1-C6 alkoxy group, C1-C12 alkylthio group, C1-C12 1 to 12 N-alkylamino group, C 2 to C 12 N,N-dialkylamino group, C 1 to C 12 N-alkylsulfamoyl group, or C 2 to C 12 N,N-dialkylsulfamoyl group. .

Q ¹ and Q ² are each independently selected from ^{-CR 2 'R 3' -,} -S-, -NH-, -NR 2 '- represents a, -CO- or -O-, R ^2' and R ^{3 'is} Each independently represents a hydrogen atom or an alkyl group having 1 to 4 carbon atoms.

Y ¹ , Y ² and Y ³ each independently represent an optionally substituted aromatic hydrocarbon group or an aromatic heterocyclic group.

W ¹ and W ² each independently represent a hydrogen atom, a cyano group, a methyl group, or a halogen atom, and m represents an integer of 0-6.

Examples of the aromatic hydrocarbon group for Y ¹ , Y ² and Y ³ include aromatic hydrocarbon groups having 6 to 20 carbon atoms such as phenyl group, naphthyl group, anthryl group, phenanthryl group, and biphenyl group, and phenyl group and naphthyl group It is preferable, and a phenyl group is more preferable. The aromatic heterocyclic group includes at least one hetero atom such as a furyl group, a pyrrolyl group, a thienyl group, a pyridinyl group, a thiazolyl group, and a benzothiazolyl group, an oxygen atom, and a sulfur atom. An aromatic heterocyclic group is mentioned, and a furyl group, a thienyl group, a pyridinyl group, a thiazolyl group, and a benzothiazolyl group are preferable.

Y ¹ , Y ² and Y ³ may each be a polycyclic aromatic hydrocarbon group or a polycyclic aromatic heterocyclic group which may be independently substituted. The polycyclic aromatic hydrocarbon group refers to a condensed polycyclic aromatic hydrocarbon group or a group derived from an aromatic ring group. The polycyclic aromatic heterocyclic group refers to a condensed polycyclic aromatic heterocyclic group or a group derived from an aromatic ring set.

Z ⁰ , Z ¹ and Z ² are each independently a hydrogen atom, a halogen atom, a C 1 to C 6 alkyl group, a cyano group, a nitro group, preferably a C 1 to C 12 alkoxy group, and Z ⁰ is a hydrogen atom, a C 1 The alkyl group and cyano group of -12 are more preferable, and Z ¹ and Z ² are more preferably a hydrogen atom, a fluorine atom, a chlorine atom, a methyl group, and a cyano group.

Q ¹ and Q ² is ^{-NH-, -S-, -NR 2 '-} , -O- is preferable, and, R ^2' is preferably a hydrogen atom. Among them, -S-, -O-, and -NH- are particularly preferred.

Among formulas (Ar-1) to (Ar-22), formulas (Ar-6) and (Ar-7) are preferred from the viewpoint of molecular stability.

In formulas (Ar-16) to (Ar-22), Y ¹ may form an aromatic heterocyclic group together with the nitrogen atom to which it is bonded and Z ⁰ . For example, a pyrrole ring, an imidazole ring, a pyrroline ring, a pyridine ring, a pyrazine ring, a pyrimidine ring, an indole ring, a quinoline ring, an isoquinoline ring, a purine ring, a pyrrolidine ring, and the like can be mentioned. This aromatic heterocyclic group may have a substituent. Further, Y ¹ may be a polycyclic aromatic hydrocarbon group or a polycyclic aromatic heterocyclic group which may be substituted above, together with the nitrogen atom and Z ^{0 to} which it is bonded.

Examples of the aromatic group represented by Ar include groups represented by the following formula (Ar-23).

In formula (Ar-23), *, Z ¹ , Z ² , Q ¹ and Q ² represent the same meaning as above, and U ¹ represents a non-metal atom of Group 14 to Group 16 which may have a substituent bonded thereto. . Examples of nonmetallic atoms of groups 14 to 16 include carbon atoms, nitrogen atoms, oxygen atoms, and sulfur atoms, preferably =O, =S, =NR' and =C(R')R' And the like. Examples of the substituent R'include a hydrogen atom, a halogen atom, an alkyl group, a halogenated alkyl group, an alkenyl group, an aryl group, a cyano group, an amino group, a nitro group, a nitroso group, a carboxyl group, an alkylsulfinyl group having 1 to 6 carbon atoms, Alkylsulfonyl group, fluoroalkyl group having 1 to 6 carbon atoms, alkoxy group having 1 to 6 carbon atoms, alkylsulfanyl group having 1 to 6 carbon atoms, N-alkylamino group having 1 to 6 carbon atoms, N,N-di group having 2 to 12 carbon atoms Alkylamino group, a C1-C6 N-alkylsulfamoyl group, a C2-C12 dialkylsulfamoyl group, etc. are mentioned, In the case where a non-metal atom is a carbon atom (C), two R'are the same as each other. It may be good or different.

