WO2009122942A1 - 光学シート、光学シートの製造方法、成形体ならびに成形体の製造方法 - Google Patents

光学シート、光学シートの製造方法、成形体ならびに成形体の製造方法 Download PDF

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WO2009122942A1
WO2009122942A1 PCT/JP2009/055693 JP2009055693W WO2009122942A1 WO 2009122942 A1 WO2009122942 A1 WO 2009122942A1 JP 2009055693 W JP2009055693 W JP 2009055693W WO 2009122942 A1 WO2009122942 A1 WO 2009122942A1
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optical sheet
sheet
aromatic polycarbonate
roll
resin composition
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PCT/JP2009/055693
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English (en)
French (fr)
Japanese (ja)
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川東　宏至
木暮　真巳
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出光興産株式会社
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Priority to CN200980112383.9A priority Critical patent/CN101981097B/zh
Publication of WO2009122942A1 publication Critical patent/WO2009122942A1/ja

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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/365—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using pumps, e.g. piston pumps
    • B29C48/37—Gear pumps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/91—Heating, e.g. for cross linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/9145—Endless cooling belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/92—Measuring, controlling or regulating
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/02—Diffusing elements; Afocal elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92009—Measured parameter
    • B29C2948/92114—Dimensions
    • B29C2948/92152—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92009—Measured parameter
    • B29C2948/9218—Weight
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92009—Measured parameter
    • B29C2948/922—Viscosity; Melt flow index [MFI]; Molecular weight
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92009—Measured parameter
    • B29C2948/92247—Optical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2948/00—Indexing scheme relating to extrusion moulding
    • B29C2948/92—Measuring, controlling or regulating
    • B29C2948/92504—Controlled parameter
    • B29C2948/92742—Optical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
    • B29C48/387—Plasticisers, homogenisers or feeders comprising two or more stages using a screw extruder and a gear pump
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
    • B29C48/911—Cooling
    • B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
    • B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0026—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0016—Lenses
    • B29L2011/005—Fresnel lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00—Optical elements, e.g. lenses, prisms
    • B29L2011/0083—Reflectors
    • 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
    • C08J2369/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates

Definitions

  • the present invention relates to an optical sheet used for a light guide plate and the like, a method for manufacturing the optical sheet, a molded body in which irregularities are formed on the surface of the optical sheet, and a method for manufacturing the molded body. More specifically, an optical sheet excellent in transparency and light guide obtained by extruding a specific thermoplastic resin under specific conditions and controlling a higher order structure in the solid structure of the sheet, and the optical sheet
  • the present invention relates to a manufacturing method, a molded body, and a molded body manufacturing method.
  • the backlight for liquid crystal displays mounted on the LED light source is also actively studied for thinning and screen enlargement.
  • the light guide plate dominates the product size, and therefore, consideration has been given to reducing the thickness of the light guide plate and enlarging the screen. Specifically, the thickness that has already been 0.8 mm has been reduced to 0.6 to 0.4 mm, and recently, the thickness has been further reduced to 0.2 mm, which is 0.3 mm or less.
  • a light guide plate used for a backlight for mobile devices is mainly made of polycarbonate resin.
  • a polycarbonate resin is molded into a plate shape mainly by an injection molding method, and at the same time, fine irregularities optically designed for the purpose of uniformly emitting a backlight on the surface are formed.
  • Patent Documents 1 and 2 resin compositions that have been improved in light guide properties for light guide plate applications for injection molding are frequently used.
  • these resin compositions are not only limited by the thickness of the light guide plate and the screen size in the injection molding method, but also birefringence (retardation) occurs due to shear orientation during injection molding, and color misregistration tends to occur during light emission.
  • birefringence retardation
  • the sheet becomes cloudy at the time of the extrusion molding, especially, when the thickness exceeds 2 mm, the cloudiness becomes remarkable.
  • the luminance characteristic is deteriorated. It was difficult to obtain an original sheet for a light guide plate with the resin composition by an extrusion method.
  • Patent Document 3 Even if the fluidity of the resin composition during injection molding is improved (Patent Document 3), a light guide plate having a thickness of 2.6 inches or more and a thickness of 0.25 mm or less cannot be molded by the injection molding method. It has been extremely difficult to obtain a product that is a limit region and exhibits brightness performance as a light guide plate. For large screens such as those for notebook computers, light guide plates made of polymethyl methacrylate (PMMA) have been used. However, as the thickness is reduced, impact strength is insufficient and warping (dimensional stability) Insufficient performance), there are problems such as generation of moire fringes and lowering of luminance due to displacement from the light source.
