WO2010071093A1 - 偏光フィルムの製造法 - Google Patents
偏光フィルムの製造法 Download PDFInfo
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- WO2010071093A1 WO2010071093A1 PCT/JP2009/070799 JP2009070799W WO2010071093A1 WO 2010071093 A1 WO2010071093 A1 WO 2010071093A1 JP 2009070799 W JP2009070799 W JP 2009070799W WO 2010071093 A1 WO2010071093 A1 WO 2010071093A1
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- Prior art keywords
- film
- degree
- polarizing film
- pva
- stretching
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
- B29C55/06—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed
- B29C55/065—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed in several stretching steps
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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
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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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- 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
- B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
- B29K2029/04—PVOH, i.e. polyvinyl alcohol
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/0034—Polarising
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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
- C08J2329/00—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 at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
- C08J2329/02—Homopolymers or copolymers of unsaturated alcohols
- C08J2329/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
Definitions
- the present invention relates to a method for producing a polarizing film that can be used as a member constituting a polarizing plate of a liquid crystal display device.
- Liquid crystal display devices were used in small devices such as calculators and watches in the early stages of their development, but in recent years notebook computers, liquid crystal monitors, liquid crystal color projectors, liquid crystal televisions, in-vehicle navigation systems, mobile phones, It is used in a wide range of measuring instruments used indoors and outdoors.
- improvement in display quality for example, improvement in contrast, is increasingly required, and polarization performance is strongly improved even for polarizing plates, which are one of LCD members. It has been demanded.
- polarizing plates are film originals made of polyvinyl alcohol (hereinafter sometimes referred to as PVA), uniaxial stretching, dyeing treatment with iodine or dichroic dye, fixing treatment with boron compounds, etc. And a protective film such as a cellulose triacetate film or an acetic acid / butyric acid cellulose film is bonded to one side or both sides of the obtained polarizing film.
- PVA polyvinyl alcohol
- a protective film such as a cellulose triacetate film or an acetic acid / butyric acid cellulose film is bonded to one side or both sides of the obtained polarizing film.
- various methods such as a method for improving the structure of PVA as a raw material, a method for controlling the physical properties of a PVA film, and a method for devising the manufacturing conditions of a polarizing plate are proposed. It has contributed to improving the contrast of LCDs.
- Patent Document 1 describes that a polarizing film made of PVA having a polymerization degree of 2500 or more, preferably 6000 to 10,000 is excellent in optical properties.
- PVA having a high degree of polymerization is an advantageous technique for improving the polarization performance, but industrial implementation has been difficult.
- the relationship between the complete dissolution temperature (X) in hot water and the equilibrium swelling degree (Y) is shown by the following equation as a raw film.
- the manufacturing method of the polarizing film using the PVA-type film which is the range is described.
- the polymerization degree of the PVA used in the above invention is preferably in the range of 3500 to 5000, and even if the production method is applied to the high polymerization degree PVA as it is, as shown in Comparative Examples described later, It has been found that the polarizing performance of the obtained polarizing film is not sufficient.
- an object of the present invention is to provide a method for producing a polarizing film, which can process a film made of PVA having a high degree of polymerization into a polarizing film having high polarization performance.
- the original film is wet-stretched in an iodine-potassium iodide aqueous solution.
- the film raw material is preferably obtained by heat treatment at 115 to 130 ° C. after film formation.
- the wet stretching step it is preferable to further include a step of stretching the obtained stretched film further three times or less in an aqueous boric acid solution.
- the present invention also includes a polarizing film obtained by the above production method and having a transmittance of 43.0% or more and a polarization degree of 99.97% or more.
- a film made of PVA having a high degree of polymerization can be processed into a polarizing film having high polarization performance, and industrial production of a polarizing film having high polarization performance becomes possible.
- the degree of polymerization of PVA used in the present invention is required to be 5000 or more, preferably 5500 or more, and more preferably 6000 or more in order to correspond to the good polarization performance intended by the present invention.
- the degree of polymerization of PVA is less than 5000, it becomes difficult to develop high polarization performance.
- the polymerization degree of PVA as used in the field of this invention means the polymerization degree (viscosity average polymerization degree) measured according to the method as described in the Example mentioned later.
- the degree of saponification of PVA is preferably 99 mol% or more, more preferably 99.8 mol% or more.
