WO2009119191A1 - アクリル樹脂含有フィルム、それを用いた偏光板及び液晶表示装置 - Google Patents
アクリル樹脂含有フィルム、それを用いた偏光板及び液晶表示装置 Download PDFInfo
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- WO2009119191A1 WO2009119191A1 PCT/JP2009/052765 JP2009052765W WO2009119191A1 WO 2009119191 A1 WO2009119191 A1 WO 2009119191A1 JP 2009052765 W JP2009052765 W JP 2009052765W WO 2009119191 A1 WO2009119191 A1 WO 2009119191A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
- C08L1/08—Cellulose derivatives
- C08L1/10—Esters of organic acids, i.e. acylates
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
- C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
- C08L33/08—Homopolymers or copolymers of acrylic acid esters
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2333/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
- C08J2333/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters
- C08J2333/06—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C08J2333/08—Homopolymers or copolymers of acrylic acid esters
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
Definitions
- the present invention relates to an acrylic resin-containing film that is transparent, has high heat resistance, and remarkably improves brittleness, a polarizing plate using the same, and a liquid crystal display device.
- PMMA polymethyl methacrylate
- the PMMA resin film has poor heat resistance, there is a problem that the shape changes in use at high temperatures or in long-term use.
- This problem is an important issue not only as a physical property of a single film but also in a polarizing plate and a display device using such a film. That is, in the long-term use of the liquid crystal display device, the polarizing plate curls as the film is deformed, so that the entire panel is warped or even when used in a position between the polarizer and the liquid crystal cell. Since the preferable phase difference changes, there are problems that the viewing angle fluctuates and the color changes.
- the acrylic resin film is excellent in transparency and suitable as an optical film, but it is brittle and has a characteristic that it does not show much retardation even when stretched. There is a problem that it is not necessarily suitable. Further, when adjusting the phase difference by adding a phase difference controlling agent, there is a problem that the compatibility is not good when only the acrylic resin or the cellulose resin is used depending on the phase difference controlling agent.
- phase separation may occur and haze may deteriorate.
- the film may be deformed or the phase difference may not be maintained when left at a high temperature for a long time.
- PC polycarbonate
- Patent Document 5 discloses an inexpensive and moisture-resistant film by blending acrylic resin with butyl-modified acetylcellulose, but this film was not sufficiently overcome the brittleness of acrylic. . Furthermore, with the recent increase in the size of displays, the reduction in the thickness of members, and the reduction in weight, these issues such as transparency, high heat resistance, and brittleness have become more prominent. JP 2002-12728 A JP 2005-146084 A JP 2007-191706 A JP-A-5-306344 Japanese Patent Laid-Open No. 5-119217
- the present invention has been made in view of the above-described problems and circumstances, and its solution is to provide an acrylic resin-containing film that is transparent, has high heat resistance, and has markedly improved brittleness, and a polarizing plate using the acrylic resin-containing film. That is.
- An acrylic resin-containing film containing an acrylic resin as a main constituent comprising an acrylic resin and a cellulose ester resin in a compatible state at a mass ratio of 95: 5 to 30:70, Or a part of the acrylic resin having a mesogenic group as a substituent or a divalent linking group, and the cellulose ester resin has a total substitution degree of the acyl group of 2.00 to 3.00 and a carbon number of 3 to
- the acrylic resin-containing film is characterized in that the substitution degree of the acyl group of No. 7 is 1.2 to 3.0, and the weight average molecular weight (Mw) of the cellulose ester resin is 75000 or more.
- the in-plane retardation value Ro (590) defined by the following formula (I) is in the range of 30 to 300 nm, and the retardation value Rt (590) in the thickness direction defined by the following formula (II) is 50. 4.
- Ro (590) (nx ⁇ ny) ⁇ d (nm)
- Rt (590) ⁇ (nx + ny) / 2 ⁇ nz ⁇ ⁇ d (nm)
- Ro (590) represents the in-plane retardation value in the film at a wavelength of 590 nm
- Rt (590) represents the retardation value in the thickness direction in the film at 590 nm
- D represents the thickness (nm) of the optical film
- nx represents the maximum refractive index in the plane of the film at 590 nm, and is also referred to as the refractive index in the slow axis direction.
- ny represents the refractive index in the direction perpendicular to the slow axis in the film plane at 590 nm
- nz represents the refractive index of the film in the thickness direction at 590 nm.
- a polarizing plate characterized by using the acrylic resin-containing film according to any one of 1 to 4 on at least one surface.
- the present invention is transparent, has high heat resistance, significantly improves brittleness, and has an acrylic resin-containing film having a retardation necessary for improving the viewing angle of a liquid crystal panel, and polarized light using the same Board can be provided.
- phase difference control agents have poor compatibility, and some have problems with bleeding out and haze.
- some are compatible with acrylic resin but not cellulose ester resin.
- some are compatible with cellulose ester resin but not compatible with acrylic resin.
- Acrylic resin and cellulose ester resin are used in combination. In the film, the selection range of the retardation control agent is narrowed.
- the compatibility with the acrylic resin of the film is obtained by having the main chain of the acrylic resin.
- the low molecular weight retardation control agent has a problem in heat resistance by lowering the Tg of the film, but in this case, it can be made a relatively high molecular weight compound by controlling the degree of polymerization. Can solve the problem. Thereby, since the softening point is increased, it is possible to prevent deformation of the film when left at a high temperature.
- the acrylic resin may not be sufficiently brittle from the beginning, but if a low molecular weight component is added thereto, the brittleness is remarkably deteriorated, and it may become impossible to process a slit or the like and become impractical as a film.
- the viewing angle of each type of liquid crystal panel such as VA and IPS and the retardation of the retardation film required to improve the color change when viewed from an angle, the graft amount of the mesogenic group, the stretching ratio of the film, etc. can be obtained by controlling.
- the problem of brittleness peculiar to acrylic can be improved.
- the blend of acrylic resin and cellulose resin is not as large as moisture-permeable and cellulose ester resin alone, and it is larger than cycloolefin polymer that does not pass through at all, so it balances the durability of polarizing plate with moisture and heat and the drying property when making polarized light Also excellent.
- the acrylic resin-containing film of the present invention is an acrylic resin-containing film containing an acrylic resin as a main constituent component, and the acrylic resin and the cellulose ester resin are mixed at a mass ratio of 95: 5 to 30:70.
- the acrylic resin is an acrylic resin having all or a part of the mesogenic group as a substituent or a divalent linking group
- the cellulose ester resin has a total substitution degree of the acyl group of 2.00.
- the substitution degree of the acyl group having 3 to 7 carbon atoms is 3.0 to 3.00 and the weight average molecular weight (Mw) of the cellulose ester resin is 75000 or more.
- the acrylic resin-containing film of the present invention is an acrylic resin-containing film containing an acrylic resin as a main component, and the acrylic resin and the cellulose ester resin are used in a mass ratio of 95: 5 to 30:70.
- the acrylic resin is an acrylic resin having all or part of the mesogenic group as a substituent or a divalent linking group
- the cellulose ester resin has a total substitution degree of the acyl group. 2.00 to 3.00, the degree of substitution of the acyl group having 3 to 7 carbon atoms is 1.2 to 3.0, and the weight average molecular weight (Mw) of the cellulose ester resin is 75,000 or more.
- the weight average molecular weight (Mw) of either one or both of the acrylic resin having a mesogenic group or the acrylic resin not having a mesogenic group is 80,000 to 1,000,000.
- Mw weight average molecular weight
- the in-plane retardation value Ro (590) defined by the formula (I) is 30 to 300 nm, and the retardation value Rt (590) in the thickness direction defined by the formula (II) is 50. It is preferable that the thickness is ⁇ 300 nm.
- the acrylic resin according to the present invention is characterized in that all or a part thereof is an acrylic resin having a mesogenic group as a substituent or a divalent linking group.
- the “mesogenic group” refers to a rigid linear portion that exhibits liquid crystallinity in liquid crystal constituent molecules.
- This mesogenic group is preferably composed of two or more aromatic rings or alicyclic rings and a linking group that connects them. Some or all of these aromatic or alicyclic hydrogen atoms may be substituted.
- Typical examples of the aromatic ring or alicyclic ring include a benzene ring, a naphthalene ring, and a cyclohexane ring, and the linking group is a divalent group with less flexibility, such as a single bond, an ether bond, a carbonyl group, a carbonyloxy group, Typical examples are trans-ethylene group, ethynylene group, azo group, azoxy group, —CH ⁇ N—, and alkylene group.
- the acrylic resin according to the present invention may be a polymerizable compound having a mesogenic group as a substituent or a divalent linking group, that is, an acrylic resin obtained by homopolymerizing a (meth) acrylate compound.
- the acrylic resin obtained by copolymerizing the (meth) acrylate compound which has and the compound which has ethylenically unsaturated bonds, such as the (meth) acrylate compound which does not have a mesogenic group, may be sufficient.
- a compound represented by the following general formula (MA1) can be used, but is not limited thereto.
- the mesogenic group represented by M represents a group in which an aromatic ring, an alicyclic ring, a heterocyclic ring or a condensed ring is bonded via a connecting chain or directly, and is represented by the following general formula (2). be able to.
- R represents a hydrogen atom, an alkyl group having 1 to 18 carbon atoms, an alkoxy group having 1 to 18 carbon atoms, an alkenyl group having 2 to 18 carbon atoms, or an alkenyloxy group having 2 to 18 carbon atoms.
- —CH 2 — is —O—, —S—, —CO—, —COO—, May be substituted with —OCO— or —OCO—O—
- Z 1 And Z 2 are a single bond, —COO—, —OCO—, —CH 2 CH 2 —, —CH ⁇ CH—, — (CH 2 ) 4 —, —CH 2 O—, —OCH
- alkoxy group having 1 to 18 carbon atoms examples include methyloxy, chloromethyloxy, trifluoromethyloxy, cyanomethyloxy, Ethyloxy, dichloroethyloxy, pro Ruoxy, isopropyloxy, butyloxy, sec-butyloxy, tert-butyloxy, isobutyloxy, amyloxy, isoamyloxy, tert-amyloxy, hexyloxy, cyclohexyloxy, heptyloxy, isoheptyloxy, tert-heptyloxy, n-octyloxy, Isooctyloxy, tertiary octyloxy, 2-ethylhexyloxy and the like.
- alkenyl group having 2 to 18 carbon atoms examples include vinyl, 1-methylethenyl, 2-methylethenyl, propenyl, butenyl, isobutenyl, pentenyl, hexenyl, heptenyl Octenyl, decenyl, pentadecenyl, eicosenyl, tricocenyl and the like.
- alkenyloxy group having 2 to 18 carbon atoms examples include vinyloxy, 1-methylethenyloxy, 2- Tylethenyloxy, propenyloxy, butenyloxy, isobutenyloxy, pentenyloxy, hexenyloxy, heptenyloxy, octenyloxy, decenyloxy, pentadecenyloxy, eicocenyloxy, tricosenyloxy, etc.
- halogen atom as the group examples include a fluorine atom, a chlorine atom, a bromine atom, and an iodine atom.
- polymerizable compound having a mesogenic group represented by the general formula (MA1) include the following compound Nos. MA1-1 to MA1-12 can be mentioned. However, the present invention is not limited by the following compounds.
- a compound represented by the following general formula (MA2) can be used, but is not limited thereto.
- the compound represented by the following general formula (MA2) can be synthesized by a method according to the method described in JP-A-2005-263789.
- R 1 and R 2 each independently represent a hydrogen atom or a methyl group, l and t each represent 0 to 14, m and s each represents 0 or 1, and rings A, B, C and D each independently represent Represents an aromatic or aliphatic hydrocarbon 6-membered ring, hetero 6-membered ring or condensed ring, and Z 1 , Z 2 and Z 3 are each independently a direct bond, —CH 2 O—, —OCH 2 —, — COO—, —OCO—, —CH 2 —CH 2 —, —CH ⁇ CH—, —CF ⁇ CF— or —C ⁇ C—, each of n, p, q and r independently represents 0 or 1 2 ⁇ n + p + q + r ⁇ 4, where l and t represent different numbers, or m and s represent different numbers.
- the di (meth) acrylate compound represented by the general formula (MA2) specifically, the following compound No. MA2-1 to MA2-20 and the like.
- the compound represented by the general formula (MA2) can be synthesized by a method according to the method described in JP-A-11-116534.
- the acrylic resin according to the present invention may be a resin having a monomer unit represented by the following general formula (MA3) having a mesogenic group.
- R 1 represents a hydrogen atom or a methyl group
- a represents a positive integer of 1 to 6
- X 1 represents a —CO 2 — group or —OCO— group
- R 2 represents an alkoxy having 1 to 6 carbon atoms.
- a group, a cyano group, a fluoro group or an alkyl group having 1 to 6 carbon atoms, b and c each represents an integer of 1 or 2
- Specific examples of the polymerizable compound that can be used to synthesize a resin having a monomer unit represented by the general formula (MA3) include the following compounds.
- Synthesis of a polymerizable compound that can be used to synthesize a resin having a monomer unit represented by the general formula (MA3) is a method according to a method described in JP-A-2001-354732 Can be done.
- the polymerizable compound having a mesogenic group according to the present invention when polymerized as a polymerizable liquid crystalline monomer, it can be used alone or in combination of two or more. Moreover, the polymerizable compound according to the present invention can be copolymerized with another liquid crystalline monomer and a compound having an ethylenically unsaturated bond such as a (meth) acrylic acid ester.
- the amount of these other liquid crystalline monomers and compounds used is within a range in which the polymerizable compound having a mesogenic group according to the present invention is 1% by mass or more, particularly 3% by mass or more, in all monomers. Although it is preferable, the amount used is appropriate depending on the structure of the liquid crystalline monomer and compound.
- the compound having an ethylenically unsaturated bond such as a (meth) acrylic acid ester having no copolymerizable mesogenic group, includes an alkyl methacrylate having 2 to 18 carbon atoms, and an alkyl carbon number.
- Is an ⁇ , ⁇ -unsaturated acid such as alkyl acrylate, acrylic acid, methacrylic acid, etc., unsaturated divalent carboxylic acid such as maleic acid, fumaric acid, itaconic acid, styrene, ⁇ -methylstyrene, nucleus
- Aromatic vinyl compounds such as substituted styrene, ⁇ , ⁇ -unsaturated nitriles such as acrylonitrile and methacrylonitrile, maleic anhydride, maleimide, N-substituted maleimide, glutaric anhydride, etc. Two or more kinds can be used in combination.
- methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, s-butyl acrylate, 2-ethylhexyl acrylate, and the like are preferable from the viewpoint of thermal decomposition resistance and fluidity of the copolymer.