  • PMMA polymethyl methacrylate
  • PET polyethylene terephthalate
  • Patent Document 4 a polycarbonate resin composition for a light guide plate in which 0.02 to 2 parts by weight of a phosphorus-based and / or phenol-based antioxidant is blended with 100 parts by weight of a polycarbonate resin. Further, since a blue dye or the like is used and the molding temperature is high, the total light transmittance is only about 90%, and further improvement is desired.
  • Japanese Patent Laid-Open No. 10-73725 Japanese Patent No. 3330498
  • JP 2002-60609 Patent 3516908
  • An object of the present invention is to provide an optical sheet which can be easily processed into a molded body such as a light guide plate having a thin wall and a large screen and has a high light transmittance, and a method for producing the same.
  • the present inventors have achieved the above-mentioned problems by using an aromatic polycarbonate having a specific molecular weight and an antioxidant and molding at a specific temperature. Found to get.
  • the present invention has been completed based on such findings. That is, the present invention (1) (A) Aromatic polycarbonate resin composition containing 100 parts by weight of aromatic polycarbonate having a viscosity average molecular weight of 22,000 or less and (B) 0.01-1 part by weight of an antioxidant, and containing no blue dye or pigment. Is an optical sheet that is cooled below the glass transition temperature after being extruded from the extruder, and has a total light transmittance of 91% or more at a thickness of 0.1 to 1 mm.
  • the optical sheet according to (1) wherein the antioxidant of the component (B) is a phosphorus-based antioxidant and / or a phenol-based antioxidant, (6)
  • the method for producing an optical sheet according to the above (1) comprising a heat treatment step of heat treatment at a temperature equal to or higher than ° C.
  • the molded product according to (7) which is any one of a light guide plate, a diffusion sheet, a retroreflecting plate, a prism sheet, and a Fresnel lens sheet, (9)
  • the present invention provides a method for producing a molded article, wherein a concavo-convex pattern is formed on the surface of the optical sheet according to (1).
  • the present invention excels in optical properties (light guiding properties, color tone) such as transferability, high transparency, low birefringence, and the like suitable for the production of molded articles such as a light guide plate having a thickness and area that cannot be achieved by the injection molding method.
  • optical sheet, a light guide plate, and the like are provided.
  • Tension roll 2 Heating roll 3: Cooling roll 4: Pressure roll 5: Endless belt 6: Sheet supply roll 7: Tension roll 8: Heating device S: Sheet d before transferring uneven shape: Pressure roll Length of sheet 21 pinched by endless belt: extruder 22: pinching roll 23: pinching roll 24: take-up roll 25: pinching roll 26a: transfer roll 26b: transfer roll 26c: transfer roll 31: heating Roll 32: Transfer roll 33 for forming irregularities: Pre-heating roll 34: Cooling roll 35: Conveying roll 36: Endless belt
  • an aromatic polycarbonate having a viscosity average molecular weight of 22,000 or less contains (B) an antioxidant, and an aromatic polycarbonate resin composition containing no blue dye or pigment is extruded from an extruder.
  • the optical sheet is cooled below the glass transition temperature, and the total light transmittance at the thickness of the optical sheet of 0.1 to 1 mm is 91% or more.
  • the birefringence phase difference; retardation value at a wavelength of 550 nm
  • the standard deviation value of the retardation value measured at an arbitrary position in the sheet surface is preferably 10 or less.
  • the optical sheet of the present invention does not contain a blue dye or pigment, there is no reduction in luminance characteristics when processed into a light guide plate or the like. By the way, when a blue dye or pigment is contained, the luminance number decreases on the order of 10% depending on the blending amount.
  • an aromatic polycarbonate is used as a base resin and
  • an aromatic polycarbonate resin composition containing an antioxidant is used as an optical sheet, it is possible to reduce yellowing during molding into a sheet. Thus, the luminance is reduced when this sheet is processed into a light guide plate or the like.