By aligning such a polymerizable liquid crystal compound to form a polymer in the alignment state of the polymerizable liquid crystal compound, the polymer layer 2 having reverse wavelength dispersibility can be produced. At this time, the polymerizable liquid crystal compound may be used alone, or two or more types having different molecular structures may be mixed and used.

In addition, in the case of polymerization in an orientation state, a polymerizable liquid crystal compound exhibiting constant wavelength dispersibility may be used. As a specific example of such a polymerizable liquid crystal compound, "3.8.6 Network (completely crosslinked)" and "6.5.1" of the Liquid Crystal Handbook (by the Editorial Committee of the Liquid Crystal Handbook, published on October 30, 2000 by Maruzen Co., Ltd.) Liquid crystal material b. Among the compounds described in "polymerizable nematic liquid crystal material", a compound having a polymerizable group can be mentioned. As these polymerizable liquid crystal compounds, commercially available products may be used.

The polymer layer (2) constituting the polymer layer (6) with a base film or the optical laminate (7) with a base film used in the method of the present invention is, for example, a polymerizable liquid crystal compound, the base film (5) or It is obtained by applying a composition (hereinafter also referred to as "composition for forming an optically anisotropic layer") on the alignment layer 8 by diluting with a solvent in some cases, and polymerizing the solvent after drying if necessary. By polymerizing the polymerizable liquid crystal compound while maintaining the alignment state, a liquid crystal cured film having the alignment state is obtained, and the laminate (polymer layer with base film) having such a liquid crystal cured film functions as a retardation plate.

The content of the polymerizable liquid crystal compound in the composition for forming an optically anisotropic layer (when multiple types are included, the total amount) is 100 parts by mass of the solid content of the composition for forming an optically anisotropic layer from the viewpoint of enhancing the orientation of the polymerizable liquid crystal compound. Relatively, it is usually 70 to 99.9 parts by mass, for example, preferably 80 to 99 parts by mass, more preferably 85 to 97 parts by mass, and still more preferably 85 to 95 parts by mass. In addition, the solid content referred to herein refers to the total amount of components excluding the solvent from the composition for forming an optically anisotropic layer.

In addition to the polymerizable liquid crystal compound, the composition for forming an optically anisotropic layer may contain known components such as a solvent, a polymerization initiator, a polymerization inhibitor, a photosensitizer, and a leveling agent. These components can be appropriately selected depending on the kind of the polymerizable liquid crystal compound to be used or the like. Hereinafter, as the polymerizable liquid crystal compound constituting the polymer layer (2), a suitable component is exemplified when the polymerizable liquid crystal compound represented by the above formula (I) is used.

As the solvent, an organic solvent capable of dissolving the constituents of the composition for forming an optically anisotropic layer, such as a polymerizable liquid crystal compound, is preferable, and a solvent capable of dissolving the constituents of the composition for forming an optically anisotropic layer, such as a polymerizable liquid crystal compound. As, a solvent that is inert to the polymerization reaction of the polymerizable liquid crystal compound is more preferable. Specifically, alcohol solvents such as water, methanol, ethanol, ethylene glycol, isopropyl alcohol, propylene glycol, methyl cellosolve, butyl cellosolve, propylene glycol monomethyl ether, and phenol; Ester solvents such as ethyl acetate, butyl acetate, ethylene glycol methyl ether acetate, γ-butyrolactone, propylene glycol methyl ether acetate, and ethyl lactate; Ketone solvents such as acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, methyl amyl ketone, and methyl isobutyl ketone; Non-chlorinated aliphatic hydrocarbon solvents such as pentane, hexane, and heptane; Non-chlorinated aromatic hydrocarbon solvents such as toluene and xylene; Nitrile solvents such as acetonitrile; Ether solvents such as tetrahydrofuran and dimethoxyethane; And chlorinated hydrocarbon solvents such as chloroform and chlorobenzene. You may use in combination of two or more types of organic solvents. Among them, alcohol solvents, ester solvents, ketone solvents, non-chlorinated aliphatic hydrocarbon solvents, and non-chlorinated aromatic hydrocarbon solvents are preferable.

The content of the solvent is, for example, preferably 10 to 10,000 parts by mass, more preferably 100 to 5000 parts by mass, further preferably 100 to 2000 parts by mass, based on 100 parts by mass of the solid content of the composition for forming an optically anisotropic layer. The solid content concentration in the composition for forming an optically anisotropic layer is preferably 2 to 50% by mass, more preferably 5 to 50% by mass, and still more preferably 5 to 30%.