- n-Butyl acrylate is particularly preferably used.
- the acrylic resin used in the acrylic resin-containing film of the present invention preferably has a weight average molecular weight (Mw) of 80,000 to 1,000,000 from the viewpoint of mechanical strength as a film and fluidity when producing the film.
- Mw weight average molecular weight
- the weight average molecular weight of the acrylic resin according to the present invention can be measured by gel permeation chromatography.
- the measurement conditions are as follows.
- the acrylic resin production method is not particularly limited, and any known method such as suspension polymerization, emulsion polymerization, bulk polymerization, or solution polymerization may be used.
- a polymerization initiator a normal peroxide type and an azo type can be used, and a redox type can also be used.
- the polymerization temperature may be 30 to 100 ° C. for suspension or emulsion polymerization, and 80 to 160 ° C. for bulk or solution polymerization.
- polymerization can be carried out using alkyl mercaptan or the like as a chain transfer agent.
- acrylic resin having no mesogenic group As the acrylic resin having no mesogenic group according to the present invention, a commercially available product can also be used. For example, Delpet 60N, 80N (Asahi Kasei Chemicals Co., Ltd.), Dialal BR52, BR80, BR83, BR85, BR88 (Mitsubishi Rayon Co., Ltd.), KT75 (Electrochemical Industry Co., Ltd.) and the like can be mentioned. .
- the acrylic resin used in the present invention includes a methacrylic resin.
- the resin is not particularly limited, but a resin comprising 50 to 99% by mass of methyl methacrylate units and 1 to 50% by mass of other monomer units copolymerizable therewith is preferable.
- the cellulose ester resin according to the present invention has a total acyl group substitution degree (T) of 2.00 to 3.00 and a carbon number of 3 particularly from the viewpoint of improvement in brittleness and transparency when mixed with an acrylic resin.
- the substitution degree of the acyl group of ⁇ 7 is preferably from 1.2 to 3.0. That is, the cellulose ester resin is a cellulose ester resin substituted with an acyl group having 3 to 7 carbon atoms.
- propionyl, butyryl and the like are preferably used, and a propionyl group is particularly preferably used.
- the total substitution degree of the acyl group of the cellulose ester resin is less than 2.0, that is, when the residual degree of the hydroxyl groups at the 2, 3, and 6 positions of the cellulose ester molecule is more than 1.0, the acrylic resin (A ) And the haze is a problem.
- the total substitution degree of the acyl group is 2.0 or more, if the substitution degree of the acyl group having 3 to 7 carbon atoms is less than 1.2, still sufficient compatibility cannot be obtained, Brittleness will decrease.
- the substitution degree of the acyl group having 2 carbon atoms that is, the acetyl group is high
- the substitution degree of the acyl group having 3 to 7 carbon atoms is 1.
- the compatibility is lowered and the haze is increased.
- the substitution degree of the acyl group having 8 or more carbon atoms is high
- the substitution degree of the acyl group having 3 to 7 carbon atoms is less than 1.2. In such a case, the brittleness is lowered and desired characteristics cannot be obtained.
- the total substitution degree (T) is 2.0 to 3.0, and the substitution degree of the acyl group having 3 to 7 carbon atoms is 1.2 to 3.0. If there is no problem, It is preferable that the total degree of substitution of acyl groups having 3 to 7 carbon atoms, that is, acetyl groups or acyl groups having 8 or more carbon atoms is 1.3 or less.
- acyl group is meant to include those further having a substituent.
- the carbon number of the acyl group includes a substituent of the acyl group.
- the number of substituents X substituted on the aromatic ring is preferably 0 to 5. Also in this case, it is necessary to pay attention so that the degree of substitution of the acyl group having 3 to 7 carbon atoms including the substituent is 1.2 to 3.0. For example, since the benzyl group has 7 carbon atoms, when it has a substituent containing carbon, the benzyl group has 8 or more carbon atoms and is not included in the acyl group having 3 to 7 carbon atoms. Become.
- substituents substituted on the aromatic ring when the number of substituents substituted on the aromatic ring is 2 or more, they may be the same or different from each other, but they may be linked together to form a condensed polycyclic compound (for example, naphthalene, indene, indane, phenanthrene, quinoline). , Isoquinoline, chromene, chroman, phthalazine, acridine, indole, indoline, etc.).
- a condensed polycyclic compound for example, naphthalene, indene, indane, phenanthrene, quinoline.
- Isoquinoline chromene, chroman, phthalazine, acridine, indole, indoline, etc.
- a structure having at least one kind of a substituted or unsubstituted aliphatic acyl group having 3 to 7 carbon atoms is used as a structure used in the cellulose resin according to the present invention.
- the substitution degree of the cellulose ester resin according to the present invention is such that the total substitution degree (T) of the acyl group is 2.00 to 3.00, and the substitution degree of the acyl group having 3 to 7 carbon atoms is 1.2 to 3.0. It is.
- the total substitution degree of acyl groups other than an acyl group having 3 to 7 carbon atoms, that is, an acetyl group and an acyl group having 8 or more carbon atoms is 1.3 or less.
- the cellulose ester resin according to the present invention is preferably at least one selected from cellulose acetate propionate, cellulose acetate butyrate, cellulose acetate benzoate, cellulose propionate, and cellulose butyrate, and particularly cellulose acetate propionate. Nate and cellulose propionate are more preferable.
- cellulose ester resins are cellulose acetate propionate and cellulose acetate butyrate, and those having an acyl group having 3 or 4 carbon atoms as a substituent are preferable.
- the portion not substituted with an acyl group usually exists as a hydroxyl group. These can be synthesized by known methods.
- substitution degree of the acetyl group and the substitution degree of other acyl groups were determined by the method prescribed in ASTM-D817-96.
- the weight average molecular weight (Mw) of the cellulose ester resin according to the present invention is 75000 or more, particularly from the viewpoint of improvement in compatibility with the acrylic resin and brittleness, preferably in the range of 75000 to 300000, and 100000 to 24000. It is more preferable that the value be within the range, and that of 160000 to 240000 is particularly preferable.
- the acrylic resin and the cellulose ester resin are contained in a compatible state at a mass ratio of 95: 5 to 30:70, preferably 95: 5 to 50:50, More preferably, it is 90:10 to 60:40.
- the acrylic resin and the cellulose ester resin need to be contained in a compatible state.
- the physical properties and quality required for an optical film are achieved by supplementing each other by dissolving different resins.
- Whether the acrylic resin and the cellulose ester resin are in a compatible state can be determined, for example, based on the glass transition temperature Tg.
- the glass transition temperatures of the two resins are different, when the two resins are mixed, there are two or more glass transition temperatures of the mixture because there is a glass transition temperature of each resin.
- the glass transition temperature specific to each resin disappears, and the glass transition temperature of the compatible resin is obtained by becoming one glass transition temperature.
- the glass transition temperature referred to here is an intermediate value determined according to JIS K7121 (1987) using a differential scanning calorimeter (DSC-7 model manufactured by Perkin Elmer) at a heating rate of 20 ° C./min.
- the point glass transition temperature (Tmg) is an intermediate value determined according to JIS K7121 (1987) using a differential scanning calorimeter (DSC-7 model manufactured by Perkin Elmer) at a heating rate of 20 ° C./min.
- the point glass transition temperature (Tmg) The point glass transition temperature (Tmg).
- the acrylic resin and the cellulose ester resin are each preferably an amorphous resin, and either one may be a crystalline polymer or a partially crystalline polymer. It is preferable that the non-crystalline resin is formed by the compatibility between the cellulose ester resin and the cellulose ester resin.
- the weight average molecular weight (Mw) of the acrylic resin, the weight average molecular weight (Mw) of the cellulose ester resin, and the degree of substitution are fractionated using the difference in solubility in the solvent of both resins. Then, it is obtained by measuring each.
- fractionating the resin it is possible to extract and separate the soluble resin by adding a compatible resin in a solvent that is soluble only in either one. At this time, heating operation or reflux is performed. May be. A combination of these solvents may be combined in two or more steps to separate the resin. The dissolved resin and the resin remaining as an insoluble matter are filtered off, and the solution containing the extract can be separated by an operation of evaporating the solvent and drying.
- These fractionated resins can be identified by general structural analysis of polymers. Even when the acrylic resin-containing film of the present invention contains a resin other than an acrylic resin or a cellulose ester resin, it can be separated by the same method.
- the weight average molecular weights (Mw) of the compatible resins are different, the high molecular weight substances are eluted earlier by gel permeation chromatography (GPC), and the lower molecular weight substances are eluted after a longer time. Therefore, it can be easily fractionated and the molecular weight can be measured.
- GPC gel permeation chromatography
- the molecular weight of the compatible resin is measured by GPC, and at the same time, the resin solution eluted every time is separated, the solvent is distilled off, and the structure of the dried resin is quantitatively analyzed. By detecting the resin composition for each fraction, each compatible resin can be specified. By measuring the molecular weight distribution of each of the resins separated in advance based on the difference in solubility in a solvent by GPC, it is possible to detect each of the compatible resins.
- the process of obtaining a mixed resin by polymerizing a precursor of an acrylic resin such as a monomer, dimer or oligomer with a cellulose ester resin is complicated, and the resin produced by this method is The control of the reaction is difficult.
- a resin is synthesized by such a method, graft polymerization, cross-linking reaction or cyclization reaction often occurs, and the resin is not dissolved in a solvent or often cannot be melted by heating, so that the optical film can be stabilized. It is difficult to use as a resin to be manufactured. Therefore, the resin obtained by such a method does not correspond to a resin containing the acrylic resin and the cellulose ester resin according to the present invention in a compatible state.
- the acrylic resin-containing film of the present invention may contain a resin and additives other than acrylic resin and cellulose ester resin as long as the function as an optical film is not impaired.
- the resin to be added may be mixed without being dissolved even if it is in a compatible state.
- the total mass of the acrylic resin and the cellulose ester resin in the acrylic resin-containing film of the present invention is preferably 55% by mass or more of the acrylic resin-containing film, more preferably 60% by mass or more, and particularly preferably 70% by mass. % Or more.
- the acrylic resin-containing film may contain acrylic particles.
- the acrylic particles according to the present invention are characterized by being present in the state of particles in the acrylic resin, cellulose ester resin and acrylic resin-containing film (also referred to as incompatible state).
- the acrylic particles are obtained by, for example, collecting a predetermined amount of the prepared acrylic resin-containing film, dissolving in a solvent, stirring, and sufficiently dissolving and dispersing the PTFE film having a pore diameter less than the average particle diameter of the acrylic particles. It is preferable that the weight of the insoluble matter filtered and collected using the membrane filter is 90% by mass or more of the acrylic particles added to the acrylic resin-containing film.
- the acrylic particles used in the present invention are not particularly limited, but are preferably acrylic particles having a layer structure of two or more layers, and particularly preferably the following multilayer structure acrylic granular composite.
- the multilayer structure acrylic granular composite is formed by laminating an innermost hard layer polymer, a cross-linked soft layer polymer exhibiting rubber elasticity, and an outermost hard layer polymer from the center to the outer periphery.
- Preferred embodiments of the multilayer structure acrylic granular composite used in the acrylic resin composition according to the present invention include the following.
- (c) the innermost hard In the presence of a polymer comprising a layer and a crosslinked soft layer, a monomer mixture comprising 80 to 99% by mass of methyl methacrylate and 1 to 20% by
- Outermost hard layer weight And the obtained three-layer structure polymer is an innermost hard layer polymer (a) 5 to 40% by mass, a soft layer polymer (b) 30 to 60% by mass, and An outermost hard layer polymer (c) comprising 20 to 50% by mass, having an insoluble part when fractionated with acetone, and an acrylic granular composite having a methyl ethyl ketone swelling degree of 1.5 to 4.0 at the insoluble part .
- the innermost hard layer polymer (a) constituting the multilayer structure acrylic granular composite is 80 to 98.9% by mass of methyl methacrylate and 1 to 20 mass of alkyl acrylate having 1 to 8 carbon atoms in the alkyl group. % And a monomer mixture consisting of 0.01 to 0.3% by mass of a polyfunctional grafting agent is preferred.
- examples of the alkyl acrylate having 1 to 8 carbon atoms in the alkyl group include methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, s-butyl acrylate, 2-ethylhexyl acrylate, and the like. And n-butyl acrylate are preferably used.
- the proportion of the alkyl acrylate unit in the innermost hard layer polymer (a) is 1 to 20% by mass.
- the thermal decomposability of the polymer is increased, while the unit is 20% by mass. If it exceeds 50%, the glass transition temperature of the innermost hard layer polymer (c) is lowered, and the impact resistance imparting effect of the three-layer structure acrylic granular composite is lowered.
- polyfunctional grafting agent examples include polyfunctional monomers having different polymerizable functional groups, such as allyl esters of acrylic acid, methacrylic acid, maleic acid, and fumaric acid, and allyl methacrylate is preferably used.
- the polyfunctional grafting agent is used to chemically bond the innermost hard layer polymer and the soft layer polymer, and the ratio used during the innermost hard layer polymerization is 0.01 to 0.3% by mass. .
- the crosslinked soft layer polymer (b) constituting the acrylic granular composite is an alkyl acrylate having from 9 to 8 carbon atoms having an alkyl group of 1 to 8 in the presence of the innermost hard layer polymer (a). What is obtained by polymerizing a monomer mixture consisting of 10% by mass, 0.01 to 5% by mass of a multifunctional crosslinking agent and 0.5 to 5% by mass of a multifunctional grafting agent is preferred.
- n-butyl acrylate or 2-ethylhexyl acrylate is preferably used as the alkyl acrylate having 4 to 8 carbon atoms in the alkyl group.
- Examples of other monofunctional monomers that can be copolymerized include styrene and substituted styrene derivatives. As the ratio of the alkyl acrylate having 4 to 8 carbon atoms in the alkyl group and styrene increases, the glass transition temperature of the produced polymer (b) decreases as the former increases, that is, it can be softened.
- the refractive index of the soft layer polymer (b) at room temperature is set to the innermost hard layer polymer (a), the outermost hard layer polymer (c), and the hard heat. It is more advantageous to make it closer to the plastic acrylic resin, and the ratio between them is selected in consideration of these.
- polyfunctional grafting agent those mentioned in the section of the innermost layer hard polymer (a) can be used.
- the polyfunctional grafting agent used here is used to chemically bond the soft layer polymer (b) and the outermost hard layer polymer (c), and the proportion used during the innermost hard layer polymerization is impact resistance. From the viewpoint of the effect of imparting properties, 0.5 to 5% by mass is preferable.
- polyfunctional crosslinking agent generally known crosslinking agents such as divinyl compounds, diallyl compounds, diacrylic compounds, dimethacrylic compounds and the like can be used, but polyethylene glycol diacrylate (molecular weight 200 to 600) is preferably used.