- the degree of saponification of PVA is less than 99 mol%, PVA tends to be eluted in the polarizing film manufacturing process described later, and the eluted PVA may adhere to the film and reduce the performance of the polarizing film.
- the PVA used in the present invention can be produced by saponifying a polyvinyl ester polymer obtained by polymerizing a vinyl ester.
- vinyl esters include vinyl acetate, vinyl formate, vinyl propionate, vinyl butyrate, vinyl pivalate, vinyl versatate, vinyl laurate, vinyl stearate, vinyl benzoate, and the like. 1 type or 2 types or more are selected. Among these, vinyl acetate is preferably used from the viewpoints of availability, ease of production of PVA, cost, and the like.
- the polymerization temperature is not particularly limited, but when methanol is used as a polymerization solvent, the polymerization temperature is preferably around 60 ° C. near the boiling point of methanol.
- PVA is not limited to a saponified vinyl ester homopolymer unless the effects of the present invention are impaired.
- Film raw material is obtained by forming the above PVA into a film.
- a film forming method in addition to a method of melt-extruding hydrous PVA, a casting film forming method, a wet film forming method (discharge into a poor solvent), a gel film forming method (after once cooling and gelling a PVA aqueous solution, Solvent extraction and removal), cast film forming method (flowing PVA aqueous solution on substrate and drying), and a combination of these methods can be employed.
- the melt extrusion film forming method and the cast film forming method are preferable because a good PVA film (film raw material) can be obtained.
- Examples of the solvent used in the above film formation include dimethyl sulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, ethylene glycol, glycerin, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, and trimethylol.
- Propane, ethylenediamine, diethylenetriamine, water and the like can be mentioned, and one or more of these can be used.
- water, dimethyl sulfoxide, and a mixed solvent thereof are preferably used.
- the volatile fraction of a film-forming stock solution mainly composed of PVA and a solvent varies depending on the film-forming method and the molecular weight of PVA, but is preferably 50 to 95% by mass, more preferably 60 to 95% by mass, and 70 to 95%. More preferred is mass%. If the volatile content is less than 50% by mass, the viscosity of the film-forming stock solution becomes too high, and filtration or defoaming during preparation becomes difficult, and it may be difficult to obtain a film original without foreign matter or defects. There is. On the other hand, if the volatile content exceeds 95% by mass, the viscosity of the film-forming stock solution becomes too low, and it may be difficult to produce a film stock having the desired thickness and thickness accuracy.
- a plasticizer may be used in the production of the original film.
- the plasticizer include glycerin, diglycerin, ethylene glycol and the like, but are not limited thereto.
- the amount of the plasticizer used is not particularly limited, but is usually within a range of 10 to 15 parts by mass with respect to 100 parts by mass of PVA.
- Examples of the method for drying the original film after film formation include drying with hot air, contact drying using a hot roll, and drying using an infrared heater. One of these methods may be employed alone, or two or more may be employed in combination.
- the drying temperature is not particularly limited but is preferably in the range of 50 to 70 ° C. Further, the drying time at this time is approximately 45 to 75 minutes, although it depends on the concentration of the film forming stock solution and the film forming conditions.
- the heat treatment method for the original film after film formation include a method using hot air and a method of bringing the original film into contact with a hot roll. One of these methods may be employed alone, or two or more may be employed in combination.
- the heat treatment temperature is not particularly limited but is preferably in the range of 115 to 130 ° C. Further, the heat treatment temperature at this time is preferably within 5 minutes.
- the thickness of the original film thus obtained is preferably 20 to 120 ⁇ m, more preferably 20 to 80 ⁇ m, and further preferably 20 to 40 ⁇ m. If the thickness is less than 20 ⁇ m, the film may be easily broken in the stretching step described later. Moreover, when thickness exceeds 120 micrometers, there exists a possibility that the stress concerning a film at the time of extending
- the swelling degree A of the original film needs to be 200 to 240%, preferably 205 to 235%, and more preferably 210 to 230%.
- the degree of swelling A is less than 200%, the tension at the time of stretching becomes too large, and it becomes difficult to perform sufficient stretching.
- the degree of swelling A exceeds 240%, water absorption is high, so that wrinkles and end curls are likely to occur in the polarizing film manufacturing process described later, which causes breakage during stretching.
- the temperature and time for heat-treating the film raw film after film formation may be adjusted.
- the degree of swelling A of the original film can be measured by the method described later in the item of Examples.