  • aromatic polycarbonate As the aromatic polycarbonate as the component (A), bisphenol A type polycarbonate is preferable from the viewpoint of optical transparency, mechanical strength, and heat resistance.
  • the aromatic polycarbonate can be usually produced by reacting a dihydric phenol and a polycarbonate precursor such as phosgene or a carbonate compound.
  • a branching agent may be added if necessary, and a reaction between a dihydric phenol and a carbonate precursor such as phosgene, or It is produced by a transesterification reaction between a dihydric phenol and a carbonate precursor such as diphenyl carbonate.
  • bisphenol A 2,2-bis (4-hydroxyphenyl) propane
  • bisphenols other than bisphenol A include bis (4-hydroxyphenyl) methane; 1,1-bis (4-hydroxyphenyl) ethane; 2,2-bis (4-hydroxyphenyl) butane; (4-hydroxyphenyl) octane; 2,2-bis (4-hydroxyphenyl) phenylmethane; 2,2-bis (4-hydroxy-1-methylphenyl) propane; bis (4-hydroxyphenyl) naphthylmethane; 1 1,2-bis (4-hydroxy-t-butylphenyl) propane; 2,2-bis (4-hydroxy-3-bromophenyl) propane; 2,2-bis (4-hydroxy-3,5-tetramethylphenyl) ) Propane; 2,2-bis (4-hydroxy-3-chlorophenyl) propane; 2,2-bis (4-hydro) Bis-3,5-tetrachlorophenyl)
  • Examples of the carbonate compound include diaryl carbonates such as diphenyl carbonate, and dialkyl carbonates such as dimethyl carbonate and diethyl carbonate. And as a molecular weight regulator, what is normally used for superposition
  • phenol on-butylphenol, mn-butylphenol, pn-butylphenol, o-isobutylphenol, m-isobutylphenol, p-isobutylphenol, ot -Butylphenol, mt-butylphenol, pt-butylphenol, on-pentylphenol, mn-pentylphenol, pn-pentylphenol, on-hexylphenol, mn-hexylphenol, pn-hexylphenol, pt-octylphenol, o-cyclohexylphenol, m-cyclohexylphenol, p-cyclohexylphenol, o-phenylphenol, m-phenylphenol, p-phenylphenol, on-nonylphenol M-nonylphenol, pn-nonylphenol, o-cumylphenol
  • branching agents include, for example, 1,1,1-tris (4-hydroxyphenyl) ethane; ⁇ , ⁇ ′, ⁇ ′′ -tris (4-hydroxyphenyl) -1,3,5-triisopropylbenzene; -[ ⁇ -methyl- ⁇ - (4'-hydroxyphenyl) ethyl] -4- [ ⁇ ', ⁇ '-bis (4 "-hydroxyphenyl) ethyl] benzene; phloroglysin, trimellitic acid, isatin bis (o-cresol)
  • a compound having three or more functional groups such as) can also be used.
  • the aromatic polycarbonate as the component (A) used in the present invention is required to have a viscosity average molecular weight of 22,000 or less, and preferably 12,000 to 20,000. If it is less than 12,000, the mechanical strength is inferior, and if it exceeds 22,000, the total light transmittance is less than 91%, which is not preferable as an optical sheet. Birefringence (phase difference; retardation value at a wavelength of 550 nm) is 150 nm or less, preferably 130 nm or less, and the standard deviation value of the retardation value measured by sampling at an arbitrary position in the sheet surface is 10 or less. It is preferable.
  • the glass transition temperature of the aromatic polycarbonate as the component (A) is about 141 to 149 ° C.
  • an arbitrary location is a total of 9 locations on a 3 cm ⁇ 3 cm grid of 1 cm pitch of two 4 cm ⁇ 4 cm portions, each of which is 60 cm or more away from a sample of an optical sheet of 100 cm ⁇ 100 cm. 18 points shall be measured.
  • antioxidants examples include phosphorus-based, phenol-based, and pentaerythritol-based ones.
  • phosphorus-based antioxidants more specifically, phosphorus-based antioxidant stabilizers such as phosphites and phosphates are preferably used.
  • phosphites include triphenyl phosphite, trisnonylphenyl phosphite, tris (2,4-di-tert-butylphenyl) phosphite, trinolyl phosphate, tridecyl phosphite, trioctyl phosphite.