- the polyfunctional cross-linking agent used here is used to generate a cross-linked structure during the polymerization of the soft layer (b) and to exhibit the effect of imparting impact resistance.
- the polyfunctional crosslinking agent is not an essential component because the crosslinked structure of the soft layer (b) is generated to some extent. Is preferably 0.01 to 5% by weight from the viewpoint of imparting impact resistance.
- the outermost hard layer polymer (c) constituting the multi-layer structure acrylic granular composite has a methyl methacrylate of 80 to 99 mass in the presence of the innermost hard layer polymer (a) and the soft layer polymer (b). % And a monomer mixture comprising 1 to 20% by mass of an alkyl acrylate having 1 to 8 carbon atoms in the alkyl group is preferred.
- the acrylic alkylate those described above are used, but methyl acrylate and ethyl acrylate are preferably used.
- the proportion of the alkyl acrylate unit in the outermost hard layer (c) is preferably 1 to 20% by mass.
- an alkyl mercaptan or the like can be used as a chain transfer agent to adjust the molecular weight for the purpose of improving compatibility with the acrylic resin.
- the outermost hard layer with a gradient such that the molecular weight gradually decreases from the inside toward the outside in order to improve the balance between elongation and impact resistance.
- the monomer mixture for forming the outermost hard layer is divided into two or more, and the molecular weight is increased from the inside by a method of sequentially increasing the amount of chain transfer agent added each time. It is possible to make it smaller toward the outside.
- the molecular weight formed at this time can also be examined by polymerizing the monomer mixture used each time under the same conditions, and measuring the molecular weight of the obtained polymer.
- the particle diameter of the acrylic granular composite which is a multilayer structure polymer preferably used in the present invention is not particularly limited, but is preferably 10 nm or more and 1000 nm or less, and more preferably 20 nm or more and 500 nm or less. More preferably, it is most preferably 50 nm or more and 400 nm or less.
- the mass ratio of the core and the shell is not particularly limited, but when the entire multilayer structure polymer is 100 parts by mass,
- the core layer is preferably 50 parts by mass or more and 90 parts by mass or less, and more preferably 60 parts by mass or more and 80 parts by mass or less.
- Examples of such commercially available multilayered acrylic granular composites include, for example, “Metablene” manufactured by Mitsubishi Rayon Co., “Kane Ace” manufactured by Kaneka Chemical Co., Ltd., “Paralloid” manufactured by Kureha Chemical Co., Ltd., Rohm and Haas “Acryloid” manufactured by KK, “Staffyroid” manufactured by Ganz Kasei Kogyo Co., Ltd., “Parapet SA” manufactured by Kuraray Co., Ltd., and the like can be used alone or in combination.
- a graft copolymer obtained by copolymerizing a monomer mixture comprising a saturated carboxylic acid monomer, an aromatic vinyl monomer, and, if necessary, other vinyl monomers copolymerizable therewith. can be mentioned.
- the rubbery polymer used for the acrylic particles that are the graft copolymer, but diene rubber, acrylic rubber, ethylene rubber, and the like can be used.
- Specific examples include polybutadiene, styrene-butadiene copolymer, block copolymer of styrene-butadiene, acrylonitrile-butadiene copolymer, butyl acrylate-butadiene copolymer, polyisoprene, butadiene-methyl methacrylate copolymer.
- the refractive indexes of the acrylic resin and the acrylic particles are close to each other because the transparency of the acrylic resin-containing film of the present invention can be obtained.
- the refractive index difference between the acrylic particles and the acrylic resin is preferably 0.05 or less, more preferably 0.02 or less, and particularly preferably 0.01 or less.
- a method of adjusting the monomer unit composition ratio of the acrylic resin and / or a composition ratio of the rubbery polymer or monomer used in the acrylic particles is prepared. Depending on the method, the difference in refractive index can be reduced, and an acrylic resin-containing film excellent in transparency can be obtained.
- the difference in refractive index referred to here means that the acrylic resin-containing film of the present invention is sufficiently dissolved in a solvent in which the acrylic resin is soluble to obtain a cloudy solution, which is subjected to an operation such as centrifugation. After separating the soluble part and the insoluble part and purifying the soluble part (acrylic resin) and the insoluble part (acrylic particles), the difference in the measured refractive index (23 ° C., measurement wavelength: 550 nm) is shown.
- the method of blending the acrylic particles with the acrylic resin is not particularly limited, and after blending the acrylic resin and other optional components in advance, usually at 200 to 350 ° C. while adding the acrylic particles, uniaxial or biaxial A method of uniformly melt-kneading with a shaft extruder is preferably used.
- a method such as in-line addition can be used.
- acrylic particles can also be used as the acrylic particles according to the present invention.
- metabrene W-341 (manufactured by Mitsubishi Rayon Co., Ltd.)
- Chemisnow MR-2G (C3)
- MS-300X (manufactured by Soken Chemical Co., Ltd.) and the like can be mentioned.
- the acrylic resin-containing film of the present invention preferably contains 0.5 to 45% by mass of acrylic particles with respect to the total mass of the resin constituting the film.
- Phase difference control agent In this application, the retardation of the retardation film corresponding to each method such as VA and IPS can be obtained by using an acrylic resin having a mesogenic group. However, in order to further optimize the retardation, the retardation control is separately performed. An agent may be added.
- the “phase difference controlling agent” refers to an additive other than an acrylic resin having a mesogenic group that is added mainly for controlling the phase difference.
- the retardation control agent compounds described in JP-A No. 2002-296421 and various ester plasticizers can be used. Hereinafter, preferred ester compounds will be described in detail.
- a compound having a structure in which aromatic rings are arranged in a plane when added as an additive and stretched is preferable.
- a compound in which an aromatic ring is contained as a block in the main chain or at the terminal is preferable.
- polyester polyol of glycol and dibasic acid examples include a dehydration condensation reaction between a glycol having an average carbon number of 2 to 3.5 and a dibasic acid having an average carbon number of 4 to 5.5, or the glycol. It is preferably one produced by a conventional method by addition of a dibasic anhydride having an average carbon number of 4 to 5.5 and a dehydration condensation reaction.
- glycol used in the polyester polyol examples include ethylene glycol, diethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 2-methyl-1,3-propanediol, 1,4-butylene glycol, and neopentyl.
- ethylene glycol or a mixture of ethylene glycol and diethylene glycol Is particularly preferably used.
- the average carbon number of the glycol is preferably in the range of 2 to 3.5 from the viewpoint of production of polyester polyol, compatibility with cellulose, transparency, and the like.
- the ethylene glycol / diethylene glycol molar ratio is preferably 25 to 100/75 to 0, and for cellulose esters having excellent compatibility with cellulose esters.
- a modifier can be obtained. Further, it is more preferably 25 to 40/75 to 60, and 60 to 95/40 to 5. By adjusting to such a range, the crystallinity and melting point of the polyester polyol are close to those of conventional ones. Productivity is also improved.
- examples of the dibasic acid constituting the polyester polyol used in the present invention include succinic acid, glutaric acid, adipic acid, and sebacic acid. These can be used alone or in combination of two or more.
- succinic acid or a mixture of succinic acid and terephthalic acid is particularly preferably used.
- the average number of carbon atoms of the dibasic acid is preferably in the range of 4 to 5.5 from the viewpoint of production of polyester polyol, compatibility with cellulose, transparency, and the like. .
- the succinic acid / terephthalic acid molar ratio is preferably 25 to 100/75 to 0, and has excellent compatibility with the cellulose ester.
- a cellulose ester modifier can be obtained. Further, it is more preferably 25 to 40/75 to 60, and 60 to 95/40 to 5. By adjusting to such a range, the crystallinity and melting point of the polyester polyol are close to those of conventional ones. Productivity is also improved.
- the glycol and dibasic acid constituting the polyester polyol used in the present invention include combinations other than the above, but the total of the average number of carbon atoms of the glycol and the average number of carbon atoms of the dibasic acid is 6-7. A combination of .5 is preferred.
- the polyester polyol obtained from the glycol and the dibasic acid may have a number average molecular weight in the range of 1,000 to 200,000, more preferably a hydroxyl-terminated polyester having a number average molecular weight of 1200 to 1000-5000. Those having a molecular weight of ⁇ 4000 are particularly preferably used.
- a retardation control agent cellulose ester modifier
- the polyester polyol having a number average molecular weight of 1000 or more is contained in the film in an amount of 2 to 30% by mass. More preferably, it is 10 to 20% by mass.
- the content of the polymer in the film depends on the type of polymer and the weight average molecular weight. It is decided accordingly.
- the content of the carboxyl group terminal in the polyester polyol used in the present invention is preferably 1/20 or less of the number of moles of the hydroxyl terminal from the viewpoint of the effect of the present invention. It is more preferable to stop at 40 or less.
- esterification catalysts such as metal organic acid salts or metal chelate compounds such as titanium, zinc, lead and zirconium, or antimony oxide can be used.
- esterification catalyst for example, tetraisopropyl titanate, tetrabutyl titanate and the like are preferably used, and 0.0005 to 0.02 mass per 100 mass parts of the total of glycol (a) and dibasic acid (b) used. Are preferably used.
- Polyester polyol polycondensation is carried out by conventional methods.
- a direct reaction between the dibasic acid and glycol, the dibasic acid or an alkyl ester thereof for example, a polyesterification reaction or transesterification reaction between a dibasic acid methyl ester and a glycol, or a hot melt condensation method
- it can be easily synthesized by any method of dehydrohalogenation reaction between acid chlorides of these acids and glycols, but polyester polyols whose number average molecular weight is not so large are preferably by direct reaction.
- the polyester polyol having a high distribution on the low molecular weight side has very good compatibility with the cellulose ester, and after forming the film, a water vapor permeability is small, and a cellulose ester film rich in transparency can be obtained.
- a conventional method can be used as a method for adjusting the molecular weight without particular limitation. For example, although depending on the polymerization conditions, the amount of these monovalent compounds can be controlled by a method of blocking the molecular ends with a monovalent acid or monovalent alcohol. In this case, a monovalent acid is preferable from the viewpoint of polymer stability.
- acetic acid, propionic acid, butyric acid, pivalic acid, benzoic acid and the like can be mentioned, but during the polycondensation reaction, such monovalent acid is not removed from the system but stopped and removed from the reaction system. Those which are easy to be distilled off when being removed from the system are selected, but these may be mixed and used.
- the number average molecular weight can also be adjusted by measuring the timing at which the reaction is stopped by the amount of water distilled off during the reaction. In addition, it can be adjusted by biasing the number of moles of glycol or dibasic acid to be charged or by controlling the reaction temperature.
- an aromatic terminal ester plasticizer represented by the following general formula (I) can be used.
- B is a benzene monocarboxylic acid residue
- G is an alkylene glycol residue having 2 to 12 carbon atoms, an aryl glycol residue having 6 to 12 carbon atoms, or an oxyalkylene glycol residue having 4 to 12 carbon atoms
- A represents an alkylene dicarboxylic acid residue having 4 to 12 carbon atoms or an aryl dicarboxylic acid residue having 6 to 12 carbon atoms
- n represents an integer of 1 or more.
- Examples of the benzene monocarboxylic acid component of the aromatic terminal ester plasticizer according to the present invention include benzoic acid, paratertiarybutylbenzoic acid, orthotoluic acid, metatoluic acid, p-toluic acid, dimethylbenzoic acid, ethylbenzoic acid, normal There are propylbenzoic acid, aminobenzoic acid, acetoxybenzoic acid and the like, and these can be used as one kind or a mixture of two or more kinds, respectively.
- alkylene glycol component having 2 to 12 carbon atoms of the aromatic terminal ester plasticizer examples include ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,2-butanediol, and 1,3-butanediol.
- Examples of the oxyalkylene glycol component having 4 to 12 carbon atoms of the aromatic terminal ester include diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, tripropylene glycol, and the like. Or it can be used as a mixture of two or more.
- aryl glycol component having 6 to 12 carbon atoms of the aromatic terminal ester examples include hydroquinone, resorcin, bisphenol A, bisphenol F, and bisphenol. These glycols are used as one kind or a mixture of two or more kinds. Can be used.
- alkylene dicarboxylic acid component having 4 to 12 carbon atoms of the aromatic terminal ester according to the present invention examples include succinic acid, maleic acid, fumaric acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, and dodecanedicarboxylic acid. They are each used as one or a mixture of two or more.
- aryl dicarboxylic acid component having 6 to 12 carbon atoms include phthalic acid, terephthalic acid, 1,5-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, and the like.
- the number average molecular weight of the aromatic terminal ester plasticizer is preferably 300 to 2000, and more preferably 500 to 1500.
- the acid value is preferably 0.5 mgKOH / g or less, the hydroxyl value is 25 mgKOH / g or less, more preferably the acid value is 0.3 mgKOH / g or less, and the hydroxyl value is 15 mgKOH / g or less.
- Acid value and hydroxyl value of aromatic terminal ester refers to the number of milligrams of potassium hydroxide necessary to neutralize the acid (carboxyl group present at the molecular terminal) contained in 1 g of a sample. The acid value and the hydroxyl value are measured according to JIS K0070.
- Example No. 1 (Aromatic terminal ester sample)> A reaction vessel was charged with 820 parts (5 moles) of phthalic acid, 608 parts (8 moles) of 1,2-propylene glycol, 610 parts (5 moles) of benzoic acid, and 0.30 parts of tetraisopropyl titanate as a catalyst. While stirring in an air stream, a reflux condenser was attached to reflux excess monohydric alcohol, and heating was continued at 130 to 250 ° C. until the acid value became 2 or less, and water produced was continuously removed. Next, the distillate is removed under reduced pressure of 6.65 ⁇ 10 3 Pa to 4 ⁇ 10 2 Pa or less at 200 to 230 ° C., and then filtered to obtain an aromatic terminal ester having the following properties. It was.
- Viscosity 25 ° C., mPa ⁇ s); 19815 Acid value: 0.4 ⁇ Sample No. 2 (Aromatic terminal ester sample)> A sample was used except that 500 parts (3.5 moles) of adipic acid, 305 parts (2.5 moles) of benzoic acid, 583 parts (5.5 moles) of diethylene glycol, and 0.45 parts of tetraisopropyl titanate as a catalyst were used in the reaction vessel. No. In the same manner as in No. 1, an aromatic terminal ester having the following properties was obtained.