The polymerization initiator is a compound capable of initiating a polymerization reaction such as a polymerizable liquid crystal. As the polymerization initiator, a photopolymerization initiator that generates radicals by light irradiation is preferable. Examples of the photopolymerization initiator include benzoin compounds, benzophenone compounds, benzyl ketal compounds, α-hydroxyketone compounds, α-aminoketone compounds, oxime compounds, triazine compounds, iodonium salts and sulfonium salts. As the photopolymerization initiator, only one type may be used, or two or more types may be used in combination.

A commercial product may be used as the photopolymerization initiator. As such a commercial item, specifically, Irgacure (registered trademark) 907, Irgacure 184, Irgacure 651, Irgacure 819, Irgacure 250, Irgacure 369, Irgacure 379, Irgacure Gacure 127, Irgacure 2959, Irgacure 754, Irgacure 379EG (above, manufactured by BASF Japan Co., Ltd.), Sakeall BZ, Sakeall Z, Sakeall BEE (above, manufactured by Seiko Chemical Co., Ltd.), Kayacure (kayacure) BP100 (manufactured by Nihon Kayaku Co., Ltd.), Kayacure UVI-6992 (manufactured by Dow), Adeka Optomer SP-152, Adeka Optomer SP-170, Adeka Optomer N-1717, Adeka Opto Mer N-1919, Adeka Cruise NCI-831, Adeka Cruise NCI-930 (above, manufactured by ADEKA Co., Ltd.), TAZ-A, TAZ-PP (above, manufactured by Nippon Siberheg Screw) and TAZ-104 (Sanwa Chemical Manufactured by Co., Ltd.).

Since the photoinitiator can fully utilize the energy generated from the light source and is excellent in productivity, the maximum absorption wavelength is preferably 300 nm to 400 nm, more preferably 300 nm to 380 nm, and among them, α-aceto Phenon-based polymerization initiators and oxime-based photopolymerization initiators are preferred.

As an α-acetophenone compound, 2-methyl-2-morpholino-1-(4-methylsulfanylphenyl)propan-1-one, 2-dimethylamino-1-(4-morpholinophenyl)- 2-benzylbutan-1-one and 2-dimethylamino-1-(4-morpholinophenyl)-2-(4-methylphenylmethyl)butan-1-one, and the like, and more preferably 2- Methyl-2-morpholino-1-(4-methylsulfanylphenyl)propan-1-one and 2-dimethylamino-1-(4-morpholinophenyl)-2-benzylbutan-1-one. I can. Commercially available products of the α-acetophenone compound include Irgacure 369, 379EG, 907 (above, manufactured by BASF Japan Co., Ltd.) and Seiko BEE (manufactured by Seiko Chemical Co., Ltd.).

The oxime photopolymerization initiator generates radicals such as phenyl radicals and methyl radicals by irradiation with light. The polymerization of the polymerizable liquid crystal compound proceeds suitably by this radical, but among them, an oxime-based photopolymerization initiator that generates a methyl radical is preferable from the viewpoint of high initiation efficiency of the polymerization reaction. In addition, it is preferable to use a photopolymerization initiator capable of efficiently using ultraviolet rays having a wavelength of 350 nm or more from the viewpoint of making the polymerization reaction proceed more efficiently. As a photo-radical polymerization initiator capable of efficiently using ultraviolet rays with a wavelength of 350 nm or more, a triazine compound or carbazole compound containing an oxime structure is preferable, and a carbazole compound containing an oxime ester structure is more preferable from the viewpoint of sensitivity. . As a carbazole compound containing an oxime structure, 1,2-octanedione, 1-[4-(phenylthio)-2-(O-benzoyloxime)], ethanol, 1-[9-ethyl-6- (2-methylbenzoyl)-9H-carbazol-3-yl]-1-(O-acetyloxime), and the like. Commercially available products of oxime ester photopolymerization initiators include Irgacure OXE-01, Irgacure OXE-02, Irgacure OXE-03 (above, manufactured by BASF Japan Corporation), Adeka Optomer N-1919, and Adeka Cruise NCI-831 (above, manufactured by ADEKA Corporation), etc. are mentioned.

In order to polymerize the polymerizable liquid crystal compound without disturbing the orientation of the polymerizable liquid crystal compound, the content of the polymerization initiator is usually 0.1 to 30 parts by mass, preferably 0.5 to 10 parts by mass, based on 100 parts by mass of the polymerizable liquid crystal compound. It is wealth.