  • trioctadecyl phosphite distearyl pentaerythritol diphosphite, tricyclohexyl phosphite, monobutyl diphenyl phosphite, monooctyl diphenyl phosphite, distearyl pentaerythritol diphosphite, bis (2,4-di-) tert-butylphenyl) pentaerythritol phosphite, bis (2.6-di-tert-butyl-4-methylphenyl) pentaerythritol phosphite, 2,2-methylenebis (4,6-di-ter - butylphenyl) octyl phosphite, tri-esters of phosphorous acid such as tetrakis (2,4-di -tert- butylphenyl) -4,4-diphenyl En
  • phosphate ester examples include trimethyl phosphate, triethyl phosphate, tributyl phosphate, trioctyl phosphate, triphenyl phosphate, tricresyl phosphate, tris (nonylphenyl) phosphate, 2-ethylphenyl diphenyl phosphate, and the like. These phosphorus antioxidants may be used alone or in combination of two or more.
  • distearyl pentaerythritol diphosphite bis (2,4-di-tert-butylphenyl) pentaerythritol phosphite, bis (2.6-di-tert-butyl-4-) Methylphenyl) pentaerythritol phosphite and tris (2,4-di-tert-butylphenyl) phosphite are preferred
  • pentaerythritol type especially bis (2,6-di-tert-butyl-4-methylphenyl) pentaerythritol Phosphite is particularly preferred.
  • the phosphorus antioxidants can be used alone or in combination of two or more.
  • phosphoric antioxidants can be used as they are, for example, Asahi Denka Kogyo Co., Ltd. [trade name: ADK STAB 2112], Clariant Japan Co., Ltd. product (Sand Stub P-EPQ), Sumitomo Chemical Co., Ltd. Products [Sumilyzer P-168], Ciba-Geigy products [Tris (2,4-di-tert-butylphenyl) phosphite, trade name: Irgafos 168), products of Asahi Denka Co., Ltd. [trade name: Adegas Tab PEP36, etc. Is mentioned.
  • phenolic antioxidants include ⁇ -tocopherol, butylhydroxytoluene, sinapyl alcohol, vitamin E, n-octadecyl-3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate, 2- tert-Butyl-6- (3′-tert-butyl-5′-methyl-2′-hydroxybenzyl) -4-methylphenyl acrylate, 2,6-di-tert-butyl-4- (N, N-dimethyl) Aminomethyl) phenol, 3,5-di-tert-butyl-4-hydroxybenzylphosphonate diethyl ester, 2,2′-methylenebis (4-methyl-6-tert-butylphenol), 2,2′-methylenebis (4 -Ethyl-6-tert-butylphenol), 4,4'-methylenebis (2,6-di-ter -Butylphenol), 2,2'-methylenebis (4-methyl-6-cyclohex
  • the said hindered phenolic antioxidant can be used individually or in combination of 2 or more types.
  • Commercially available phenolic antioxidants can be used as they are, for example, Asahi Denka Kogyo Co., Ltd. [trade name: ADK STAB AO-80], its products [trade name: ADK STAB AO-30], Ciba Specialty Chemicals. Products [trade name: Irganox 1010, 1076] and the like.
  • the antioxidant which is (B) component may use 1 or more types of the said phosphorus antioxidant, may use 1 or more types of phenolic antioxidant, and 1 or more types of phosphorus antioxidants. And one or more phenolic antioxidants may be used in combination.
  • the addition amount is in the range of 0.01 to 1 part by mass, preferably in the range of 0.05 to 0.3 part by mass, with respect to 100 parts by mass of the aromatic polycarbonate as the component (A). By setting it as such a range, the preferable characteristic as an optical sheet is acquired.
  • the optical sheet of the present invention has a total light transmittance of 91% or more at a thickness of 0.1 to 1 mm. After being extruded from the extruder, the total light transmittance can be 91% or more by cooling below the glass transition temperature. Preferably, it is 91.5 to 92%. By setting it to 91% or more, it is possible to prevent the luminance from being lowered. If it exceeds 92%, industrial production is difficult at present because of absorption from the molecular skeleton of the aromatic polycarbonate.
  • a light guide plate with higher display quality than a light guide plate by injection molding By using a retardation value of 150 nm or less and a standard deviation value of the retardation value measured by sampling at an arbitrary position in the sheet surface to be 10 or less, a backlight using a light guide plate processed with an optical sheet is used as a liquid crystal panel. It is possible to prevent the display quality when the display device is mounted on the display device from being deteriorated.