- Viscosity 25 ° C., mPa ⁇ s
- 90 Acid value 0.05 ⁇ Sample No. 3 (Aromatic terminal ester sample)> Except for using 570 parts (3.5 mol) of isophthalic acid, 305 parts (2.5 mol) of benzoic acid, 737 parts (5.5 mol) of dipropylene glycol and 0.40 part of tetraisopropyl titanate as a catalyst in the reaction vessel. Sample No. In the same manner as in No. 1, an aromatic terminal ester having the following properties was obtained.
- Viscosity 25 ° C., mPa ⁇ s); 33400 Acid value: 0.2
- this invention is not limited to this.
- the content of the aromatic terminal ester plasticizer according to the present invention is preferably 1 to 20% by mass, more preferably 3 to 11% by mass in the cellulose ester film.
- a polyhydric alcohol ester plasticizer can be further used as the retardation control agent.
- the polyhydric alcohol ester used in the present invention is preferably an ester of a divalent or higher aliphatic polyhydric alcohol and a monocarboxylic acid, and preferably has an aromatic ring or a cycloalkyl ring in the molecule.
- the polyhydric alcohol used in the present invention is represented by the following general formula (1).
- R1- (OH) n represents an n-valent organic group, n represents a positive integer of 2 or more, and the OH group represents an alcoholic or phenolic hydroxyl group.
- Examples of preferred polyhydric alcohols include the following, but the present invention is not limited to these.
- the monocarboxylic acid used in the polyhydric alcohol ester according to the present invention is not particularly limited, and known aliphatic monocarboxylic acid, alicyclic monocarboxylic acid, aromatic monocarboxylic acid and the like can be used. Use of an alicyclic monocarboxylic acid or aromatic monocarboxylic acid is preferable in terms of improving moisture permeability and retention. Examples of preferred monocarboxylic acids include the following, but the present invention is not limited thereto.
- aliphatic monocarboxylic acid a fatty acid having a straight chain or a side chain having 1 to 32 carbon atoms can be preferably used. More preferably, it has 1 to 20 carbon atoms, and particularly preferably 1 to 10 carbon atoms.
- acetic acid is preferred because the compatibility with the cellulose ester is increased, and it is also preferred to use a mixture of acetic acid and another monocarboxylic acid.
- Preferred aliphatic monocarboxylic acids include acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, enanthic acid, caprylic acid, pelargonic acid, capric acid, 2-ethyl-hexanecarboxylic acid, undecylic acid, lauric acid, tridecylic acid , Saturated fatty acids such as myristic acid, pentadecylic acid, palmitic acid, heptadecylic acid, stearic acid, nonadecanoic acid, arachidic acid, behenic acid, lignoceric acid, serotic acid, heptacosanoic acid, montanic acid, melicic acid, and laccelic acid, undecylenic acid, Examples thereof include unsaturated fatty acids such as oleic acid, sorbic acid, linoleic acid, linolenic acid and arachidonic acid.
- Examples of preferable alicyclic monocarboxylic acids include cyclopentanecarboxylic acid, cyclohexanecarboxylic acid, cyclooctanecarboxylic acid, and derivatives thereof.
- Examples of preferred aromatic monocarboxylic acids include those in which an alkyl group is introduced into the benzene ring of benzoic acid such as benzoic acid and toluic acid, and two or more benzene rings such as biphenyl carboxylic acid, naphthalene carboxylic acid, and tetralin carboxylic acid.
- the molecular weight of the polyhydric alcohol ester is not particularly limited, but is preferably in the range of 300 to 1500, more preferably in the range of 350 to 750. A higher molecular weight is preferred because it is less likely to volatilize, and a smaller one is preferred in terms of moisture permeability and compatibility with cellulose ester.
- the carboxylic acid used for the polyhydric alcohol ester may be one kind or a mixture of two or more kinds. Moreover, all the OH groups in the polyhydric alcohol may be esterified, or a part of the OH groups may be left as they are.
- the specific compound of a polyhydric alcohol ester is shown below.
- an esterified compound obtained by esterifying all or part of the OH group in the (meth) acrylic polymer and the compound (A) having one furanose structure or one pyranose structure Alternatively, it is also preferable to use an esterified compound obtained by esterifying all or part of the OH groups in the compound (B) in which 2 or more and 12 or less of at least one of a furanose structure or a pyranose structure are bonded.
- the esterified compound of the compound (A) and the esterified compound of the compound (B) according to the present invention are collectively referred to as a sugar ester compound.
- the benzoic acid in the above general formula may further have a substituent, for example, an alkyl group, an alkenyl group, an alkoxyl group, and a phenyl group, and these alkyl group, alkenyl group, and phenyl group have a substituent. You may have.
- Examples of the preferred compound (A) and compound (B) include the following, but the present invention is not limited to these.
- Examples of the compound (A) include glucose, galactose, mannose, fructose, xylose, or arabinose.
- Examples of the compound (B) include lactose, sucrose, nystose, 1F-fructosyl nystose, stachyose, maltitol, lactitol, lactulose, cellobiose, maltose, cellotriose, maltotriose, raffinose or kestose.
- gentiobiose, gentiotriose, gentiotetraose, xylotriose, galactosyl sucrose, and the like are also included.
- compounds having both a furanose structure and a pyranose structure are particularly preferable.
- sucrose, kestose, nystose, 1F-fructosyl nystose, stachyose and the like are preferable, and sucrose is more preferable.
- sucrose is more preferable.
- a compound in which at least one of a furanose structure or a pyranose structure is bonded in an amount of 2 or more and 3 or less is also a preferred embodiment.
- the monocarboxylic acid used for esterifying all or part of the OH groups in the compound (A) and the compound (B) according to the present invention is not particularly limited, and known aliphatic monocarboxylic acids and fats A cyclic monocarboxylic acid, an aromatic monocarboxylic acid, or the like can be used.
- the carboxylic acid used may be one type or a mixture of two or more types.
- Preferred aliphatic monocarboxylic acids include acetic acid, propionic acid, butyric acid, isobutyric acid, valeric acid, caproic acid, enanthic acid, caprylic acid, pelargonic acid, capric acid, 2-ethyl-hexanecarboxylic acid, undecylic acid, lauric acid , Saturated fatty acids such as tridecylic acid, myristic acid, pentadecylic acid, palmitic acid, heptadecylic acid, stearic acid, nonadecanoic acid, arachidic acid, behenic acid, lignoceric acid, serotic acid, heptacosanoic acid, montanic acid, melicic acid, and laccelic acid, Examples include unsaturated fatty acids such as undecylenic acid, oleic acid, sorbic acid, linoleic acid, linolenic acid, arachidonic acid and oc
- Examples of preferable alicyclic monocarboxylic acids include cyclopentane carboxylic acid, cyclohexane carboxylic acid, cyclooctane carboxylic acid, and derivatives thereof.
- aromatic monocarboxylic acids examples include aromatic monocarboxylic acids having an alkyl group or alkoxy group introduced into the benzene ring of benzoic acid such as benzoic acid and toluic acid, cinnamic acid, benzylic acid, biphenylcarboxylic acid, and naphthalene.
- aromatic monocarboxylic acids having two or more benzene rings such as carboxylic acid and tetralin carboxylic acid, or derivatives thereof.
- esterified compounds obtained by esterifying the compound (A) and the compound (B) an acetylated compound having an acetyl group introduced by esterification is preferable.
- the oligosaccharide esterified compound can be applied as a compound in which 3 to 12 of the furanose structure or the pyranose structure according to the present invention are bonded. .
- Oligosaccharides are produced by allowing an enzyme such as amylase to act on starch, sucrose, etc.
- examples of oligosaccharides that can be applied to the present invention include maltooligosaccharides, isomaltoligosaccharides, fructooligosaccharides, galactooligosaccharides, and xylooligos. Sugar.
- Oligosaccharide can also be acetylated in the same manner as the above compound (A) and compound (B).
- Acetic anhydride 200 ml was added dropwise to a solution obtained by adding pyridine (100 ml) to glucose (29.8 g, 166 mmol) and allowed to react for 24 hours. Thereafter, the solution was concentrated by evaporation and poured into ice water. After standing for 1 hour, the mixture was filtered through a glass filter to separate the solid and water. The solid on the glass filter was dissolved in chloroform and separated with cold water until it became neutral. The organic layer was separated and dried over anhydrous sodium sulfate.
- glycolose pentaacetate (58.8 g, 150 mmol, 90.9%).
- monocarboxylic acid can be used instead of the acetic anhydride.
- esterified compound according to the present invention will be given below, but the present invention is not limited thereto.
- the optical compensation film according to the present invention contains a furanose structure or a compound having one furanose structure or a pyranose structure in order to suppress the fluctuation of the retardation value and stabilize the display quality. It is preferable to contain 1 to 30% by mass of an esterified compound obtained by esterifying all or a part of the OH group in the compound (B) in which 2 to 12 of at least one kind of pyranose structure is bonded. It is preferable to contain the mass%. Within this range, it is preferable that the excellent effects of the present invention are exhibited and there is no bleeding out.
- a compound (A) having one (meth) acrylic polymer and one furanose structure or pyranose structure or in a compound (B) in which 2 to 12 at least one furanose structure or pyranose structure is bonded.
- An esterified compound obtained by esterifying all or a part of the OH group may be used in combination with another plasticizer.
- phase difference controlling agent those containing bisphenol A in the molecule are also preferred.
- a compound in which ethylene oxide or propylene oxide is added to both ends of bisphenol A can be used.
- BP series such as New Paul BP-2P, BP-3P, BP-23P, BP-5P, BPE-20 (F), BPE-20NK, BPE-20T, BPE-40, BPE-60, BPE-100
- BPE series manufactured by Sanyo Chemical Co., Ltd.
- BPX series manufactured by Adeka Co., Ltd.
- Adeka Polyether BPX-11, BPX-33, BPX-55 Adeka Polyether BPX-11, BPX-33, BPX-55.
- Diallyl bisphenol A dimethallyl bisphenol A, tetrabromobisphenol A in which bisphenol A is substituted with bromine, oligomers and polymers obtained by polymerizing this, bisphenol A bis (diphenyl phosphate) substituted with diphenyl phosphate, etc. Can be used.
- Polycarbonate obtained by polymerizing bisphenol A polyarylate obtained by polymerizing bisphenol A with a dibasic acid such as terephthalic acid, and an epoxy oligomer or polymer polymerized with an epoxy-containing monomer can also be used.
- Modiper CL130D or L440-G obtained by graft polymerization of bisphenol A and styrene or styrene acrylic can also be used.
- the acrylic resin-containing film according to the present invention may contain two or more retardation control agents.
- elution of the phase difference controlling agent can be reduced. The reason is not clear, but it seems that elution is suppressed by the ability to reduce the amount added per type and the interaction between the two phase difference control agents and the acrylic resin-containing composition.
- a plasticizer can be used in combination in order to improve the fluidity and flexibility of the composition.
- the plasticizer include phthalate ester, fatty acid ester, trimellitic ester, phosphate ester, polyester, and epoxy.
- phosphate ester plasticizers triphenyl phosphate, tricresyl phosphate, cresyl diphenyl phosphate, octyl diphenyl phosphate, diphenyl biphenyl phosphate, trioctyl phosphate, tributyl phosphate, etc.
- phthalate ester plasticizers diethyl phthalate, dimethoxy Ethyl phthalate, dimethyl phthalate, dioctyl phthalate, dibutyl phthalate, di-2-ethylhexyl phthalate and the like can be used.
- polyester-based and phthalate-based plasticizers are preferably used.
- Polyester plasticizers are superior in non-migration and extraction resistance compared to phthalate ester plasticizers such as dioctyl phthalate, but are slightly inferior in plasticizing effect and compatibility.
- the polyester plasticizer is a reaction product of a monovalent or tetravalent carboxylic acid and a monovalent or hexavalent alcohol, and is mainly obtained by reacting a divalent carboxylic acid with a glycol.
- Representative divalent carboxylic acids include glutaric acid, itaconic acid, adipic acid, phthalic acid, azelaic acid, sebacic acid and the like.
- glycol examples include glycols such as ethylene, propylene, 1,3-butylene, 1,4-butylene, 1,6-hexamethylene, neopentylene, diethylene, triethylene, and dipropylene. These divalent carboxylic acids and glycols may be used alone or in combination.
- the ester plasticizer may be any of ester, oligoester and polyester types, and the molecular weight is preferably in the range of 100 to 10000, but preferably in the range of 600 to 3000, the plasticizing effect is large.
- the viscosity of the plasticizer has a correlation with the molecular structure and molecular weight, but in the case of an adipic acid plasticizer, the range of 200 to 5000 mPa ⁇ s (25 ° C.) is preferable because of compatibility and plasticization efficiency. Furthermore, some polyester plasticizers may be used in combination.
- the plasticizer is preferably added in an amount of 0.5 to 30 parts by mass with respect to 100 parts by mass of the composition containing an acrylic resin. If the added amount of the plasticizer exceeds 30 parts by mass, the surface becomes sticky, which is not preferable for practical use.
- These plasticizers may be used alone or in combination of two or more.
- the composition containing the acrylic resin of the present invention preferably contains an ultraviolet absorber, and examples of the ultraviolet absorber used include benzotriazole, 2-hydroxybenzophenone, and salicylic acid phenyl ester.
- the ultraviolet absorber used include benzotriazole, 2-hydroxybenzophenone, and salicylic acid phenyl ester.
- 2- (5-methyl-2-hydroxyphenyl) benzotriazole, 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2H-benzotriazole, 2- (3 Triazoles such as 5-di-t-butyl-2-hydroxyphenyl) benzotriazole, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-octoxybenzophenone, 2,2'-dihydroxy-4-methoxybenzophenone And benzophenones.
- ultraviolet absorbers having a molecular weight of 400 or more are less likely to volatilize at a high boiling point and are difficult to disperse even during high-temperature molding, so that the weather resistance is effectively improved with a relatively small amount of addition. be able to.
- the transition from the thin coating layer to the substrate layer is particularly small and hardly precipitates on the surface of the laminate, the amount of contained UV absorber is maintained for a long time, and the durability of the weather resistance improvement effect is excellent. From the point of view, it is preferable.
- Examples of the ultraviolet absorber having a molecular weight of 400 or more include 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2-benzotriazole, 2,2-methylenebis [4- (1, 1,3,3-tetrabutyl) -6- (2H-benzotriazol-2-yl) phenol], bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, bis ( Hindered amines such as 1,2,2,6,6-pentamethyl-4-piperidyl) sebacate and 2- (3,5-di-t-butyl-4-hydroxybenzyl) -2-n-butylmalonic acid Bis (1,2,2,6,6-pentamethyl-4-piperidyl), 1- [2- [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionyloxy] Such as til] -4- [3- (3,5-di-tert-butyl
- 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2-benzotriazole and 2,2-methylenebis [4- (1,1,3,3- Tetrabutyl) -6- (2H-benzotriazol-2-yl) phenol] is particularly preferred.