- the manufacturing process of a polarizing film can include processes such as moisture adjustment, dyeing, stretching, and color adjustment.
- the color can be adjusted, for example, in an aqueous solution containing boric acid and potassium iodide, and dried to produce a polarizing film.
- the temperature at this time is preferably 20 to 40 ° C., more preferably 25 to 35 ° C., and further preferably 27 to 33 ° C.
- the temperature is lower than 20 ° C., the moisture content of the film raw material becomes low, the tension applied to the film at the time of subsequent stretching increases, and it may be difficult to adjust the degree of swelling B of the stretched film.
- the temperature exceeds 40 ° C., the water absorption of the original film becomes high and wrinkles and end curls tend to occur in the subsequent process, which may cause breakage during stretching.
- the time for immersing the original film is generally in the range of 30 to 120 seconds.
- the film original is dyed in, for example, an iodine-potassium iodide aqueous solution.
- the iodine concentration is preferably 0.01 to 0.1% by mass
- the potassium iodide concentration is preferably 1 to 10% by mass
- the iodine concentration is 0.02 to 0.08% by mass
- the potassium iodide concentration 2 to 8% by mass is more preferable, iodine concentration of 0.03 to 0.06% by mass, and potassium iodide concentration of 3 to 6% by mass is further preferable.
- the temperature of the aqueous solution is not particularly limited, but is preferably 25 to 40 ° C.
- Wet stretching of the original film may be performed as a step separate from the above-described moisture adjustment and dyeing, but it is efficient and preferably performed in the above-described water for water adjustment or in an aqueous solution for dyeing, It is more preferable to carry out in an aqueous solution for dyeing, that is, an iodine-potassium iodide aqueous solution.
- an aqueous solution for dyeing that is, an iodine-potassium iodide aqueous solution.
- the stretch ratio represented by the ratio of the length of the film before and after stretching is 2.0-2. It is necessary to make it 9 times, preferably 2.2 to 2.8 times, more preferably 2.4 to 2.8 times.
- the temperature at which the original film is wet-stretched is preferably 20 to 40 ° C., more preferably 25 to 40 ° C., because the degree of swelling B of the stretched film can be easily adjusted to the range described later. It is more preferably from -35 ° C, particularly preferably from 27 to 33 ° C.
- the degree of swelling B of the stretched film needs to satisfy the following formula (2), preferably satisfies the following formula (2 ′), and more preferably satisfies the following formula (2 ′′).
- the reason why the polarization performance is improved by controlling the draw ratio is not clear, but is expected as follows. That is, when the draw ratio is too low, the fine crystals remain in the stretched film without breaking. At this time, B becomes smaller than A + 20, the stretching ratio cannot be increased in the subsequent stretching, and the polarizing performance of the obtained polarizing film is lowered. In addition, when the draw ratio is too high, orientation crystallization of PVA proceeds, so B is also smaller than A + 20, and the draw ratio cannot be increased in the subsequent drawing, and the polarizing performance of the obtained polarizing film is low. Become. On the other hand, for example, if the temperature of the bath when stretching is too high, B becomes larger than A + 35. In this case, breakage of crystals in the film progresses during stretching, and it becomes difficult to stretch with sufficient tension in subsequent stretching, and the polarizing performance of the obtained polarizing film is lowered.
- the degree of swelling B of the stretched film is preferably 230 to 265%.
- the stretching ratio and the temperature of water or aqueous solution during wet stretching may be adjusted as described above.
- the degree of swelling B of the stretched film can be measured by the method described later in the item of the examples.
- the obtained stretched film may be further stretched in a boric acid aqueous solution following the step of wet stretching the film original.
- the draw ratio at this time is preferably 3 times or less, more preferably 1.2 to 3 times, still more preferably 1.3 to 2.9 times, and most preferably 1.4 to 2.8 times.
- the draw ratio exceeds 3 times, the film frequently breaks during drawing, and it may be difficult to stably produce a polarizing film.
- the boric acid concentration in the aqueous solution is preferably 2 to 6% by mass, more preferably 2 to 5% by mass, and further preferably 2 to 4% by mass.
- concentration of boric acid is less than 2% by mass, the resulting polarizing film may have more color spots.
- concentration of boric acid exceeds 6% by mass, the cross-linking of PVA with boric acid becomes excessive, and it may be difficult to stretch the film at a high magnification.