  • the retardation value is preferably 100 nm or less, more preferably 50 nm or less.
  • the optical sheet of the present invention has a spectral light transmittance (solution) in a visible-UV spectral spectrum measured at a thickness of 0.4 mm, measured by dissolving a spectral light transmittance of 70% or more at a wavelength of 300 nm or an aromatic polycarbonate in a good solvent.
  • a spectral light transmittance (solution) in a visible-UV spectral spectrum measured at a thickness of 0.4 mm measured by dissolving a spectral light transmittance of 70% or more at a wavelength of 300 nm or an aromatic polycarbonate in a good solvent.
  • Aromatic polycarbonate resin having a light guide length of the solution cell of 5 cm, a sample solution concentration of 12 g / dl, a solvent dichloromethane, and a wavelength of 450 nm) of 94% or more is used as the component (A) of the polycarbonate resin composition. preferable.
  • a light guide plate formed using an optical sheet light having a wavelength of 400 to 700 nm in the visible light region enters from the end face, is guided and propagates in the end face direction, and the direction of light in the thickness direction (plane direction) Surface emission is achieved by controlling the nature.
  • the light incident in the direction of the end face is emitted from the end face on the opposite side, and the spectral characteristics of the light are measured, so that evaluation suitable for the light propagation of the light guide plate can be performed.
  • a measurement with a thin molded piece of 1 mm or less needs to prepare a special measuring device, which is actually difficult.
  • the sheet characteristics are evaluated based on the spectral characteristics in the thickness direction (plane direction) that can be easily measured and evaluated.
  • the thickness of the sheet is as thin as 1 mm or less, it becomes difficult to detect the spectral characteristic difference specific to the sheet base material in the measurement of the spectral light transmittance that transmits visible light in the thickness direction.
  • this spectral characteristic difference even when measuring spectral characteristics in the thickness direction, it is possible to evaluate this spectral characteristic difference by paying attention to a wavelength of 380 nm or less in the ultraviolet region.
  • the evaluation result of the spectral transmittance at 300 to 380 nm by the measurement in the thickness direction does not directly reflect the spectral transmittance in the visible light region, but is relatively linked with the spectral transmittance at 300 to 380 nm in the end face direction.
  • There is a tendency to reflect the spectral characteristics in the visible light wavelength region and a substitution thereof is possible.
  • an optical resin base material having a high spectral transmittance of 300 to 380 nm measured in the thickness direction tends to have high spectral characteristics in the visible light wavelength region when measured in the end face direction. If the spectral light transmittance is less than 70%, the light guide performance is insufficient, and thus the luminance decreases. More preferably, it is 73% or more.
  • the viscosity average molecular weight of the aromatic polycarbonate (A) in the optical sheet of the present invention is 22000 or less, preferably 14000 to 20000. More preferably, it is 15000 to 19000. If it is less than 14,000, the strength of the product will be insufficient, and the yield will be reduced due to the adhesion of chips during the external processing of the product. In particular, when the thickness of the optical sheet is 0.3 mm or less, the strength tends to be insufficient, and the optical sheet tends to be easily damaged. When the viscosity average molecular weight exceeds 22,000, depending on the extrusion molding conditions, the yellowing and retardation values of the resin base material are likely to increase, and it becomes difficult to reach a total light transmittance of 91%.
  • a light guide plate or the like is formed by transferring a fine uneven pattern (prism, dot, dome-shaped convex lens) of several to several hundred microns on a sheet surface by roll embossing or press forming a resin sheet to form an uneven pattern.
  • a fine uneven pattern pris, dot, dome-shaped convex lens
  • the transferability at this time also deteriorates.
  • the optical sheet of the present invention is produced by extrusion molding of an aromatic polycarbonate resin composition, but it is thermoplastic as component (C) in addition to the aromatic polycarbonate as component (A) and the antioxidant as component (B).
  • a small amount of polyacrylic acid alkyl ester resin may be added.
  • Spectral characteristics are further improved by adding a small amount of component (C).
  • Component (C) is preferably added so that the ratio of component (A) / component (C) is 99.99 / 0.01 to 99.00 / 1.00 (mass ratio). More preferably, it is 99.95 / 0.05 to 99.50 / 0.50, and particularly preferably 99.90 / 0.10 to 99.70 / 0.30.