- antioxidants can also be added to the acrylic resin used in the acrylic resin-containing film of the present invention in order to improve thermal decomposability and thermal coloring during molding.
- an antistatic agent can be added to impart antistatic performance to the acrylic resin-containing film.
- a flame retardant acrylic resin composition containing a phosphorus flame retardant may be used.
- Phosphorus flame retardants used here include red phosphorus, triaryl phosphate ester, diaryl phosphate ester, monoaryl phosphate ester, aryl phosphonate compound, aryl phosphine oxide compound, condensed aryl phosphate ester, halogenated alkyl phosphorus. Examples thereof include one or a mixture of two or more selected from acid esters, halogen-containing condensed phosphates, halogen-containing condensed phosphonates, halogen-containing phosphites, and the like.
- triphenyl phosphate 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, phenylphosphonic acid, tris ( ⁇ -chloroethyl) phosphate, tris (dichloropropyl) Examples thereof include phosphate and tris (tribromoneopentyl) phosphate.
- production methods such as an inflation method, a T-die method, a calendar method, a cutting method, a casting method, an emulsion method, and a hot press method can be used. From the viewpoints of suppressing foreign matter defects and optical defects such as die lines, solution casting by casting is preferred.
- Organic solvent useful for forming the dope when the acrylic resin-containing film of the present invention is produced by the solution casting method is not limited as long as it dissolves acrylic resin, cellulose ester resin, and other additives simultaneously. Can be used.
- methylene chloride as a non-chlorinated organic solvent, methyl acetate, ethyl acetate, amyl acetate, acetone, tetrahydrofuran, 1,3-dioxolane, 1,4-dioxane, cyclohexanone, ethyl formate, 2,2,2-trifluoroethanol, 2,2,3,3-hexafluoro-1-propanol, 1,3-difluoro-2-propanol, 1,1,1,3,3,3-hexafluoro- 2-methyl-2-propanol, 1,1,1,3,3,3-hexafluoro-2-propanol, 2,2,3,3,3-pentafluoro-1-propanol, nitroethane, etc.
- Methylene chloride, methyl acetate, ethyl acetate and acetone can be preferably used.
- the dope preferably contains 1 to 40% by mass of a linear or branched aliphatic alcohol having 1 to 4 carbon atoms.
- a linear or branched aliphatic alcohol having 1 to 4 carbon atoms.
- the dope composition is dissolved in%.
- linear or branched aliphatic alcohol having 1 to 4 carbon atoms examples include methanol, ethanol, n-propanol, iso-propanol, n-butanol, sec-butanol, and tert-butanol. Ethanol is preferred because of the stability of these dopes, the relatively low boiling point, and good drying properties.
- a method carried out at normal pressure a method carried out below the boiling point of the main solvent, a method carried out under pressure above the boiling point of the main solvent, JP-A-9-95544 and JP-A-9-
- Various dissolution methods can be used such as a method performed by a cooling dissolution method as described in JP-A-95557 or JP-A-9-95538, a method performed at high pressure as described in JP-A No. 11-21379,
- a method of pressurizing at a temperature equal to or higher than the boiling point of the main solvent is preferable.
- the total amount of acrylic resin and cellulose ester resin in the dope is preferably 15 to 45% by mass.
- An additive is added to the dope during or after dissolution to dissolve and disperse, then filtered through a filter medium, defoamed, and sent to the next step with a liquid feed pump.
- a filter medium having a collected particle diameter of 0.5 to 5 ⁇ m and a drainage time of 10 to 25 sec / 100 ml.
- agglomerates remaining at the time of particle dispersion and agglomerates generated upon addition of the main dope are only aggregated by using a filter medium having a collected particle diameter of 0.5 to 5 ⁇ m and a drainage time of 10 to 25 sec / 100 ml. Can be removed.
- the concentration of particles is sufficiently thinner than that of the additive solution, so that aggregates do not stick together at the time of filtration and the filtration pressure does not increase suddenly.
- FIG. 1 is a diagram schematically showing a dope preparation step, a casting step, and a drying step of a solution casting film forming method preferable for the present invention.
- the main dope solution is filtered by the main filter 3, and an ultraviolet absorbent additive solution is added in-line from 16 to this.
- the main dope may contain about 10 to 50% by weight of recycled material.
- the return material may contain acrylic particles. In that case, it is preferable to control the addition amount of the acrylic particle addition liquid in accordance with the addition amount of the return material.
- the additive solution containing acrylic particles preferably contains 0.5 to 10% by mass of acrylic particles, more preferably 1 to 10% by mass, and more preferably 1 to 5% by mass. Most preferably.
- Recycled material is a finely pulverized acrylic resin-containing film that is generated when an acrylic resin-containing film is formed.
- the original fabric is used.
- an acrylic resin, a cellulose ester resin, and in some cases, acrylic particles kneaded into pellets can be preferably used.
- An endless metal belt 31 such as a stainless steel belt or a rotating metal drum, which feeds the dope through a liquid feed pump (for example, a pressurized metering gear pump) to the pressure die 30 and transfers it infinitely. This is a step of casting the dope from the pressure die slit to the casting position on the support.
- a liquid feed pump for example, a pressurized metering gear pump
- the pressure die includes a coat hanger die and a T die, and any of them is preferably used.
- the surface of the metal support is a mirror surface.
- two or more pressure dies may be provided on the metal support, and the dope amount may be divided and stacked. Or it is also preferable to obtain the film of a laminated structure by the co-casting method which casts several dope simultaneously.
- Solvent evaporation step In this step, the web (the dope is cast on the casting support and the formed dope film is called a web) is heated on the casting support to evaporate the solvent.
- the web on the support after casting is preferably dried on the support in an atmosphere of 40 to 100 ° C. In order to maintain the atmosphere at 40 to 100 ° C., it is preferable to apply hot air at this temperature to the upper surface of the web or heat by means such as infrared rays.
- Peeling process It is the process of peeling the web which the solvent evaporated on the metal support body in a peeling position. The peeled web is sent to the next process.
- the temperature at the peeling position on the metal support is preferably 10 to 40 ° C., more preferably 11 to 30 ° C.
- the residual solvent amount at the time of peeling of the web on the metal support at the time of peeling is preferably peeled in the range of 50 to 120% by mass depending on the strength of drying conditions, the length of the metal support, and the like.
- the amount of residual solvent is determined.
- the amount of residual solvent in the web is defined by the following formula.
- Residual solvent amount (%) (mass before web heat treatment ⁇ mass after web heat treatment) / (mass after web heat treatment) ⁇ 100 Note that the heat treatment for measuring the residual solvent amount represents performing heat treatment at 115 ° C. for 1 hour.
- the peeling tension at the time of peeling the metal support from the film is usually 196 to 245 N / m. However, if wrinkles easily occur at the time of peeling, it is preferable to peel with a tension of 190 N / m or less. It is preferable to peel at a minimum tension of ⁇ 166.6 N / m, and then peel at a minimum tension of ⁇ 137.2 N / m, and particularly preferable to peel at a minimum tension of ⁇ 100 N / m.
- the temperature at the peeling position on the metal support is preferably ⁇ 50 to 40 ° C., more preferably 10 to 40 ° C., and most preferably 15 to 30 ° C.
- a drying device 35 that alternately conveys the web through a plurality of rolls arranged in the drying device and / or a tenter stretching device 34 that clips and conveys both ends of the web with a clip are used. And dry the web.
- the drying means is generally to blow hot air on both sides of the web, but there is also a means to heat by applying microwaves instead of wind. Too rapid drying tends to impair the flatness of the finished film. Drying at a high temperature is preferably performed from about 8% by mass or less of the residual solvent. Throughout, drying is generally performed at 40-250 ° C. In particular, drying at 40 to 160 ° C. is preferable.
- tenter stretching apparatus When using a tenter stretching apparatus, it is preferable to use an apparatus capable of independently controlling the film gripping length (distance from the start of gripping to the end of gripping) by the left and right gripping means of the tenter. In the tenter process, it is also preferable to intentionally create sections having different temperatures in order to improve planarity.
- the stretching operation may be performed in multiple stages, and it is also preferable to perform biaxial stretching in the casting direction and the width direction.
- biaxial stretching When biaxial stretching is performed, simultaneous biaxial stretching may be performed or may be performed stepwise.
- stepwise means that, for example, stretching in different stretching directions can be sequentially performed, stretching in the same direction is divided into multiple stages, and stretching in different directions is added to any one of the stages. Is also possible. That is, for example, the following stretching steps are possible.
- Simultaneous biaxial stretching includes stretching in one direction and contracting the other while relaxing the tension.
- the preferred draw ratio for simultaneous biaxial stretching can be in the range of x1.01 to x1.5 in both the width direction and the longitudinal direction.
- the amount of residual solvent in the web is preferably 20 to 100% by mass at the start of the tenter, and drying is preferably performed while the tenter is applied until the amount of residual solvent in the web is 10% by mass or less. More preferably, it is 5% by mass or less.
- the drying temperature is preferably 30 to 150 ° C, more preferably 50 to 120 ° C, and most preferably 70 to 100 ° C.
- the temperature distribution in the width direction of the atmosphere is small from the viewpoint of improving the uniformity of the film.
- the temperature distribution in the width direction in the tenter process is preferably within ⁇ 5 ° C, and within ⁇ 2 ° C. Is more preferable, and within ⁇ 1 ° C. is most preferable.
- Winding step This is a step of winding up the acrylic resin-containing film by the winder 37 after the residual solvent amount in the web is 2% by mass or less, and by setting the residual solvent amount to 0.4% by mass or less. A film having good dimensional stability can be obtained.
- a generally used one may be used, and there are a constant torque method, a constant tension method, a taper tension method, a program tension control method with a constant internal stress, etc., and these may be used properly.
- the acrylic resin-containing film of the present invention is preferably a long film. Specifically, the acrylic resin-containing film is about 100 m to 5000 m, and is usually in the form of a roll.
- the film width is preferably 1.3 to 4 m, more preferably 1.4 to 2 m.
- the film thickness of the acrylic resin-containing film of the present invention is not particularly limited, but when used for a polarizing plate protective film described later, it is preferably 20 to 200 ⁇ m, more preferably 25 to 100 ⁇ m, and 30 to 80 ⁇ m. It is particularly preferred that
- the acrylic resin-containing film of the present invention has an in-plane retardation value Ro (590) defined by the following formula (I) in the range of 30 to 300 nm, and a thickness direction defined by the following formula (II)
- the retardation value Rt (590) is preferably adjusted so as to be in the range of 50 to 300 nm.
- Ro (590) (nx ⁇ ny) ⁇ d (nm)
- Rt (590) ⁇ (nx + ny) / 2 ⁇ nz ⁇ ⁇ d (nm)
- Ro (590) represents the in-plane retardation value in the film at a wavelength of 590 nm
- Rt (590) represents the retardation value in the thickness direction in the film at 590 nm
- D represents the thickness (nm) of the optical film
- nx represents the maximum refractive index in the plane of the film at 590 nm, and is also referred to as the refractive index in the slow axis direction.
- ny represents the refractive index in the direction perpendicular to the slow axis in the film plane at 590 nm
- nz represents the refractive index of the film in the thickness direction at 590 nm.
- the in-plane retardation value Ro (590) is preferably in the range of 60 to 250 nm.
- the retardation value Rt (590) in the thickness direction is preferably in the range of 60 to 250 nm.
- the acrylic resin-containing film of the present invention is preferably adjusted so that the wavelength dispersion (DSP) defined by the following formula (III) is 0.82 to 0.95.
- DSP Ro (480) / Ro (630)
- Ro (480) represents an in-plane retardation value at a wavelength of 480 nm
- Ro (630) represents an in-plane retardation value at 630 nm.
- Adjustment of retardation and wavelength dispersion (DSP) within the above range is possible by optimizing the composition of the acrylic resin-containing film and performing stretching according to this composition.
- composition of the acrylic resin-containing film is optimized by adjusting the ratio of the acrylic resin and the cellulose ester resin within the mass ratio of 51:49 to 95: 5, and the phase difference controlling agent according to the resin ratio. This is done by adjusting the combination and the amount to be added.
- the stretching temperature (combination of the temperature of each compartment), magnification, stretching speed, stretching order, residual solvent amount of the film during stretching, etc. are adjusted and controlled.
- the retardation value and the chromatic dispersion (DSP) can be set to desired values.
- the retardation and wavelength dispersion (DSP) By adjusting the retardation and wavelength dispersion (DSP) to such a range, the variation in the color of the liquid crystal display device using this acrylic resin-containing film is reduced, the viewing angle is widened, and the front contrast is improved. be able to.
- the change in color is how much the color of the image of the liquid crystal display changes when the angle is inclined 60 ° obliquely from the normal direction of the display device and 360 ° is observed.
- the front contrast is a ratio of luminance when observed from the normal direction of the display screen of white display and black display of the liquid crystal display device.
- Front contrast (brightness of white display measured from normal direction of display device) / (brightness of black display measured from normal direction of display device)
- the viewing angle is an angle at which a certain level of contrast can be maintained when the viewing direction of the liquid crystal display device is tilted from the normal direction.
- the acrylic resin-containing film of the present invention is preferably adjusted so that the photoelastic coefficient is ⁇ 5 ⁇ 10 ⁇ 12 to 5 ⁇ 10 ⁇ 12 / Pa.
- the ratio of each resin of the acrylic resin and the cellulose ester resin is adjusted within a mass ratio of 51:49 to 95: 5. This is done by adjusting the combination of the retardation control agent and the amount to be added according to the ratio to optimize the composition of the acrylic resin-containing film.
- the acrylic resin-containing film according to the present invention has a low haze, a high temperature device such as a projector, and a use in a high temperature environment such as an in-vehicle display device.
- the temperature is preferably 105 ° C to 145 ° C, and more preferably controlled to 110 ° C to 130 ° C.
- the acrylic resin-containing film is 120 mm (length) ⁇ 10 mm (width).
- the temperature is increased at a rate of temperature increase of 30 ° C./min while pulling at a tension of 10 N, and the temperature at the time of 9 N is measured three times, and the average value can be obtained.
- the acrylic resin-containing film of the present invention preferably has a glass transition temperature (Tg) of 110 ° C. or higher. More preferably, it is 120 ° C. or higher. Especially preferably, it is 150 degreeC or more.
- Tg glass transition temperature
- the glass transition temperature referred to here is an intermediate value determined according to JIS K7121 (1987) using a differential scanning calorimeter (DSC-7 model manufactured by Perkin Elmer) at a heating rate of 20 ° C./min. Point glass transition temperature (Tmg).