- the concentration of potassium iodide is preferably 3 to 10% by mass, more preferably 4 to 8% by mass. When the concentration of potassium iodide is less than 3% by mass, the resulting polarizing film may be more bluish. On the other hand, when the concentration of potassium iodide exceeds 10% by mass, the resulting polarizing film may become reddish.
- the boric acid aqueous solution may contain a metal compound such as iron or zirconium as another component.
- the temperature of the aqueous solution is not particularly limited, but is preferably 50 to 60 ° C, more preferably 55 to 60 ° C, and further preferably 57 to 60 ° C. If the stretching temperature is less than 50 ° C., it may be difficult to stretch the film to a high magnification. Moreover, when extending
- the color adjustment after stretching is preferably performed in an aqueous solution containing boric acid and potassium iodide.
- a metal compound such as zinc chloride or zinc iodide may be added to the aqueous solution.
- the temperature of the aqueous solution is preferably lower than the stretching temperature in order to prevent a decrease in polarization performance, specifically 20 to 50 ° C. is preferable, and 30 to 40 ° C. is more preferable. There is no particular limitation on the color adjustment time.
- the obtained polarizing film can be dried by various types of dryers using a batch method, a continuous float method, a continuous roll contact method, or the like.
- the drying temperature is preferably from 40 to 80 ° C., more preferably from 45 to 70 ° C., in order to prevent sublimation of iodine from the polarizing film and to suppress the elimination reaction of boric acid crosslinked with PVA. More preferably, it is ⁇ 60 ° C.
- the polarizing film thus obtained preferably has excellent polarizing performance for use in polarizing plates and the like. That is, the transmittance of the polarizing film is preferably 43.0% or more, and the degree of polarization is preferably 99.97% or more (more preferably 99.98% or more).
- the present invention will be specifically described with reference to examples and the like, but the present invention is not limited to the following examples.
- the viscosity average polymerization degree P of PVA the swelling degree A of the original film, the swelling degree B of the stretched film, the transmittance Y and the polarization degree V of the polarizing film were evaluated by the following methods.
- the evaporating dish heated for 1 hour with a dryer at 105 ° C. was cooled with a desiccator for 30 minutes, and the mass a (g) of the evaporating dish was measured.
- a 10 mL sample for measuring the degree of polymerization was transferred to this evaporating dish with a whole pipette, dried for 16 hours with a dryer at 105 ° C., cooled with a desiccator for 30 minutes, and the mass b (g) was measured.
- Example 1 A 5.5 mass% PVA aqueous solution containing 100 parts by mass of PVA having a polymerization degree of 5800 and a saponification degree of 99.8 mol% and 12 parts by mass of glycerin as a plasticizer was cast on a metal roll at 60 ° C. Partial drying was performed to obtain a PVA film having a thickness of 40 ⁇ m. This film was fixed to a metal frame and heat treated at 120 ° C. for 3 minutes. When the degree of swelling A of the original film after heat treatment was measured by the method described in (2) above, it was 230%.
- the original film is cut into a flow direction 11 cm ⁇ width direction 10 cm, attached to a stretching jig 4 cm between chucks with the flow direction as the stretching direction, immersed in pure water at 30 ° C. for 1 minute, It is immersed in a dyeing solution (temperature 30 ° C.) containing 0.03% by mass of iodine and 3% by mass of potassium iodide, and stretched 2.6 times at a rate of 0.13 m / min. Adsorbed. When the degree of swelling B of this stretched film was measured by the method described in (3) above, it was 260%.
- this stretched film was immersed in a stretching solution (temperature 57.5 ° C.) containing 4% by mass of boric acid and 6% by mass of potassium iodide, and 2.3 at a rate of 0.13 m / min. After stretching twice, the stretching direction was fixed and dried at 50 ° C. for 4 minutes to obtain a polarizing film.
- a stretching solution temperature 57.5 ° C.
- boric acid 4% by mass of boric acid and 6% by mass of potassium iodide
- 2.3 a rate of 0.13 m / min.
- the stretching direction was fixed and dried at 50 ° C. for 4 minutes to obtain a polarizing film.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in (4) and (5) above, they were 44.0% and 99.99%, respectively, and a polarizing film with good polarization performance was obtained. It was.