  • thermoplastic polyacrylic acid alkyl ester resin as component (C) is a polymer having a repeating unit of at least one selected from monomer units of acrylic acid, acrylic acid ester, acrylonitrile and derivatives thereof, a homopolymer or A copolymer with styrene, butadiene or the like may also be used.
  • polyacrylic acid polymethyl methacrylate (PMMA), polyacrylonitrile, ethyl acrylate-acrylic acid-2-chloroethyl copolymer, acrylic acid-n-butyl-acrylonitrile copolymer, acrylonitrile-styrene copolymer And acrylonitrile-butadiene copolymer and acrylonitrile-butadiene-styrene copolymer.
  • PMMA polymethyl methacrylate
  • PMMA polymethyl methacrylate
  • known ones can be used as polymethyl methacrylate (PMMA).
  • thermoplastic polyacrylic acid alkyl ester resin as component (C) preferably has a molecular weight of 200 to 100,000, more preferably 20,000 to 60,000. When the molecular weight is 200 to 100,000, phase separation between the component (A) and the component (C) does not become too fast at the time of molding, so that sufficient transparency can be obtained in the optical sheet.
  • the method for producing the optical sheet of the present invention is not particularly limited, but a desired optical sheet can be produced according to the following method for producing an optical sheet of the present invention.
  • the method for producing an optical sheet of the present invention includes a molding step of melt-extruding the aromatic polycarbonate resin composition into a sheet, a cooling step of rapidly cooling the melt-extruded sheet-like molded body to a glass transition temperature or lower, and cooling A heat treatment step of heat-treating the sheet-like molded body at 50 ° C. or more and below the glass transition temperature of the polycarbonate resin.
  • the said cooling process can cool the said sheet-like molded object by allowing the said sheet-like molded object to pass through the slit where cooling water flows down.
  • the heat treatment step can be carried out by sandwiching and heating the front and back surfaces of the sheet-like molded body with a metal endless belt and / or metal roll having a mirror surface.
  • an optical sheet that can be used as a light guide plate can be manufactured by selecting molding conditions even with a sheet molding machine that is generally equipped with three rolls.
  • the cylinder temperature and die temperature of the extruder are about 220 to 340 ° C., preferably about 240 to 320 ° C., depending on the difference in resin composition, glass transition temperature, and the like.
  • Resin containing (A) component / (C) component in a ratio of 99.99 / 0.01 to 99.00 / 1.00 (mass ratio) and (B) an antioxidant in the above-described ratio When performing extrusion molding using the composition as a raw material, a cooling step of rapidly cooling the sheet-like molded body obtained by the above melt extrusion to a glass transition temperature or lower is important. Extrusion molding including such a cooling step When the apparatus is applied, an optical sheet having higher optical transparency can be obtained.
  • the cooling temperature needs to be lower than the glass transition temperature, preferably 140 ° C. or lower, more preferably 120 ° C. or lower.
  • the total light transmittance at a thickness of 0.1 to 1 mm of the optical sheet can be set to 91% or higher.
  • the lower limit of the cooling temperature is about 50 ° C. although it depends on the difference in resin composition, glass transition temperature, and the like. By setting the temperature to 50 ° C. or higher, it is possible to reduce the residual strain in the molded optical sheet and ensure optical isotropy. Cooling is usually performed using a plurality of rolls.
  • the cylinder temperature of the extruder is about 220 to 340 ° C, preferably about 240 to 320 ° C.
  • the cooled sheet-like formed body is subjected to a heat treatment step in which heat treatment is performed at a temperature of 50 ° C.
  • the endless belt wound around a plurality of rolls and heated by the heating roll unit is caused to travel while the formed sheet is in close contact with the endless belt and the roll.
  • a method for producing a sheet in which the sheet is peeled from the endless belt after linear pressure welding, and the heated sheet is kept warm and / or heated while traveling from the side opposite to the endless belt (See FIG. 1). Heat insulation and / or heating is performed by a heat insulation plate, hot air blowing, and infrared rays.
  • 1 is a tension roll
  • 2 is a heating roll
  • 3 is a cooling roll
  • 4 is a rolling roll
  • 5 is an endless belt
  • 6 is a sheet supply roll
  • 7 is a tension roll
  • 8 is a heating device.