- the acrylic resin-containing film of the present invention has a defect of 5 ⁇ m or more in diameter in the film plane of 1 piece / 10 cm square. More preferably, it is 0.5 piece / 10 cm square or less, more preferably 0.1 piece / 10 cm square or less.
- the diameter of the defect indicates the diameter when the defect is circular, and when it is not circular, the range of the defect is determined by observing with a microscope according to the following method, and the maximum diameter (diameter of circumscribed circle) is determined.
- the range of the defect is the size of the shadow when the defect is observed with the transmitted light of the differential interference microscope when the defect is a bubble or a foreign object.
- the defect is a change in the surface shape, such as transfer of a roll flaw or an abrasion
- the size is confirmed by observing the defect with the reflected light of a differential interference microscope.
- the film breaks with the defect as a starting point, and the productivity may be significantly reduced.
- the diameter of a defect becomes 5 micrometers or more, it can confirm visually by polarizing plate observation etc., and when used as an optical member, a bright spot may arise.
- the coating agent may not be formed uniformly, resulting in defects (coating defects).
- the defect is a void in the film (foaming defect) generated due to the rapid evaporation of the solvent in the drying process of the solution casting, a foreign matter in the film forming stock solution, or a foreign matter mixed in the film forming. This refers to the foreign matter (foreign matter defect) in the film.
- the acrylic resin-containing film of the present invention preferably has a breaking elongation in at least one direction of 10% or more, more preferably 20% or more, as measured in accordance with JIS-K7127-1999.
- the upper limit of the elongation at break is not particularly limited, but is practically about 250%. In order to increase the elongation at break, it is effective to suppress defects in the film caused by foreign matter and foaming.
- the thickness of the acrylic resin-containing film of the present invention is preferably 20 ⁇ m or more. More preferably, it is 30 ⁇ m or more.
- the upper limit of the thickness is not particularly limited, but in the case of forming a film by a solution casting method, the upper limit is about 250 ⁇ m from the viewpoint of applicability, foaming, solvent drying, and the like.
- the thickness of the film can be appropriately selected depending on the application.
- the acrylic resin-containing film of the present invention preferably has a total light transmittance of 90% or more, more preferably 93% or more.
- the practical upper limit is about 99%.
- it is necessary not to introduce additives and copolymerization components that absorb visible light, or to remove foreign substances in the polymer by high-precision filtration. It is effective to reduce the diffusion and absorption of light inside the film.
- the acrylic resin-containing film of the present invention is characterized in that the haze value (turbidity), which is one of the indices indicating transparency, is 1.0% or less, but the luminance when incorporated in a liquid crystal display device, From the viewpoint of contrast, it is preferably 0.5% or less.
- the surface roughness also affects the haze value as surface haze, it is also effective to reduce the particle size and addition amount of acrylic particles within the above range, or to reduce the surface roughness of the film contact portion during film formation It is.
- the total light transmittance and haze value of the acrylic resin-containing film are values measured according to JIS-K7361-1-1997 and JIS-K7136-2000.
- the acrylic resin-containing film of the present invention can be preferably used as an optical acrylic resin-containing film as long as it satisfies the physical properties as described above, but is excellent in workability and heat resistance by having the following composition. Film can be obtained.
- the acrylic resin-containing film contains an acrylic resin and a cellulose ester resin in a mass ratio of 95: 5 to 30:70, and the total acyl groups of the cellulose ester resin.
- the degree of substitution (T) is 2.00 to 2.99
- the degree of acetyl group substitution (ac) is 0.10 to 1.89
- the number of carbons of acyl groups other than acetyl groups is 3 to 7
- the weight average molecular weight The excellent effect of the present invention can be obtained by an acrylic resin-containing film characterized in that Mw) is 75,000 to 250,000.
- the acrylic resin and the cellulose ester resin are contained in a mass ratio of 95: 5 to 30:70, but the acrylic resin is preferably 50% by mass or more.
- the acrylic resin-containing film of the present invention may contain a resin other than acrylic resin and cellulose ester resin.
- the total mass of the acrylic resin and the cellulose ester resin is 55 to 100% by mass, preferably 60 to 99% by mass of the acrylic resin-containing film.
- the polarizing plate according to the present invention can be produced by a general method. It is preferable that an adhesive layer is provided on the back side of the acrylic resin-containing film of the present invention, and is bonded to at least one surface of a polarizer produced by immersing and stretching in an iodine solution.
- the film may be used on the other surface, or another polarizing plate protective film may be used.
- cellulose ester films for example, Konica Minoltack KC8UX, KC4UX, KC5UX, KC8UY, KC4UY, KC12UR, KC8UCR-3, KC8UCR-4, KC8UCR-5, KV8UY-HA, KV8UX-RHA, KV8UX-RHA Etc.
- cellulose ester films for example, Konica Minoltack KC8UX, KC4UX, KC5UX, KC8UY, KC4UY, KC12UR, KC8UCR-3, KC8UCR-4, KC8UCR-5, KV8UY-HA, KV8UX-RHA, KV8UX-RHA Etc.
- a polarizer which is a main component of a polarizing plate, is an element that transmits only light having a plane of polarization in a certain direction.
- a typical polarizing film known at present is a polyvinyl alcohol polarizing film, which is a polyvinyl alcohol. There are one in which iodine is dyed on a system film and one in which dichroic dye is dyed.
- the polarizer is formed by forming a polyvinyl alcohol aqueous solution into a film and dyeing the film by uniaxial stretching or dyeing or uniaxially stretching, and then performing a durability treatment with a boron compound.
- a pressure-sensitive adhesive having a storage elastic modulus at 25 ° C. in the range of 1.0 ⁇ 10 4 Pa to 1.0 ⁇ 10 9 Pa in at least a part of the pressure-sensitive adhesive layer is used. It is preferable to use a curable pressure-sensitive adhesive that forms a high molecular weight body or a crosslinked structure by various chemical reactions after the pressure-sensitive adhesive is applied and bonded.
- urethane adhesives examples include, for example, urethane adhesives, epoxy adhesives, aqueous polymer-isocyanate adhesives, curable adhesives such as thermosetting acrylic adhesives, moisture-curing urethane adhesives, polyether methacrylate types
- curable adhesives such as thermosetting acrylic adhesives, moisture-curing urethane adhesives, polyether methacrylate types
- anaerobic pressure-sensitive adhesives such as ester-based methacrylate type and oxidized polyether methacrylate, cyanoacrylate-based instantaneous pressure-sensitive adhesives, and acrylate-peroxide-based two-component instantaneous pressure-sensitive adhesives.
- the above-mentioned pressure-sensitive adhesive may be a one-component type or a type in which two or more components are mixed before use.
- the pressure-sensitive adhesive may be a solvent system using an organic solvent as a medium, or an aqueous system such as an emulsion type, a colloidal dispersion type, or an aqueous solution type that is a medium containing water as a main component. It may be a solvent type.
- concentration of the pressure-sensitive adhesive liquid may be appropriately determined depending on the film thickness after adhesion, the coating method, the coating conditions, and the like, and is usually 0.1 to 50% by mass.
- liquid crystal display device By incorporating the polarizing plate bonded with the acrylic resin-containing film of the present invention into at least one surface of the liquid crystal cell and incorporating it into the liquid crystal display device, various liquid crystal display devices with excellent visibility can be produced.
- the polarizing plate according to the present invention is bonded to a liquid crystal cell via the adhesive layer or the like.
- the polarizing plate according to the present invention is a reflective type, transmissive type, transflective type LCD or TN type, STN type, OCB type, HAN type, VA type (PVA type, MVA type), IPS type, etc. Preferably used.
- a large-screen display device having a screen of 30 or more, especially 30 to 54 there is no white spot at the periphery of the screen and the effect is maintained for a long time.
- Example 1 Acrylic resins a1-1 to a1-5 having the following mesogenic groups were prepared by the following method.
- N mol% of the monomer unit (2) constituting the acrylic resin having a mesogenic group.
- an acrylic resin having a mesogenic group is represented by a block body.
- the monomer was completely dissolved by heating and stirring under a nitrogen stream.
- 100 mg of azobisisobutyronitrile (AIBN) dissolved in a small amount of the mixed solvent was added dropwise. After refluxing for 8 hours, the heating was stopped and the reaction solution was returned to room temperature, and then the reaction solution was dropped into 150 ml of methanol to reprecipitate the polymer.
- AIBN azobisisobutyronitrile
- Table 8 shows the amounts of the monomer units (1) and the monomer units (2) used as the reaction substrate, the ratio of the monomer units (2), the yield of the acrylic resin having the mesogenic group, and the weight average molecular weight.
- Formation of acrylic resin film 1 The produced dope solution was uniformly cast on a stainless steel band support at a temperature of 22 ° C. and a width of 2 m using a belt casting apparatus. With the stainless steel band support, the solvent was evaporated until the amount of residual solvent reached 100%, and peeling was performed from the stainless steel band support with a peeling tension of 162 N / m.
- the solvent of the peeled acrylic resin was evaporated at 35 ° C., slit to 1.6 m width, and then dried at a drying temperature of 135 ° C. while being stretched 1.3 times in the width direction by a tenter. At this time, the residual solvent amount when starting stretching with a tenter was 10%.
- the draw ratio in the MD direction calculated from the rotational speed of the stainless steel band support and the operating speed of the tenter was 1.1 times.
- the residual solvent amount of the acrylic resin-containing film 1 shown in Tables 1 to 5 was 0.1%, the film thickness was 60 ⁇ m, and the winding length was 4000 m.
- the acrylic resin (a1) having a mesogenic group, the acrylic resin (a2) having no mesogenic group, and the cellulose ester resin (B) were changed in the types and composition ratios as shown in Tables 1 to 3 below. In the same manner as the resin-containing film 1, acrylic resin-containing films 2 to 41 were produced.
- acrylic resins having no mesogenic group in addition to Diamond BR85 (manufactured by Mitsubishi Rayon Co., Ltd.), dialnal BR52, dialnal BR80, dialnal BR88, dialnal BR83 (above, manufactured by Mitsubishi Rayon Co., Ltd.), Delpet 80N (Asahi Kasei Chemicals Corporation) was used.
- ac represents an acetyl group
- p represents a propionyl group
- b represents a butyryl group
- bz represents a benzoyl group
- ph represents a phthalyl group
- Acrylic resin Dianal BR85 (manufactured by Mitsubishi Rayon Co., Ltd.) and acrylic resin a1-1, CAP482-20 (manufactured by Eastman Chemical Co., Ltd.) are mixed at a ratio of 60:10:30 and dried with hot air. After using a machine to dry at 90 ° C. for 2 hours to sufficiently remove moisture, use a T-die type film melt extrusion machine (T-die width 500 mm) having a resin melt kneader equipped with a 65 mm ⁇ screw, Extrusion was performed under the molding conditions of a molten resin temperature of 240 ° C. and a T-die temperature of 240 ° C. to form an acrylic resin film 41. The formed film had a thickness of 60 ⁇ m.
- thermoplastic copolymer described in Example 1 of JP 2007-191706 A was prepared, and a pellet composition according to Example 7 was prepared.
- Tables 1 to 3 show the contents of the various films produced above.
- the same film No. of the upper part of Table 1 and Table 3 is used.
- the same film number at the bottom of Table 2 and Table 3. The entire contents of each film are integrated with the description in the column.
- (A) / (B) in Table 3 represents the ratio of the acrylic resin (A) and the cellulose ester resin (B).
- (A2) / (a1) represents the ratio of the acrylic resin (a2) having no mesogenic group and the acrylic resin (a1) having a mesogenic group.
- An acrylic resin-containing film conditioned for 24 hours in an air-conditioned room at 23 ° C. and 55% RH is cut out at 120 mm (length) ⁇ 10 mm (width) under the same conditions and heated at 30 ° C./min while being pulled with a tension of 10 N. The temperature was continuously increased at a speed, and the temperature at 9 N was measured three times, and the average was obtained.
- the tearing surface is very smooth and is torn straight.
- the polarizing plate which used the acrylic resin containing film of this invention as the polarizing plate protective film was produced as follows.
- a 120 ⁇ m-thick long roll polyvinyl alcohol film was immersed in 100 parts by mass of an aqueous solution containing 1 part by mass of iodine and 4 parts by mass of boric acid, and stretched in the transport direction 5 times at 50 ° C. to form a polarizing film.
- Example 1 the acrylic resin-containing film 1 produced in Example 1 was subjected to corona treatment using an acrylic adhesive on one side of the polarizing film, and then bonded.
- KC8UCR-5 manufactured by Konica Minolta Opto Co., Ltd., which is an alkali saponified retardation film, was bonded to the other surface of the polarizing film and dried to prepare a polarizing plate P1.
- polarizing plates P2 to P42 were prepared using acrylic resin-containing films 2 to 42.
- the polarizing plate using the acrylic resin-containing film of the present invention was excellent in film cutting property and easy to process.
- the viewing angle of the liquid crystal display device was measured using EZ-Contrast 160D manufactured by ELDIM in an environment of 23 ° C. and 55% RH.
- ⁇ No viewing angle variation
- ⁇ Slight viewing angle variation is observed
- ⁇ Viewing angle variation is observed
- ⁇ Viewing angle variation is very large (color shift)
- the display was displayed in black, and the color change when observed from an oblique angle of 45 ° was evaluated under the following criteria in an environment of 23 ° C. and 55% RH.
- Example 2 Preparation of acrylic particles (C1)> A reactor with a reflux condenser with an internal volume of 60 liters was charged with 38.2 liters of ion-exchanged water and 111.6 g of sodium dioctylsulfosuccinate, and the temperature was raised to 75 ° C. under a nitrogen atmosphere while stirring at a rotational speed of 250 rpm. The effect of oxygen was virtually eliminated. 0.36 g of APS was added, and after stirring for 5 minutes, a monomer mixture consisting of 1657 g of MMA, 21.6 g of BA, and 1.68 g of ALMA was added all at once. Completed.
- a small amount of the polymer latex thus obtained was collected, and the flat particle size was determined by the absorbance method, which was 0.10 ⁇ m.
- the remaining latex was put into a 3% by mass sodium sulfate warm aqueous solution, salted out and coagulated, and then dried after repeated dehydration and washing to obtain acrylic particles (C1) having a three-layer structure.
- Acrylic resin-containing films 25-1 to 25-6 were produced in the same manner as in the method for producing acrylic resin-containing film 25 described in Example 1.
- the acrylic resin-containing film 25-5 was prepared by adding the following ultraviolet absorber.
- Tinuvin 109 (manufactured by Ciba Japan Co., Ltd.) 1.5 parts by mass Tinuvin 171 (manufactured by Ciba Japan Co., Ltd.) 0.7 parts by mass
- the acrylic resin-containing film 25-4 is replaced with C2 instead of acrylic particles C1.