- Example 2 A 5.5 mass% PVA aqueous solution containing 100 parts by mass of PVA having a polymerization degree of 5800 and a saponification degree of 99.8 mol% and 12 parts by mass of glycerin as a plasticizer was cast on a metal roll at 60 ° C. Partial drying was performed to obtain a PVA film having a thickness of 40 ⁇ m. This film was fixed to a metal frame and heat treated at 115 ° C. for 3 minutes. When the degree A of swelling of the original film after heat treatment was measured by the method described in (2) above, it was 240%.
- Example 2 a polarizing film was obtained in the same manner as in Example 1.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in (4) and (5) above, they were 44.0% and 99.99%, respectively, and a polarizing film with good polarization performance was obtained. It was.
- Example 3 A 5.5% by mass PVA aqueous solution containing 100 parts by mass of PVA having a polymerization degree of 9100 and a saponification degree of 99.8 mol% and 12 parts by mass of glycerin as a plasticizer was cast on a metal roll at 60 ° C. Partial drying was performed to obtain a PVA film having a thickness of 20 ⁇ m. This film was fixed to a metal frame and heat treated at 110 ° C. for 3 minutes. When the degree of swelling A of the original film after heat treatment was measured by the method described in (2) above, it was 230%.
- Example 2 a polarizing film was obtained in the same manner as in Example 1.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in (4) and (5) above, they were 44.0% and 99.99%, respectively, and a polarizing film with good polarization performance was obtained. It was.
- Example 4 A 5.5 mass% PVA aqueous solution containing 100 parts by mass of PVA having a polymerization degree of 5200 and a saponification degree of 99.8 mol% and 12 parts by mass of glycerin as a plasticizer was cast on a metal roll at 60 ° C. Partial drying was performed to obtain a PVA film having a thickness of 40 ⁇ m. This film was fixed to a metal frame and heat treated at 110 ° C. for 3 minutes. When the degree A of swelling of the original film after heat treatment was measured by the method described in (2) above, it was 205%.
- Example 2 a polarizing film was obtained in the same manner as in Example 1.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in (4) and (5) above, they were 44.0% and 99.98%, respectively, and a polarizing film with good polarization performance was obtained. It was.
- Example 5 A 5.5 mass% PVA aqueous solution containing 100 parts by mass of PVA having a polymerization degree of 5500 and a saponification degree of 99.8 mol% and 12 parts by mass of glycerin as a plasticizer was cast on a metal roll at 60 ° C. Partial drying was performed to obtain a PVA film having a thickness of 30 ⁇ m. This film was fixed to a metal frame and heat-treated at 130 ° C. for 3 minutes. When the degree A of swelling of the original film after heat treatment was measured by the method described in (2) above, it was 215%.
- Example 2 a polarizing film was obtained in the same manner as in Example 1.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in (4) and (5) above, they were 44.0% and 99.99%, respectively, and a polarizing film with good polarization performance was obtained. It was.
- Example 2 a polarizing film was obtained in the same manner as in Example 1.
- the transmittance and degree of polarization of this polarizing film were measured by the methods described in (4) and (5) above, which were 44.0% and 99.92%, respectively, and the degree of polarization of the polarizing film was slightly insufficient. It was.
- Example 2 a polarizing film was obtained in the same manner as in Example 1.
- the transmittance and degree of polarization of this polarizing film were measured by the methods described in (4) and (5) above, which were 44.0% and 99.92%, respectively, and the degree of polarization of the polarizing film was slightly insufficient. It was.
- Example 2 a polarizing film was obtained in the same manner as in Example 1.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in (4) and (5) above, they were 44.0% and 99.87%, respectively, and the polarization degree of the polarizing film was slightly insufficient. It was.
- a polarizing film was obtained in the same manner as in Example 1 except that the draw ratio was 3.5 times.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in the above (4) and (5), they were 44.0% and 99.90%, respectively, and the polarization degree of the polarizing film was slightly insufficient. It was.
- a polarizing film was obtained in the same manner as in Example 1 except that the draw ratio was 1.4.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in (4) and (5) above, they were 44.0% and 99.80%, respectively, and the polarization degree of the polarizing film was slightly insufficient. It was.
- a polarizing film was obtained in the same manner as in Example 1 except that the draw ratio was 4.6 times.
- the transmittance and polarization degree of this polarizing film were measured by the methods described in the above (4) and (5), they were 44.0% and 99.40%, respectively, and the polarization degree of the polarizing film was slightly insufficient. It was.
- the target value of the draw ratio was changed from 4.6 times to 5.0 times in order to improve the degree of polarization, the draw breakage occurred and a polarizing film could not be obtained.