By blending a polymerization inhibitor, the polymerization reaction of the polymerizable liquid crystal compound can be controlled. Examples of the polymerization inhibitor include hydroquinones having substituents such as hydroquinone and alkyl ether; Catechols having a substituent such as alkyl ether such as butyl catechol; Radical supplements such as pyrogallols and 2,2,6,6-tetramethyl-1-piperidinyloxy radicals; Thiophenols; β-naphthylamines and β-naphthols are mentioned.

The content of the polymerization inhibitor is usually 0.1 to 30 parts by mass, preferably 0.5 to 100 parts by mass of the polymerizable liquid crystal compound in order to polymerize the polymerizable liquid crystal compound without disturbing the orientation of the polymerizable liquid crystal compound. It is 10 parts by mass.

Examples of the photosensitizer include xanthones such as xanthone and thioxanthone; Anthracenes having substituents such as anthracene and alkyl ether; Phenothiazine; Rubrene is mentioned.

By using a photosensitizer, a photoinitiator can be highly sensitive. The content of the photosensitizer is usually 0.1 to 30 parts by mass, and preferably 0.5 to 10 parts by mass based on 100 parts by mass of the polymerizable liquid crystal compound.

As the leveling agent, an organic modified silicone oil type, a polyacrylate type, and a perfluoroalkyl type leveling agent are mentioned, for example. Specifically, DC3PA, SH7PA, DC11PA, SH28PA, SH29PA, SH30PA, ST80PA, ST86PA, SH8400, SH8700, FZ2123 [above, all manufactured by Toray Dow Corning Co., Ltd.], KP321, KP323, KP324, KP326, KP340, KP341 , X22-161A, KF6001 [above, all manufactured by Shin-Etsu Chemical Co., Ltd.], TSF400, TSF401, TSF410, TSF4300, TSF4440, TSF4445, TSF-4446, TSF4452, TSF4460 (above, all Momentive Performance Materials Japan Joint company), fluorinert (registered trademark) FC-72, copper FC-40, copper FC-43, copper FC-3283 [above, all manufactured by Sumitomo 3M], Megapak (registered trademark) ) R-08, East R-30, East R-90, East F-410, East F-411, East F-443, East F-445, East F-470, East F-477, East F-479, F-482, F-483 [above, all manufactured by DIC Corporation], Ftop (brand name) EF301, EF303, EF351, EF352 [above, all manufactured by Mitsubishi Materials Denshi Kasei Corporation] , Suffron (registered trademark) S-381, East S-382, East S-383, East S-393, East SC-101, East SC-105, KH-40, SA-100 [above, all AGC Semiy Chemical Co., Ltd.], brand name E1830, copper E5844 [Daikin Fine Chemical Co., Ltd. product], BM-1000, BM-1100, BYK-352, BYK-353 and BYK-361N (all brand names: BM Chemie Manufactured by company), etc. are mentioned. You may combine two or more types of leveling agents.

By using a leveling agent, a smoother optically anisotropic layer can be formed. In addition, during the manufacturing process of the retardation plate, the fluidity of the composition for forming an optically anisotropic layer may be controlled or the crosslinking density of the retardation plate may be adjusted. The content of the leveling agent is usually 0.1 to 30 parts by mass, preferably 0.1 to 10 parts by mass per 100 parts by mass of the polymerizable liquid crystal compound.

The alignment layer (8) constituting the polymer layer (6) with a base film or the optical laminate (7) with a base film used in the method of the present invention requires a polymerizable liquid crystal compound constituting the polymer layer (2). It has an orientation regulating force to align in the direction, has a solvent resistance that is not dissolved by application of a composition for forming an optically anisotropic layer containing the polymerizable liquid crystal compound, and is heated for removal of the solvent or alignment of the polymerizable liquid crystal compound. It is preferable to have heat resistance in processing. Examples of the alignment layer include an alignment layer containing an alignment polymer, a photo-alignment layer, and a groove alignment layer having an uneven pattern or a plurality of grooves on the surface.

When the orientation polymer is included, examples of the orientation polymer include polyamide or gelatin having an amide bond, polyimide having an imide bond, and a hydrolyzate thereof such as polyamic acid, polyvinyl alcohol, alkyl-modified polyvinyl alcohol, poly Acrylamide, polyoxazole, polyethyleneimine, polystyrene, polyvinylpyrrolidone, polyacrylic acid and polyacrylic acid esters are mentioned. Among them, polyvinyl alcohol is preferred. You may combine two or more types of orientation polymers.

The alignment layer containing the alignment polymer is usually applied by applying an alignment polymer composition in which the alignment polymer is dissolved in a solvent to a substrate and removing the solvent to form a coating film or applying the alignment polymer composition to the substrate and removing the solvent. It is obtained by forming a film and rubbing the coating film.