- METABLEN W-341 (manufactured by Mitsubishi Rayon Co., Ltd.), acrylic resin-containing film 25-5 as single-layer MR-2G (manufactured by Soken Chemical Co., Ltd.) as C3, acrylic resin-containing film 25-6 as MS-300X ( Soken Chemical Co., Ltd.) was used as C4.
- the polarizing plate and the liquid crystal display device produced using the acrylic resin-containing film of the present invention showed excellent properties in visibility and color shift.
Abstract
Description
式(I):Ro(590)=(nx-ny)×d(nm)
式(II):Rt(590)={(nx+ny)/2-nz}×d(nm)
〔上式中、Ro(590)は波長590nmにおけるフィルム内の面内リターデーション値を表し、Rt(590)は590nmにおけるフィルム内の厚さ方向のリターデーション値を表す。また、dは光学フィルムの厚さ(nm)を表し、nxは590nmにおけるフィルムの面内の最大の屈折率を表し、遅相軸方向の屈折率ともいう。nyは590nmにおけるフィルム面内で遅相軸に直角な方向の屈折率を表し、nzは590nmにおける厚み方向におけるフィルムの屈折率を表す。〕
5.前記1から4のいずれか一項に記載のアクリル樹脂含有フィルムを少なくとも一方の面に用いたことを特徴とする偏光板。
3、6、12、15 濾過器
4、13 ストックタンク
5、14 送液ポンプ
8、16 導管
10 紫外線吸収剤仕込釜
20 合流管
21 混合機
30 ダイ
31 金属支持体
32 ウェブ
33 剥離位置
34 テンター装置
35 ロール乾燥装置
41 粒子仕込釜
42 ストックタンク
43 ポンプ
44 濾過器
本発明のアクリル樹脂含有フィルムは、上述のように、アクリル樹脂を主要構成成分として含有するアクリル樹脂含有フィルムであって、アクリル樹脂とセルロースエステル樹脂とを95:5~30:70の質量比で相溶状態で含有し、当該アクリル樹脂は、その全部又は一部がメソゲン基を置換基又は2価の連結基として有するアクリル樹脂であり、かつ当該セルロースエステル樹脂は、そのアシル基の総置換度が2.00~3.00、炭素数が3~7のアシル基の置換度が1.2~3.0であり、当該セルロースエステル樹脂の重量平均分子量(Mw)が75000以上であることを特徴とする。
本発明に係るアクリル樹脂は、その全部又は一部がメソゲン基を置換基又は2価の連結基として有するアクリル樹脂であることを特徴とする。
本発明に係るアクリル樹脂は、メソゲン基を置換基又は2価の連結基として有する重合性化合物、すなわち、(メタ)アクリレート化合物を単独重合して得たアクリル樹脂であっても、当該メソゲン基を有する(メタ)アクリレート化合物とメソゲン基を有しない(メタ)アクリレート化合物等エチレン性不飽和結合を有する化合物とを共重合させて得たアクリル樹脂であってもよい。
前記一般式(MA1)において、Mで表されるメソゲン基は、芳香環、脂環、複素環又は縮合環が連結鎖を介して又は直接結合した基を表し、下記一般式(2)で表すことができる。
(式中、Rは水素原子、炭素数1~18のアルキル基、炭素数1~18のアルコキシ基、炭素数2~18のアルケニル基、炭素数2~18のアルケニルオキシ基を表し、この基は非置換であるか、あるいは置換基として少なくとも1個のハロゲン原子あるいはシアノ基を有しており、該基中-CH2-は-O-、-S-、-CO-、-COO-、-OCO-、-OCO-O-で置換されてもよい。A1及びA2それぞれ独立して1,4-フェニレン[該基中-CH=は-N=又は-S=で置換されていてもよい]、1,4-シクロヘキシレン[該基中-CH2 -は-O-又は-S-で置換されていてもよい]、2,6-ナフチレン又は2,6-デカヒドロナフチレン [該基中-CH=は-N=又は-S=で置換されていてもよい]を表す。Z1及びZ2は単結合、-COO-、-OCO-、-CH2CH2-、-CH=CH-、-(CH2)4-、-CH2O-、-OCH2-、-(CH2)3O-、-O(CH2)3-、-CH=CHCH2O-、-OCH2CH=CH-、-C=C-、-(CH2)2COO-、-OCO(CH2)2-、-CF=CF-、-CF2O-又は-OCF2-を表す。p、qは各独立して0~3の整数である。)
上記一般式(2)中、Rで表される炭素数1~18のアルキル基としては、メチル、クロロメチル、トリフルオロメチル、シアノメチル、エチル、ジクロロエチル、プロピル、イソプロピル、ブチル、第二ブチル、第三ブチル、イソブチル、アミル、イソアミル、第三アミル、ヘキシル、2-ヘキシル、3-ヘキシル、シクロヘキシル、1-メチルシクロヘキシル、ヘプチル、2-ヘプチル、3-ヘプチル、イソヘプチル、第三ヘプチル、n-オクチル、イソオクチル、第三オクチル、2-エチルヘキシル、ノニル、イソノニル、デシル、ステアリル等が挙げられ、炭素数1~18のアルコキシ基としては、メチルオキシ、クロロメチルオキシ、トリフルオロメチルオキシ、シアノメチルオキシ、エチルオキシ、ジクロロエチルオキシ、プロピルオキシ、イソプロピルオキシ、ブチルオキシ、第二ブチルオキシ、第三ブチルオキシ、イソブチルオキシ、アミルオキシ、イソアミルオキシ、第三アミルオキシ、ヘキシルオキシ、シクロヘキシルオキシ、ヘプチルオキシ、イソヘプチルオキシ、第三ヘプチルオキシ、n-オクチルオキシ、イソオクチルオキシ、第三オクチルオキシ、2-エチルヘキシルオキシ等が挙げられ、炭素数2~18のアルケニル基としては、ビニル、1-メチルエテニル、2-メチルエテニル、プロペニル、ブテニル、イソブテニル、ペンテニル、ヘキセニル、ヘプテニル、オクテニル、デセニル、ペンタデセニル、エイコセニル、トリコセニル等が挙げられ、炭素数2~18のアルケニルオキシ基としては、ビニルオキシ、1-メチルエテニルオキシ、2-メチルエテニルオキシ、プロペニルオキシ、ブテニルオキシ、イソブテニルオキシ、ペンテニルオキシ、ヘキセニルオキシ、ヘプテニルオキシ、オクテニルオキシ、デセニルオキシ、ペンタデセニルオキシ、エイコセニルオキシ、トリコセニルオキシ等が挙げられ、置換基としてのハロゲン原子としては、フッ素原子、塩素原子、臭素原子、ヨウ素原子が挙げられる。
上記一般式(MA2)中、環A、B、C及びDで表される炭化水素6員環としては、1,4-フェニレン、1,4-シクロヘキサン、1,4-シクロヘキセン等が挙げられ、複素6員環としては、ジオキサン、ピリジル、ピリミジル等が挙げられ、縮合環としてはナフタレン等が挙げられる。
前記一般式(MA3)で表される単量体単位を有する樹脂を合成するために用いることができる重合性化合物の具体例としては、下記化合物が挙げられる。
カラム: Shodex K806、K805、K803G(昭和電工(株)製を3本接続して使用した)
カラム温度:25℃
試料濃度: 0.1質量%
検出器: RI Model 504(GLサイエンス社製)
ポンプ: L6000(日立製作所(株)製)
流量: 1.0ml/min
校正曲線: 標準ポリスチレンSTK standard ポリスチレン(東ソー(株)製)Mw=2,800,000~500迄の13サンプルによる校正曲線を使用した。13サンプルは、ほぼ等間隔に用いることが好ましい。
本発明に係るセルロースエステル樹脂は、特に脆性の改善やアクリル樹脂と混合された場合の透明性の観点から、アシル基の総置換度(T)が2.00~3.00、炭素数が3~7のアシル基の置換度が1.2~3.0であることが好ましい。即ち、セルロースエステル樹脂は炭素数が3~7のアシル基により置換されたセルロースエステル樹脂であり、具体的には、プロピオニル、ブチリル等が好ましく用いられるが、特にプロピオニル基が好ましく用いられる。
炭素数が3~7以外のアシル基、即ち、アセチル基や炭素数が8以上のアシル基の置換度の総計が1.3以下とされることが好ましい。
本発明においては、アクリル樹脂含有フィルムにアクリル粒子を含有させてもよい。
本願において、メソゲン基を有するアクリル樹脂を用いることでVAやIPSなどの各方式に対応した位相差フィルムの位相差を得ることができるが、さらに位相差を最適化するために別途、位相差制御剤を添加しても良い。ここで「位相差制御剤」とは、位相差を制御することを主眼として加えるメソゲン基を有するアクリル樹脂以外の添加剤をいう。当該位相差制御剤としては、特開2002-296421号公報記載の化合物や種々のエステル系可塑剤を用いることができる。以下において、好ましいエステル系化合物について詳細な説明をする。
本発明において使用され得るポリエステルポリオールとしては、炭素数の平均が2~3.5であるグリコールと炭素数の平均が4~5.5である二塩基酸との脱水縮合反応、又は該グリコールと炭素数の平均が4~5.5である無水二塩基酸の付加及び脱水縮合反応による常法により製造されるものであることが好ましい。
かかるポリエステルポリオールに用いられるグリコールとしては、例えばエチレングリコール、ジエチレングリコール、1,2-プロピレングリコール、1,3-プロピレングリコール、2-メチル-1,3-プロパンジオール、1,4-ブチレングリコール、ネオペンチルグリコール、3-メチル-1,5-ペンタンジオール、1,6-ヘキサンジオールなどが挙げられ、これらを単独又は2種以上を併用して用いられ、例えばエチレングリコール、またはエチレングリコールとジエチレングリコールの混合物などが特に好ましく用いられる。
次に本発明に用いられるポリエステルポリオールを構成する二塩基酸としては、例えばコハク酸、グルタル酸、アジピン酸、セバチン酸等を挙げることができる。これらを単独又は2種以上を併用して用いることができ、例えばコハク酸、またはコハク酸とテレフタル酸の混合物等が特に好ましく用いられる。
本発明に係る位相差制御剤として、下記一般式(I)で表される芳香族末端エステル系可塑剤を用いることができる。
(式中、Bはベンゼンモノカルボン酸残基、Gは炭素数2~12のアルキレングリコール残基または炭素数6~12のアリールグリコール残基または炭素数が4~12のオキシアルキレングリコール残基、Aは炭素数4~12のアルキレンジカルボン酸残基または炭素数6~12のアリールジカルボン酸残基を表し、またnは1以上の整数を表す。)
一般式(I)中、Bで示されるベンゼンモノカルボン酸残基とGで示されるアルキレングリコール残基またはオキシアルキレングリコール残基またはアリールグリコール残基、Aで示されるアルキレンジカルボン酸残基またはアリールジカルボン酸残基とから構成されるものであり、通常のポリエステル系可塑剤と同様の反応により得られる。
「酸価」とは、試料1g中に含まれる酸(分子末端に存在するカルボキシル基)を中和するために必要な水酸化カリウムのミリグラム数をいう。酸価及び水酸基価はJIS K0070に準拠して測定したものである。
反応容器に、フタル酸820部(5モル)、1,2-プロピレングリコール608部(8モル)、安息香酸610部(5モル)及び触媒としてテトライソプロピルチタネート0.30部を一括して仕込み窒素気流中で攪拌下、還流凝縮器を付して過剰の1価アルコールを還流させながら、酸価が2以下になるまで130~250℃で加熱を続け生成する水を連続的に除去した。次いで200~230℃で6.65×103Pa~最終的に4×102Pa以下の減圧下、留出分を除去し、この後濾過して次の性状を有する芳香族末端エステルを得た。
酸価 ;0.4
〈サンプルNo.2(芳香族末端エステルサンプル)〉
反応容器に、アジピン酸500部(3.5モル)、安息香酸305部(2.5モル)、ジエチレングリコール583部(5.5モル)及び触媒としてテトライソプロピルチタネート0.45部を用いる以外はサンプルNo.1と全く同様にして次の性状を有する芳香族末端エステルを得た。
酸価 ;0.05
〈サンプルNo.3(芳香族末端エステルサンプル)〉
反応容器にイソフタル酸570部(3.5モル)、安息香酸305部(2.5モル)、ジプロピレングリコール737部(5.5モル)及び触媒としてテトライソプロピルチタネート0.40部を用いる以外はサンプルNo.1と全く同様にして次の性状を有する芳香族末端エステルを得た。
酸価 ;0.2
以下に、本発明に係る芳香族末端エステル系可塑剤の具体的化合物を示すが、本発明はこれに限定されない。
本発明では、位相差制御剤として、更に多価アルコールエステル系可塑剤を使用することができる。
式中、R1はn価の有機基、nは2以上の正の整数、OH基はアルコール性またはフェノール性水酸基を表す。
本発明に係る位相差制御剤としては、(メタ)アクリル系重合体と、フラノース構造もしくはピラノース構造を1個有する化合物(A)中のOH基のすべてもしくは一部をエステル化したエステル化化合物、或いは、フラノース構造もしくはピラノース構造の少なくとも1種を2個以上、12個以下結合した化合物(B)中のOH基のすべてもしくは一部をエステル化したエステル化化合物とを用いることも好ましい。なお、本願においては、本発明に係る化合物(A)のエステル化化合物及び化合物(B)のエステル化化合物を総称して、糖エステル化合物とも称す。
本発明に係る位相差制御剤としては、分子内にビスフェノールAを含有しているものも好ましい。ビスフェノールAの両端にエチレンオキサイド、プロピレンオキサイドを付加した化合物などを用いることができる。
オリゴマーやポリマーなども用いることができる。
本発明のアクリル樹脂含有フィルムにおいては、組成物の流動性や柔軟性を向上するために、可塑剤を併用することも可能である。可塑剤としては、フタル酸エステル系、脂肪酸エステル系、トリメリット酸エステル系、リン酸エステル系、ポリエステル系、あるいはエポキシ系等が挙げられる。
アクリル樹脂含有フィルムの製膜方法の例を説明するが、本発明はこれに限定されるものではない。
本発明のアクリル樹脂含有フィルムを溶液流延法で製造する場合のドープを形成するのに有用な有機溶媒は、アクリル樹脂、セルロースエステル樹脂、その他の添加剤を同時に溶解するものであれば制限なく用いることが出来る。
アクリル樹脂、セルロースエステル樹脂に対する良溶媒を主とする有機溶に、溶解釜中で該アクリル樹脂、セルロースエステル樹脂、場合によってアクリル粒子、その他の添加剤を攪拌しながら溶解しドープを形成する工程、或いは該アクリル樹脂、セルロースエステル樹脂溶液に、場合によってアクリル粒子溶液、その他の添加剤溶液を混合して主溶解液であるドープを形成する工程である。