- the polarizing film obtained by the production method of the present invention taking advantage of the excellent properties of high polarization performance, calculator, wristwatch, notebook computer, liquid crystal monitor, liquid crystal color projector, liquid crystal television, in-vehicle navigation system, mobile phone, It can be effectively used for producing a polarizing plate which is a component part of a liquid crystal display device such as a measuring instrument used indoors and outdoors.
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Abstract
Description
Y > -0.0667X+6.73 ・・・・(I)
X ≧ 65 ・・・・(II)
しかしながら、上記の発明に使用されるPVAの重合度は好ましくは3500~5000の範囲であり、該製造方法をそのまま高重合度PVAに適用しても、後述する比較例に示されるように、得られる偏光フィルムの偏光性能が充分でないことが判明した。すなわち、高重合度のPVAからなる偏光フィルムを工業的に製造するには、PVAの構造、PVAフィルムの物性、偏光フィルムの製造条件等に関する知見を総動員して、新たな製造法を見出すことが必要であった。
200 ≦ A ≦ 240 (1)
A+20 ≦ B ≦ A+35 (2)
本発明において用いられるPVAの重合度は、本発明の目的とする良好な偏光性能に対応するため、5000以上であることが必要であり、5500以上が好ましく、6000以上がより好ましい。PVAの重合度が5000未満であると、高い偏光性能を発現することが困難となる。PVAの重合度の上限としては特に制限はないが、高重合度になるほどPVAの生産性が低下するので、工業的な観点から10000以下であることが好ましい。なお、本発明でいうPVAの重合度は、後述する実施例に記載の方法にしたがって測定した重合度(粘度平均重合度)を意味する。
A+20 ≦ B ≦ A+35 (2)
A+20 ≦ B ≦ A+33 (2’)
A+20 ≦ B ≦ A+30 (2”)
PVA0.28g、蒸留水70g、および撹拌子を、100mL共通すり合わせ三角フラスコに投入した。95℃の恒温槽に、栓をした上記三角フラスコを浸漬し、撹拌子で撹拌しながらPVAを溶解し、0.4%PVA水溶液を作製した。このPVA水溶液をブフナー漏斗形ガラスろ過器3Gでろ過し、30℃の恒温水槽中で冷却して、重合度測定用サンプルとした。参照試料として、別の100mL共栓すり合わせ三角フラスコに蒸留水を70g入れて栓をし、30℃の恒温水槽に浸漬した。
c = 1000×(b-a)/10
ηr = t1/t0
[η] = 2.303×Log(ηr/c)
Log(P) = 1.613×Log([η]×104/8.29)
フィルム原反を5cm×5cmに裁断し、30℃の蒸留水1Lに4時間浸漬した。このフィルム原反を蒸留水中から取り出し、2枚のろ紙ではさんで表面の水滴を吸収させた後、質量Dを測定した。さらに、このフィルム原反を105℃の乾燥機で16時間乾燥し、デシケーターで30分間冷却した後、質量Eを測定し、下記式によりフィルム原反の膨潤度Aを算出した。
A = 100×D/E(%)
湿式延伸したフィルムを、延伸方向10cm×幅方向5cmに切り取り、さらにヨウ素0.03質量%、ヨウ化カリウム3質量%のヨウ素-ヨウ化カリウム水溶液(30℃)に4時間浸漬した。この延伸フィルムをヨウ素-ヨウ化カリウム水溶液から取り出し、2枚のろ紙ではさんで表面の水滴を吸収させた後、質量Fを測定した。この延伸フィルムを105℃の乾燥機で16時間乾燥し、デシケーターで30分間冷却した後、質量Gを測定し、下記式により延伸フィルムの膨潤度Bを算出した。
B = 100×F/G(%)
偏光フィルムの幅方向の中央部から、延伸方向に4cm×幅方向に4cmの正方形のサンプルを2枚採取し、日立製作所製の分光光度計U-4100(積分球付属)を用いて、JIS Z 8722(物体色の測定方法)に準拠し、C光源、2°視野の可視光領域の視感度補正を行い、1枚の偏光フィルムサンプルについて、延伸軸方向に対して45°傾けた場合の光の透過率と-45°傾けた場合の光の透過率を測定して、それらの平均値Y1(%)を求めた。もう1枚の偏光フィルムサンプルについても同様にして、45°傾けた場合の光の透過度と-45°傾けた場合の光の透過度を測定して、それらの平均値Y2(%)を求めた。下記式によりY1とY2を平均し、偏光フィルムの透過率Y(%)とした。
Y = (Y1+Y2)/2
上記(4)で採取した2枚の偏光フィルムを、その延伸方向が平行になるように重ねた場合の光の透過率Y∥(%)、延伸方向が直交するように重ねた場合の光の透過率Y⊥(%)を、(4)に記載された透過率の場合と同様にして測定し、下記式により偏光度V(%)を求めた。
V = {(Y∥-Y⊥)/(Y∥+Y⊥)}1/2×100
重合度5800、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する5.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み40μmのPVAフィルムを得た。このフィルムを金属枠に固定し、120℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、230%であった。