The concentration of the oriented polymer in the oriented polymer composition may be within a range in which the oriented polymer is completely dissolved in a solvent. The content of the oriented polymer with respect to the oriented polymer composition is preferably 0.1 to 20% by mass, more preferably 0.1 to 10% by mass.

The orientation polymer composition can be obtained from the market. As a commercially available oriented polymer composition, Saneva (registered trademark, manufactured by Nissan Chemical Industry Co., Ltd.), optomer (registered trademark, manufactured by JSR Corporation), etc. are mentioned.

As a method of applying the oriented polymer composition to the substrate, the same method as the method of applying the composition for forming an optically anisotropic layer to the substrate to be described later can be mentioned. As a method of removing the solvent contained in the oriented polymer composition, a natural drying method, a ventilation drying method, a heat drying method, a vacuum drying method, and the like may be mentioned.

The coating film formed from the oriented polymer composition may be subjected to a rubbing treatment. By performing the rubbing treatment, it is possible to impart an orientation regulating force to the coating film.

As a method of the rubbing treatment, for example, a method of bringing the rubbing cloth into contact with the rotating rubbing roll by winding the rubbing cloth into contact with the coating film is exemplified. When performing the rubbing treatment, if masking is performed, a plurality of regions (patterns) having different orientation directions may be formed in the alignment film.

The photo-alignment film is usually obtained by applying a composition for forming a photo-alignment film containing a polymer or monomer having a photoreactive group and a solvent to a substrate, removing the solvent, and then irradiating polarized light (preferably polarized UV). The photo-alignment film can arbitrarily control the direction of the orientation regulating force by selecting the polarization direction of the polarized light to be irradiated.

The photoreactive group refers to a group that generates orientation ability by irradiation with light. Specifically, a group involved in a photoreaction that is the origin of the orientation ability, such as an orientation organic reaction, isomerization reaction, photodimerization reaction, photocrosslinking reaction, or photodecomposition reaction of molecules generated by light irradiation can be mentioned. As the photoreactive group, a group having an unsaturated bond, particularly a double bond, is preferable, and a carbon-carbon double bond (C=C bond), a carbon-nitrogen double bond (C=N bond), a nitrogen-nitrogen double bond (N=N Bonds) and a group having at least one selected from the group consisting of carbon-oxygen double bonds (C=O bonds).

The photoreactive group having a C=C bond includes, for example, a vinyl group, a polyene group, a stilbene group, a stilbazole group, a stilbazolium group, a chalcone group, and a cinnamoyl group. As a photoreactive group having a C=N bond, a group having a structure such as an aromatic cipro base and an aromatic hydrazone may be mentioned. Examples of the photoreactive group having an N=N bond include an azobenzene group, an azonaphthalene group, an aromatic heterocyclic azo group, a bisazo group, a formazane group, and a group having an azoxybenzene structure. As a photoreactive group which has a C=O bond, a benzophenone group, a coumarin group, an anthraquinone group, and a maleimide group are mentioned, for example. These groups may have substituents such as an alkyl group, an alkoxy group, an aryl group, an allyloxy group, a cyano group, an alkoxycarbonyl group, a hydroxyl group, a sulfonic acid group, and a halogenated alkyl group.

The group involved in the photo-dimerization reaction or the photo-crosslinking reaction is preferable from the viewpoint of excellent orientation. Among them, a photoreactive group involved in the photodimerization reaction is preferable, and a cinnamoyl group and a chalcone group are preferable in that the amount of polarization irradiation required for orientation is relatively small, and a photo-alignment film excellent in thermal stability and aging stability is easily obtained. Do. As the polymer having a photoreactive group, it is particularly preferable to have a cinnamoyl group in which the terminal portion of the side chain of the polymer has a cinnamic acid structure.

The content of the polymer or monomer having a photoreactive group in the composition for forming a photo-alignment film can be adjusted according to the type of the polymer or monomer or the thickness of the target photo-alignment film, and is preferably at least 0.2% by mass, and 0.3 to 10 The range of mass% is more preferable. As long as the characteristics of the photo-alignment film are not significantly impaired, the composition for forming a photo-alignment film may contain a polymer material such as polyvinyl alcohol or polyimide, or a photosensitizer.

As a method of applying the composition for forming a photo-alignment film to the substrate, the same method as the method of applying the composition for forming an optically anisotropic layer to the substrate to be described later may be mentioned. As a method of removing the solvent from the applied composition for forming a photo-alignment film, the same method as the method of removing the solvent from the oriented polymer composition may be mentioned.