ドープを送液ポンプ(例えば、加圧型定量ギヤポンプ)を通して加圧ダイ30に送液し、無限に移送する無端の金属ベルト31、例えばステンレスベルト、或いは回転する金属ドラム等の金属支持体上の流延位置に、加圧ダイスリットからドープを流延する工程である。
ウェブ(流延用支持体上にドープを流延し、形成されたドープ膜をウェブと呼ぶ)を流延用支持体上で加熱し、溶媒を蒸発させる工程である。
金属支持体上で溶媒が蒸発したウェブを、剥離位置で剥離する工程である。剥離されたウェブは次工程に送られる。
尚、残留溶媒量を測定する際の加熱処理とは、115℃で1時間の加熱処理を行うことを表す。
剥離後、ウェブを乾燥装置内に複数配置したロールに交互に通して搬送する乾燥装置35、及び/またはクリップでウェブの両端をクリップして搬送するテンター延伸装置34を用いて、ウェブを乾燥する。
・幅手方向に延伸-幅手方向に延伸-流延方向に延伸-流延方向に延伸
また、同時2軸延伸には、一方向に延伸し、もう一方を張力を緩和して収縮させる場合も含まれる。同時2軸延伸の好ましい延伸倍率は幅手方向、長手方向ともに×1.01倍~×1.5倍の範囲でとることができる。
ウェブ中の残留溶媒量が2質量%以下となってからアクリル樹脂含有フィルムとして巻き取り機37により巻き取る工程であり、残留溶媒量を0.4質量%以下にすることにより寸法安定性の良好なフィルムを得ることが出来る。
以下、本発明のアクリル樹脂含有フィルムの物性等についての特徴について説明する。
本発明のアクリル樹脂含有フィルムは、下記式(I)により定義される面内リターデーション値Ro(590)が30~300nmの範囲内であり、下記式(II)により定義にされる厚さ方向のリターデーション値Rt(590)が50~300nmの範囲内であるように調整することが好ましい。
式(I):Ro(590)=(nx-ny)×d(nm)
式(II):Rt(590)={(nx+ny)/2-nz}×d(nm)
〔上式中、Ro(590)は波長590nmにおけるフィルム内の面内リターデーション値を表し、Rt(590)は590nmにおけるフィルム内の厚さ方向のリターデーション値を表す。また、dは光学フィルムの厚さ(nm)を表し、nxは590nmにおけるフィルムの面内の最大の屈折率を表し、遅相軸方向の屈折率ともいう。nyは590nmにおけるフィルム面内で遅相軸に直角な方向の屈折率を表し、nzは590nmにおける厚み方向におけるフィルムの屈折率を表す。〕
面内リターデーション値Ro(590)は、好ましくは、60~250nmの範囲内である。
本発明のアクリル樹脂含有フィルムは、下記式(III)により定義される波長分散(DSP)が0.82~0.95であるように調整することが好ましい。
式(III):DSP=Ro(480)/Ro(630)
〔式中、Ro(480)は波長480nmにおける面内位相差値を表し、Ro(630)は630nmにおける面内位相差値を表す。〕
上記範囲内にリターデーションと波長分散(DSP)を調整することは、アクリル樹脂含有フィルムの組成を最適化し、この組成に応じた延伸を行うことで可能である。
視野角は液晶表示装置の観察方向を法線方向から傾けていった場合に一定レベルのコントラストを維持できる角度のことである。
本発明のアクリル樹脂含有フィルムは、光弾性係数が-5×10-12~5×10-12/Paであるように調整することが好ましい。
本発明に係るアクリル樹脂含有フィルムは、ヘーズを低くし、プロジェクターのような高温になる機器や、車載用表示機器のような、高温の環境下での使用を考慮すると、その張力軟化点を、105℃~145℃とすることが好ましく、110℃~130℃に制御することがより好ましい。
本発明に係る偏光板は、一般的な方法で作製することが出来る。本発明のアクリル樹脂含有フィルムの裏面側に粘着層を設け、沃素溶液中に浸漬延伸して作製した偏光子の少なくとも一方の面に、貼り合わせることが好ましい。
本発明のアクリル樹脂含有フィルムを貼合した偏光板を少なくとも液晶セルの一方の面に用いて液晶表示装置に組み込むことによって、種々の視認性に優れた液晶表示装置を作製することが出来る。本発明に係る偏光板は、前記粘着層等を介して液晶セルに貼合する。
以下のメソゲン基を有するアクリル樹脂a1-1~a1-5を下記の方法によって作製した。
(ドープ液組成)
メソゲン基を有しないアクリル樹脂(a2)
アクリル樹脂ダイヤナールBR85(三菱レイヨン(株)製) 60質量部
メソゲン基を有するアクリル樹脂(a1)
アクリル樹脂a1-1 10質量部
CAP482-20(アシル基総置換度2.75、アセチル基置換度0.19、プロピオニル基置換度2.56、Mw=200000 イーストマンケミカル(株)製)
30質量部
メチレンクロライド 300質量部
エタノール 40質量部
上記組成物を、加熱しながら十分に溶解し、ドープ液を作製した。
上記作製したドープ液を、ベルト流延装置を用い、温度22℃、2m幅でステンレスバンド支持体に均一に流延した。ステンレスバンド支持体で、残留溶剤量が100%になるまで溶媒を蒸発させ、剥離張力162N/mでステンレスバンド支持体上から剥離した。
チヌビン171(チバ・ジャパン(株)製) 0.7質量部
11:LA-31(ADEKA(株)製) 1.5質量部
また、セルロースエステル樹脂のアシル基は、acはアセチル基、pはプロピオニル基、bはブチリル基、bzはベンゾイル基、phはフタリル基を表す。
(ヘーズ)
上記作製した各々のフィルム試料について、23℃、55%RHの空調室で24時間調湿した後、同条件下においてフィルム試料1枚をJIS K-7136に従って、ヘーズメーター(NDH2000型、日本電色工業(株)製)を使用して測定した。
テンシロン試験機(ORIENTEC社製、RTC-1225A)を用いて、以下のような評価を行った。
23℃、55%RHの空調室で24時間調湿したアクリル樹脂含有フィルムを、同条件下、100mm(縦)×10mm(幅)で切り出し、縦方向の中央部で、曲率半径0mm、折り曲げ角が180°でフィルムがぴったりと重なるように山折り、谷折りと2つにそれぞれ1回ずつ折りまげ、この評価を3回測定して、以下のように評価した。尚、ここでの評価の折れるとは、割れて2つ以上のピースに分離したことを表わす。
×・・・3回のうち少なくとも1回は折れる
(フィルム変形)
フィルム試料を90℃、DRY(相対湿度5%RH以下)の雰囲気下に1000時間放置後、フィルム変形の度合いを23℃55%RHの条件下で目視観察した。
△・・・フィルムの変形が認められる
×・・・著しいフィルムの変形が認められる
(湿度変化に対する寸法変化)
作製したフィルムの流延方向に、目印(十字)を2箇所つけて60℃、90%RHで1000時間処理し、処理前と処理後の目印(十字)の距離を23℃55%RHの条件下、光学顕微鏡で測定し、下記基準で評価した。
23℃、55%RHの空調室で24時間調湿した試料を、同条件下、軽荷重引き裂き(エルメンドルフ)試験機(東洋精機(株)製)を用いてフィルムを引き裂き、以下のように評価した。
作製したアクリル樹脂含有フィルムから試料35mm×35mmを切り出し、25℃,55%RHで2時間調湿し、自動複屈折計(KOBRA21DH、王子計測(株))で、480nm、590nm及び630nmにおける垂直方向から測定した値とフィルム面を傾けながら同様に測定したリターデーション値の外挿値より各波長におけるRo、Rtを算出した。
〈偏光板の作製〉
本発明のアクリル樹脂含有フィルムを偏光板保護フィルムとした偏光板を以下のようにして作製した。
上記作製した偏光板を使用して、本発明のアクリル樹脂含有フィルムの表示特性評価を行った。
以上のようにして作製した液晶表示装置1~35を用いて下記の評価を行った。
○:視野角変動が僅かに認められる
△:視野角変動が認められる
×:視野角変動が非常に大きい
(カラーシフト)
ディスプレイを黒表示にし、斜め45°の角度から観察した際の色変化を23℃、55%RHの環境下、下記基準で評価した。
○:色変化が僅かに認められる
△:色変化が認められる
×:色変化が非常に大きい
以上の評価の結果を表4及び表5に示す。
〈アクリル粒子(C1)の調製〉
内容積60リットルの還流冷却器付反応器に、イオン交換水38.2リットル、ジオクチルスルホコハク酸ナトリウム111.6gを投入し、250rpmの回転数で攪拌しながら、窒素雰囲気下75℃に昇温し、酸素の影響が事実上無い状態にした。APS0.36gを投入し、5分間攪拌後にMMA1657g、BA21.6g、およびALMA1.68gからなる単量体混合物を一括添加し、発熱ピークの検出後さらに20分間保持して最内硬質層の重合を完結させた。
MA;メチルアクリレート
BA;n-ブチルアクリレート
ALMA;アリルメタクリレート
PEGDA;ポリエチレングリコールジアクリレート(分子量200)
n-OM;n-オクチルメルカプタン
APS;過硫酸アンモニウム
〈アクリル樹脂含有フィルム25-1の作製〉
(ドープ液組成)
アクリル樹脂ダイヤナールBR85(三菱レイヨン(株)製) 60質量部
アクリル樹脂a1-1 10質量部
セルロースエステル(セルロースアセテートプロピオネート アシル基総置換度2.75、アセチル基置換度0.19、プロピオニル基置換度2.56、Mw=100000)
30質量部
上記調製したアクリル粒子(C1) 20質量部
メチレンクロライド 300質量部
エタノール 40質量部
上記組成物を、加熱しながら十分に溶解し、ドープ液を作製した。
チヌビン171(チバ・ジャパン(株)製) 0.7質量部
またアクリル樹脂含有フィルム25-4は、アクリル粒子C1の替わりにC2としてメタブレンW-341(三菱レイヨン社製)を、アクリル樹脂含有フィルム25-5は単層構造であるMR-2G(綜研化学社製)をC3として、アクリル樹脂含有フィルム25-6はMS-300X(綜研化学社製)をC4として用いた。
得られたアクリル樹脂含有フィルム25-1~25-6について以下の評価を実施した。
作製したアクリル樹脂含有フィルム25-1に関して、フィルム試料を12g測り取り、再び上記組成のメチクロ/エタノール溶媒に溶解させて攪拌し、充分に溶解・分散させたところで0.1μmの孔径を有するPTFE製のメンブレンフィルターT010A(ADVANTEC社製)を用いて濾過し、濾過された不溶物を充分に乾燥させてから重さを測ったところ、1.8gであった。
Claims (6)
- アクリル樹脂を主要構成成分として含有するアクリル樹脂含有フィルムであって、アクリル樹脂とセルロースエステル樹脂とを95:5~30:70の質量比で相溶状態で含有し、当該アクリル樹脂は、その全部又は一部がメソゲン基を置換基又は2価の連結基として有するアクリル樹脂であり、かつ当該セルロースエステル樹脂は、そのアシル基の総置換度が2.00~3.00、炭素数が3~7のアシル基の置換度が1.2~3.0であり、当該セルロースエステル樹脂の重量平均分子量(Mw)が75000以上であることを特徴とするアクリル樹脂含有フィルム。
- 前記メソゲン基を有するアクリル樹脂又はメソゲン基を有しないアクリル樹脂のいずれか一方又は両方の重量平均分子量(Mw)が、80000~1000000であることを特徴とする請求の範囲第1項に記載のアクリル樹脂含有フィルム。
- 前記アクリル樹脂含有フィルムが、それを構成する樹脂の総質量に対して、0.5~45質量%のアクリル粒子を含有することを特徴とする請求の範囲第1項又は第2項に記載のアクリル樹脂含有フィルム。
- 下記式(I)により定義される面内リターデーション値Ro(590)が30~300nmの範囲内であり、下記式(II)により定義される厚さ方向のリターデーション値Rt(590)が50~300nmの範囲内であることを特徴とする請求の範囲第1項から第3項のいずれか一項に記載のアクリル樹脂含有フィルム。
式(I):Ro(590)=(nx-ny)×d(nm)
式(II):Rt(590)={(nx+ny)/2-nz}×d(nm)
〔上式中、Ro(590)は波長590nmにおけるフィルム内の面内リターデーション値を表し、Rt(590)は590nmにおけるフィルム内の厚さ方向のリターデーション値を表す。また、dは光学フィルムの厚さ(nm)を表し、nxは590nmにおけるフィルムの面内の最大の屈折率を表し、遅相軸方向の屈折率ともいう。nyは590nmにおけるフィルム面内で遅相軸に直角な方向の屈折率を表し、nzは590nmにおける厚み方向におけるフィルムの屈折率を表す。〕 - 請求の範囲第1項から第4項のいずれか一項に記載のアクリル樹脂含有フィルムを少なくとも一方の面に用いたことを特徴とする偏光板。
- 請求の範囲第1項から第4項のいずれか一項に記載のアクリル樹脂含有フィルムを使用したことを特徴とする液晶表示装置。
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JPWO2017038267A1 (ja) * | 2015-09-03 | 2017-11-09 | Dic株式会社 | メソゲン基を有する化合物及びそれを含む組成物、並びに重合性組成物を重合することにより得られる重合体、光学異方体、並びに位相差膜 |
JPWO2017038266A1 (ja) * | 2015-09-03 | 2017-11-24 | Dic株式会社 | メソゲン基を有する化合物を含む組成物、並びに重合性組成物を重合することにより得られる重合体、光学異方体、並びに位相差膜 |
CN107924015A (zh) * | 2015-09-03 | 2018-04-17 | Dic株式会社 | 具有介晶基的化合物和含有其的组合物、以及通过使聚合性组合物聚合而得到的聚合物、光学各向异性体以及相位差膜 |
US10649124B2 (en) | 2015-09-03 | 2020-05-12 | Dic Corporation | Composition including compound having mesogenic group, polymer and optically anisotropic body obtained by polymerizing polymerizable composition, and phase difference film |
CN107924015B (zh) * | 2015-09-03 | 2020-06-16 | Dic株式会社 | 具有介晶基的化合物和含有其的组合物、以及聚合物、光学各向异性体以及相位差膜 |
CN109306078A (zh) * | 2017-07-27 | 2019-02-05 | 富士施乐株式会社 | 树脂组合物以及树脂成型体 |
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