重合度5800、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する5.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み40μmのPVAフィルムを得た。このフィルムを金属枠に固定し、115℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、240%であった。
重合度9100、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する5.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み20μmのPVAフィルムを得た。このフィルムを金属枠に固定し、110℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、230%であった。
重合度5200、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する5.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み40μmのPVAフィルムを得た。このフィルムを金属枠に固定し、110℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、205%であった。
重合度5500、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する5.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み30μmのPVAフィルムを得た。このフィルムを金属枠に固定し、130℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、215%であった。
重合度4800、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する6.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み40μmのPVAフィルムを得た。このフィルムを金属枠に固定し、120℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、220%であった。
重合度5800、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する5.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み40μmのPVAフィルムを得た。このフィルムを金属枠に固定し、140℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、195%であった。
重合度5800、ケン化度99.8モル%のPVA100質量部と、可塑剤としてグリセリン12質量部とを含有する5.5質量%PVA水溶液を、60℃の金属ロール上に流延し、60分乾燥して、厚み40μmのPVAフィルムを得た。このフィルムを金属枠に固定し、110℃で3分間熱処理をした。熱処理後のフィルム原反の膨潤度Aを上記(2)に記載した方法で測定したところ、250%であった。
実施例1で得られたフィルム原反について、延伸倍率を1.7倍としたこと以外は実施例1と同様にして、フィルム原反を延伸しながらヨウ素を吸着させた。得られた延伸フィルムの膨潤度Bを上記(3)に記載した方法で測定したところ、240%であった。
実施例1で得られたフィルム原反について、延伸倍率を4.2倍としたこと以外は実施例1と同様にして、フィルム原反を延伸しながらヨウ素を吸着させた。得られた延伸フィルムの膨潤度Bを上記(3)に記載した方法で測定したところ、240%であった。
実施例1で得られたフィルム原反について、延伸倍率を1.2倍としたこと以外は実施例1と同様にして、フィルム原反を延伸しながらヨウ素を吸着させた。得られた延伸フィルムの膨潤度Bを上記(3)に記載した方法で測定したところ、230%であった。
Claims (5)
- 重合度が5000以上のポリビニルアルコールを製膜して得られる、膨潤度がA(%)であるフィルム原反を、2.0~2.9倍に湿式延伸して、膨潤度がB(%)である延伸フィルムを得る工程を含む偏光フィルムの製造法であって、上記AとBとが下記式(1)および(2)を満足することを特徴とする、偏光フィルムの製造法。
200 ≦ A ≦ 240 (1)
A+20 ≦ B ≦ A+35 (2)
- 前記フィルム原反をヨウ素-ヨウ化カリウム水溶液中で湿式延伸する、請求項1に記載の偏光フィルムの製造法。
- 前記フィルム原反が、製膜後に115~130℃で熱処理されて得られたものである、請求項1または2に記載の偏光フィルムの製造法。
- 前記湿式延伸する工程に続いて、得られた延伸フィルムをさらにホウ酸水溶液中で3倍以下に延伸する工程を含む、請求項1~3のいずれか1項に記載の偏光フィルムの製造法。
- 請求項1~4のいずれか1項に記載の製造法によって得られる、透過率が43.0%以上、かつ偏光度が99.97%以上である偏光フィルム。
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KR20110102902A (ko) | 2011-09-19 |
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TW201033658A (en) | 2010-09-16 |
TWI472811B (zh) | 2015-02-11 |
JP5350368B2 (ja) | 2013-11-27 |
CN102257413A (zh) | 2011-11-23 |
JPWO2010071093A1 (ja) | 2012-05-31 |
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