In order to irradiate polarized light, a form in which the solvent is removed from the composition for forming a photo-alignment film applied on the substrate may be directly irradiated with polarized light, or a form in which polarized light is irradiated from the substrate side and the polarized light is transmitted through the substrate to be irradiated. good. Further, the polarized light is preferably substantially parallel light. The wavelength of polarized light to be irradiated is preferably in a wavelength range in which the photoreactive group of a polymer or monomer having a photoreactive group can absorb light energy. Specifically, UV (ultraviolet rays) in the wavelength range of 250 nm to 400 nm is particularly preferable. Examples of the light source for irradiating polarized light include a xenon lamp, a high pressure mercury lamp, an ultra high pressure mercury lamp, a metal halide lamp, and an ultraviolet laser such as KrF and ArF. Among them, a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, and a metal halide lamp are preferable because of their large luminous intensity of ultraviolet rays having a wavelength of 313 nm. Polarized UV can be irradiated by irradiating light from the light source through an appropriate polarizing layer. Examples of the polarizing layer include polarizing filters, polarizing prisms such as Glen Thompson, and Glenn Taylor, and polarizing layers of wire grid type.

As a method of applying the composition for forming an optically anisotropic layer on the base film 5 or the alignment layer 8, extrusion coating, direct gravure coating, reverse gravure coating, CAP coating, slit coating, and die coating And the law. Further, a method of applying using a coater such as a dip coater, a bar coater, and a spin coater may be mentioned. By adopting a CAP coating method, an ink jet method, a dip coating method, a slit coating method, a die coating method, and a coating method using a bar coater, it is possible to continuously apply in a roll-to-roll format. In the case of applying in a roll-to-roll format, an alignment layer 8 is formed by applying a composition for forming a photo-alignment layer on the base film 5, and the composition for forming an optically anisotropic layer is successively applied on the obtained alignment layer 8 It can also be applied.

Examples of the drying method for removing the solvent contained in the composition for forming an optically anisotropic layer include natural drying, air drying, heat drying, drying under reduced pressure, and a combination thereof. The composition for forming a photo-alignment film and the oriented polymer composition can be similarly dried.

The polymerization of the polymerizable liquid crystal compound is carried out, for example, by irradiating an active energy ray on the laminate to which the composition for forming an optically anisotropic layer containing the polymerizable liquid crystal compound is applied on the base film 5 or on the alignment layer 8 do. The active energy ray to be irradiated depends on the kind of the polymerizable liquid crystal compound contained in the dry film (particularly, the kind of the photopolymerizable functional group of the polymerizable liquid crystal compound), the kind of the photopolymerization initiator, and the amount of the photopolymerization initiator. It is good to choose accordingly. Specifically, light such as visible light, ultraviolet light, infrared light, X-ray, α-ray, β-ray, and γ-ray can be mentioned.

In the method of the present invention, the optical film 1 bonded with the polymer layer 6 with a base film is a film that functions for image display (display screen, etc.) (e.g., to improve the ease of viewing of an image). As a film), it means a film having various optical properties that can be inserted into an image display device such as a liquid crystal display device. As the optical film that can be used in the method of the present invention, for example, a polarizer, a retardation film, a brightness enhancing film, an antiglare film, an antireflection film, an optical functional film such as a diffusion film, a condensing film, a polarizing plate, a retardation plate, etc. I can.

In the method of the present invention, a pressure-sensitive adhesive or adhesive layer (3) for bonding the polymer layer (2) constituting the polymer layer (6) with a base film or the optical laminate (7) with a base film (1) and the optical film (1) The pressure-sensitive adhesive or adhesive constituting the is not particularly limited, and conventionally known pressure-sensitive adhesives and adhesives can be used without particular limitation. Examples of the pressure-sensitive adhesive include pressure-sensitive adhesives having a base polymer such as acrylic, rubber, urethane, silicone, and polyvinyl ether. Moreover, an energy ray-curable adhesive, a thermosetting adhesive, etc. may be sufficient. Examples of the adhesive include an active energy ray-curable adhesive, a water-based adhesive, an organic solvent-based adhesive, and a solvent-free adhesive.

1: optical film 2: polymer layer
2a: polymer layer remaining area 3: pressure-sensitive adhesive or adhesive layer
4: optical laminate 5: base film
5a: polymer layer unlaminated region 5b: base film-polymer layer boundary
6: Polymer layer with base film 7: Optical laminate with base film
8: alignment layer 11: unwinding roll 1
12: conveyance roller 13: antistatic device
14: unwinding roll 2 15: nip roll
16: peeling roll 17: winding roll
20: clean room 21: slitter device
31: upper day 32: lower day
33: long seat 34: shaft
35: wrap 36: holder
37: holder 38: bearing
39: reducer 40: motor

Claims (13)

An optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound are provided, and the polymer layer (2) is laminated through the optical film (1) and an adhesive or adhesive layer (3). As a method of manufacturing the optical laminate 4 made,
Attaching a long base film comprising a long base film 5 and the polymer layer 2 laminated on the base film 5, the base film 5 being peelable from the polymer layer 2 The polymer layer with a base film antistatic conveyance process (A) which conveys the polymer layer 6 in the longitudinal direction while antistatic,
With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) A bonding step (B) for obtaining an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2, and
Along with the peeling process (C) of peeling the said base film 5 from the optical laminated body 7 with a base film obtained in said bonding process (B), and obtaining the said optical laminated body 4,
Including a base film static elimination conveyance process (D) conveying in the longitudinal direction while static electricity elimination of the base film 5 after peeling off in the said peeling process (C),
The said polymer layer with base film antistatic conveyance process (A) includes a polymer layer slit process with a base film (SA) which cuts and cuts the end part of the said polymer layer with base film 6 in a conveyance direction, or,
The bonding step (B) includes an optical film slit step (SB1) in which the end portion of the optical film 1 before bonding with the polymer layer 6 with a base film is cut in the conveyance direction and cut out, or
The bonding step (B) cuts the end of the optical layered body 7 with the base film after bonding with the polymer layer 6 with a base film in the conveyance direction, and cuts it out. ), and
The absolute value of the charge amount of the polymer layer with a base film 6 after static elimination in the polymer layer with base film antistatic transfer step (A) is 0.01 kV or more and 6 kV or less, or the base film antistatic transfer step (D ), the absolute value of the charge amount of the base film 5 after antistatic is 0.01 kV or more and 6 kV or less
Method for producing an optical laminate. An optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound are provided, and the polymer layer (2) is laminated through the optical film (1) and an adhesive or adhesive layer (3). As a method of manufacturing the optical laminate 4 made,
Attaching a long base film comprising a long base film 5 and the polymer layer 2 laminated on the base film 5, the base film 5 being peelable from the polymer layer 2 The polymer layer with a base film antistatic conveyance process (A) which conveys the polymer layer 6 in the longitudinal direction while antistatic,
With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) A bonding step (B) for obtaining an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2, and
Along with the peeling process (C) of peeling the said base film 5 from the optical laminated body 7 with a base film obtained in said bonding process (B), and obtaining the said optical laminated body 4,
Including a base film static elimination conveyance process (D) conveying in the longitudinal direction while static electricity elimination of the base film 5 after peeling off in the said peeling process (C),
The said polymer layer with base film antistatic conveyance process (A) includes a polymer layer slit process (SA) with a base film in which an end portion of the polymer layer with base film 6 is cut out in a conveyance direction,
The absolute value of the charge amount of the polymer layer 6 with the base film after static elimination in the antistatic transfer step (A) of the polymer layer with a base film is 0.01 kV or more and 6 kV or less
Method for producing an optical laminate. The manufacturing method according to claim 2, wherein the absolute value of the amount of charge of the base film (5) after the static elimination in the base film antistatic transfer step (D) is 0.01 kV or more and 6 kV or less. The manufacturing method according to claim 2 or 3, wherein the polymer layer (2) is included at the end cut out in the polymer layer slit step (SA) with a base film. An optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound are provided, and the polymer layer (2) is laminated through the optical film (1) and an adhesive or adhesive layer (3). As a method of manufacturing the optical laminate 4 made,
Attaching a long base film comprising a long base film 5 and the polymer layer 2 laminated on the base film 5, the base film 5 being peelable from the polymer layer 2 The polymer layer with a base film antistatic conveyance process (A) which conveys the polymer layer 6 in the longitudinal direction while antistatic,
With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) A bonding step (B) for obtaining an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2, and
Along with the peeling process (C) of peeling the said base film 5 from the optical laminated body 7 with a base film obtained in said bonding process (B), and obtaining the said optical laminated body 4,
Including a base film static elimination conveyance process (D) conveying in the longitudinal direction while static electricity elimination of the base film 5 after peeling off in the said peeling process (C),
The bonding step (B) includes an optical film slit step (SB1) in which the end portion of the optical film 1 before bonding with the polymer layer 6 with a base film is cut in the conveyance direction and cut out, or
The bonding step (B) cuts the end of the optical layered body 7 with the base film after bonding with the polymer layer 6 with a base film in the conveyance direction, and cuts it out. ), and
The absolute value of the charge amount of the polymer layer with a base film 6 after static elimination in the polymer layer with base film antistatic transfer step (A) is 0.01 kV or more and 6 kV or less, or the base film antistatic transfer step (D ), the absolute value of the charge amount of the base film 5 after antistatic is 0.01 kV or more and 6 kV or less