  • S indicates a sheet before the concavo-convex shape is transferred
  • d indicates the length of the sheet sandwiched between the rolling roll 4 and the endless belt 5.
  • the elastic roll method include a method disclosed in Japanese Patent Publication No. 2004-155101.
  • a T-die is attached to an extruder to form a sheet, the sheet is passed through a first clamping roll, a second clamping roll, and a third clamping roll, and a plurality of transfer rolls are linearly formed.
  • sheets are manufactured side by side and manufactured through a take-up roll (see FIG. 2).
  • 21 is an extruder
  • 22, 23 and 25 are pinching rolls
  • 24 is a take-up roll
  • 26a, 26b and 26c are transfer rolls.
  • the molded body of the present invention such as a light guide plate having a concavo-convex pattern formed on the surface of the optical sheet
  • the optical sheet obtained by the above characteristics, composition, and manufacturing method is formed into a molded body by forming a fine uneven pattern on the surface, light distribution control is possible, a light guide plate, a diffusion sheet, a retroreflector, It can be used as a prism sheet and a Fresnel lens sheet.
  • the concavo-convex pattern include a dot shape, a convex lens shape, a concave lens shape, a V-groove prism shape, and a polygonal prism shape such as a triangular pyramid and a quadrangular pyramid.
  • gradation shading
  • a diffusion sheet used in a direct type backlight it is possible to make the luminance uniform by forming the uneven pattern in the distance from the light source shadow on the light source to the distance between the light sources. Examples of a method for forming such a concavo-convex pattern include a roll embossing method, a vacuum press molding method, and a belt transfer method.
  • a mold with a fine uneven pattern formed on a nickel-plated foil on the surface of a belt-like thin plate stainless steel is manufactured, and heat, pressure transfer and peeling are performed while the resin film is synchronously conveyed between the mold belts rotating up and down.
  • a belt transfer method for example, Japanese Patent Application Laid-Open No. 2005-321681
  • This method does not require time for evacuation, temperature increase, and temperature decrease, and can transfer to a large area with high productivity (see FIG. 3).
  • 31 is a heating roll
  • 32 is a transfer roll for forming irregularities
  • 33 is a preheating roll
  • 34 is a cooling roll
  • 35 is a transport roll
  • 36 is an endless belt.
  • the left arrow indicates the optical sheet before transferring the concavo-convex shape
  • the right arrow indicates the optical sheet after transfer, that is, a molded body such as a light guide plate.
  • a lithography method in which an acrylic UV curable resin is pressed against the optical sheet of the present invention using a mold having a fine concavo-convex pattern, and a screen printing method using a white ink.
  • a molded body such as a light guide plate can also be manufactured by simultaneously performing the optical sheet molding and the step of forming a concavo-convex pattern on the surface.
  • a manufacturing apparatus provided with such simultaneous processes, for example, a continuous extrusion embossing machine SPU-03026W manufactured by Toshiba Machine Co., Ltd. can be suitably used (see FIG. 4).
  • the pressing length is increased due to the flexibility of the special touch roll, and the transfer rate is improved.
  • the roll clearance adjustment method Pressure sensor and Positioning sensor
  • Aromatic polycarbonate PC1 Taflon FN1700A bisphenol A polycarbonate resin manufactured by Idemitsu Kosan Co., Ltd., glass transition temperature: 142 ° C., viscosity average molecular weight: 17,300, refractive index: 1.585]
  • Aromatic polycarbonate PC2 Toughlon FN1900A bisphenol A polycarbonate resin manufactured by Idemitsu Kosan Co., Ltd., glass transition temperature: 145 ° C., viscosity average molecular weight: 19,500, refractive index: 1.585]
  • Aromatic polycarbonate PC3 Toughlon FN2500A [Bisphenol A polycarbonate resin manufactured by Idemitsu Kosan Co., Ltd., glass transition temperature: 148 ° C., viscosity average molecular weight: 23,500, refractive index: 1.585]
  • Phosphorus antioxidant Adegas tab PEP36 [Bisphenol A polycarbonate resin manufactured by Idemitsu Kosan Co., Ltd., glass
  • optical sheet extrusion> Condition 1 (applied in Examples 1 to 4 and Comparative Examples 1 and 2) An optical sheet (thickness 0.4 mm) was produced by a “three roll device” provided with the extruder 21 shown in FIG.
  • Each of the second pinching roll 23 and the third pinching roll 25 was a metal roll having a diameter of 300 mm.
  • the total distance between the first transfer roll 26a and the final transfer roll 26c was 3 m.
  • Condition 2 (applied in Example 5) This was carried out using a UF roll clamping press machine (elastic roll method—see FIG. 2) manufactured by Hitz Industrial Equipment Techno Co., Ltd. The screw diameter of the extruder is 90 mm.
  • Condition 3 (applied in Example 6) A stamper with a triangular pyramid prism array (height 50 ⁇ m) formed by nickel plating was pressed against a sheet obtained by sheet molding using a continuous extrusion embossing machine SPU-03026W (see FIG. 4) manufactured by Toshiba Machine Co., Ltd. Simultaneously, pattern transfer was performed to produce a prism sheet (pattern formation 2). The screw diameter of the extruder is 26 mm ⁇ , and the temperatures of the other parts are as described in Table 1.
  • Condition 4 (applied in Comparative Example 3) The same procedure as in Condition 1 was performed except that the temperature at each location was changed to the temperature shown in Table 1.
  • Condition 5 (applied in Comparative Example 4) Injection molding was performed at a molding temperature of 360 ° C. (mold temperature: 120 ° C.) using an injection molding machine (manufactured by Sumitomo Heavy Industries, Ltd., product number SG100M-HP) having a clamping force of 100 tons.
  • ⁇ Evaluation method> (1) Total light transmittance Measured according to JIS-K-7105 using a haze meter (HGM-2DP) manufactured by Suga Test Instruments Co., Ltd. (2) Spectral Light Transmittance of Sheet An optical sheet sample having a thickness of 0.4 mm was measured for spectral light transmittance (%) at a wavelength of 300 nm using a UV-visible spectrophotometer (UV-2450) manufactured by Shimadzu Corporation. (3) Birefringence (Retardation) and Standard Deviation Value The birefringence (retardation value) for 550 nm was measured with a retardation measuring device (RETS-100) manufactured by Otsuka Electronics Co., Ltd.
  • FTS-100 retardation measuring device manufactured by Otsuka Electronics Co., Ltd.
  • an arbitrary location is a total of 9 locations on a 3 cm ⁇ 3 cm grid of 1 cm pitch of two 4 cm ⁇ 4 cm portions, each of which is 60 cm or more away from a sample of an optical sheet of 100 cm ⁇ 100 cm. 18 points were measured.
  • a formula: Standard deviation ( ⁇ ) ⁇ [ ⁇ (Re 1 ⁇ Re av ) 2 + (Re 2 ⁇ Re av ) 2 +... + (Re n ⁇ Re av ) 2 ⁇ / n] n represents the total sampling number Re n , the Re value Re av at the n-th sampling location, and the average value of Re.
  • Transferability of concavo-convex pattern For each of the light guide plates obtained in Examples 1 to 6 and Comparative Examples 1 to 4, the pattern transfer rate reflecting the luminance characteristics was carried out instead of the luminance evaluation.
  • Transfer rate (%) [height of the triangular pyramid of the transferred light guide plate ( ⁇ m) / height of the triangular pyramid in the stamper (50 ⁇ m)] ⁇ 100
  • Example 1 Using each pellet produced by melt-kneading extrusion using the compounding materials shown in Table 1, an optical sheet is produced by applying the molding conditions of “Condition 1”, “Condition 2” or “Condition 3”, A light guide plate was produced by applying the pattern formation 1 (Examples 1 to 5) or the pattern formation 2 (Example 6) to the optical sheet. The temperature at each location under each condition is as described in Table 1.
  • the optical sheet of the present invention controls the higher order structure in the solid structure by extruding a resin composition containing a specific aromatic polycarbonate under specific conditions, and optimizes the uneven pattern formed on the surface according to the application By doing so, it is processed into a light guide plate, a diffusion sheet, a retroreflecting plate, or a brightness enhancement prism sheet.

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CN101981097A (zh) 2011-02-23
TW201003161A (en) 2010-01-16
KR101567351B1 (ko) 2015-11-09
TWI442118B (zh) 2014-06-21

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