Method for producing an optical laminate. The method according to claim 5, comprising the optical laminate slit step (SB2) with the base film,
The manufacturing method in which the polymer layer 2 is included in the end cut|disconnected in this process (SB2). The polymer layer with a base film (6) provided in the polymer layer with a base film antistatic conveyance process (A) according to any one of claims 1 to 6, wherein the polymer layer (2) is the polymer layer ( It is provided on the base film 5 over the entire width direction of 2), and the width of the base film 5 is wider than that of the polymer layer 2. The polymer layer with a base film (6) provided in the polymer layer with a base film in an antistatic conveyance process (A) according to any one of claims 1 to 7, wherein the polymer layer is on the base film (5). (2) is laminated through the orientation layer 8, the orientation layer 8 is laminated on the base film 5 over the entire width direction, and the width of the base film 5 is A manufacturing method wider than the width of the alignment layer 8. The width of the polymer layer (2) of the polymer layer (6) with a base film provided in the bonding step (B) is the base film according to any one of claims 1 to 8 in the bonding step (B). A manufacturing method wider than the width of the pressure-sensitive adhesive or adhesive layer 3 formed to bond the adhesive polymer layer 6 and the optical film 1. The polymer layer (6) with a base film provided in the bonding step (B) according to any one of claims 1 to 9, wherein the polymer layer (2) is an alignment layer on the base film (5). A pressure-sensitive adhesive or adhesive that is laminated through (8) and is formed to bond the polymer layer 6 with the base film and the optical film 1 in this bonding step (B) in which the width of the alignment layer 8 is A manufacturing method that is wider than the width of the layer (3). A long base film (5) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound laminated on the base film (5) is provided, and the base film (5) comprises the polymer layer (2). As a method of conveying the polymer layer 6 with a base film which can be peeled off from) in the longitudinal direction while being charged,
A polymer layer with a base film slit step (SA) in which an end portion of the polymer layer 6 with a base film is cut and cut in a conveyance direction,
The conveying method of the polymer layer with a base film, wherein the absolute value of the charge amount of the polymer layer 6 with a base film after antistatic is 0.01 kV or more and 6 kV or less. A long base film (5), a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound, and a long optical film (1) bonded to the polymer layer (2) through an adhesive or adhesive layer (3) ), and the base film 5 is a method for producing an optical layered body 7 with a base film in which the base film 5 is peelable from the polymer layer 2,
A long base film comprising the long base film 5 and the polymer layer 2 laminated on the base film 5, and the base film 5 is peelable from the polymer layer 2 The polymer layer with a base film static elimination conveyance process (A) which conveys the adhesion polymer layer 6 in the longitudinal direction while static electricity, and
With respect to the polymer layer with a base film 6 conveyed by the said polymer layer with a base film antistatic conveyance process (A), a long optical film through an adhesive or an adhesive layer 3 on the side of the polymer layer 2 ( 1) a long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3) Step (B) of providing an optical laminate 7 with a long base film in which the base film 5 is peelable from the polymer layer 2
Including,
The said polymer layer with base film antistatic conveyance process (A) includes a polymer layer slit process with a base film (SA) which cuts and cuts the end part of the said polymer layer with base film 6 in a conveyance direction, or,
The bonding step (B) includes an optical film slit step (SB1) in which the end portion of the optical film 1 before bonding with the polymer layer 6 with a base film is cut in the conveyance direction and cut out, or
The bonding step (B) cuts the end of the optical layered body 7 with the base film after bonding with the polymer layer 6 with a base film in the conveyance direction, and cuts it out. ), and
The method for producing an optical layered product with a base film, wherein the absolute value of the charge amount of the polymer layer with a base film 6 after static electricity in the polymer layer with a base film is not less than or equal to 0.01 kV and less than or equal to 6 kV in the antistatic transfer step (A). A long optical film (1) and a polymer layer (2) composed of a polymer of a polymerizable liquid crystal compound is provided, and the polymer layer (2) is formed through the optical film (1) and an adhesive or adhesive layer (3). As a method of manufacturing the laminated optical laminate 4,
A long base film (5), the polymer layer (2), and a long optical film (1) bonded on the polymer layer (2) through the pressure-sensitive adhesive or adhesive layer (3), the base material The optical laminated body slit step (SB2) with a base film in which the end of the optical laminate 7 with a long base film capable of being peeled off from the polymer layer 2 is cut in the conveying direction, and the end Along with the peeling step (C) of peeling the said base film 5 from the said optical laminated body 7 with a base film after cutting out, and obtaining the said optical laminated body 4,
A base film static elimination conveyance process (D) which conveys in the longitudinal direction while static electricity elimination of the said base material film 5 after peeling in said peeling process (C) is provided,
The method for manufacturing an optical laminate, wherein the absolute value of the amount of charge of the base film 5 after the static elimination in the base film antistatic conveyance step (D) is 0.01 kV or more and 6 kV or less.

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