WO2010092926A1 - 積層光学体、光学フィルム、および該光学フィルムを用いた液晶表示装置、ならびに積層光学体の製造方法 - Google Patents
積層光学体、光学フィルム、および該光学フィルムを用いた液晶表示装置、ならびに積層光学体の製造方法 Download PDFInfo
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- WO2010092926A1 WO2010092926A1 PCT/JP2010/051783 JP2010051783W WO2010092926A1 WO 2010092926 A1 WO2010092926 A1 WO 2010092926A1 JP 2010051783 W JP2010051783 W JP 2010051783W WO 2010092926 A1 WO2010092926 A1 WO 2010092926A1
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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
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
- B32B27/281—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyimides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
- B32B27/288—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyketones
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
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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
- G02B5/3016—Polarising elements involving passive liquid crystal elements
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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
- G02F1/13363—Birefringent elements, e.g. for optical compensation
- G02F1/133634—Birefringent elements, e.g. for optical compensation the refractive index Nz perpendicular to the element surface being different from in-plane refractive indices Nx and Ny, e.g. biaxial or with normal optical axis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/412—Transparent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/418—Refractive
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/42—Polarizing, birefringent, filtering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/514—Oriented
- B32B2307/516—Oriented mono-axially
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/728—Hydrophilic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
- B32B2457/202—LCD, i.e. liquid crystal displays
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K2323/00—Functional layers of liquid crystal optical display excluding electroactive liquid crystal layer characterised by chemical composition
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
- Y10T428/264—Up to 3 mils
- Y10T428/265—1 mil or less
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
Definitions
- the present invention relates to a laminated optical body, an optical film, a liquid crystal display device using the optical film, and a method for producing the laminated optical body.
- the liquid crystal display device includes a polarizing plate as an essential component due to its display mechanism.
- a polarizing plate a uniaxially stretched film obtained by adsorbing a dichroic substance on a polyvinyl alcohol (PVA) film is widely used. Since such a polarizing plate is produced by stretching a long PVA film in the longitudinal direction, the absorption axis is expressed in the longitudinal direction.
- PVA polyvinyl alcohol
- a predetermined retardation film is used, and its slow axis is a polarizing plate (in practice, polarized light contained in the polarizing plate). It is necessary to provide it perpendicularly to the absorption axis of the child. Therefore, a laminate including a polarizing plate and a retardation film (so-called retardation plate integrated polarizing plate) is often used.
- the conventional polarizing plate has a problem that the dimensional change is large under a high temperature and high humidity environment. As a result, even in the retardation plate integrated polarizing plate, there is a problem that the retardation film is distorted due to the dimensional change of the polarizing plate in a high temperature and high humidity environment, resulting in retardation unevenness.
- a problem also arises when a specific retardation film is used.
- a laminate including a retardation film as an optical compensation film of a TN (Twisted (Nematic) type liquid crystal display device, a laminate including a retardation film (so-called O plate) that is tilted and aligned is known.
- O plate a retardation film
- it is necessary to adjust the direction (back and front) of the inclination orientation of O plate at the time of bonding.
- the method of laminating one by one decreases the production efficiency due to the confirmation work of the tilt orientation direction, and makes a mistake in pasting. There is a problem of a decrease in yield due to.
- the laminating by roll-to-roll is very preferable.
- the conventional polarizing plate has an absorption axis in the original MD due to the manufacturing method thereof, so that the slow axis of the O plate is perpendicular to the absorption axis and roll-to-roll is used.
- the O plate In the case of bonding, it is necessary to express the slow axis of the O plate on the original TD. As with other retardation films, it is extremely difficult for the O plate to accurately express the slow axis in the original TD. Furthermore, in a laminate using a conventional polarizing plate and an O plate, the O plate is distorted due to, for example, dimensional change (for example, shrinkage) of the polarizing plate in a high-temperature and high-humidity environment, and the angle of tilted orientation is shifted. As a result, it may be difficult to achieve desired optical compensation.
- dimensional change for example, shrinkage
- the present invention has been made in order to solve the above-described conventional problems, and the object thereof is excellent in production efficiency, the axial shift of the slow axis and retardation unevenness of the retardation film are extremely small, and It is an object of the present invention to provide a laminated optical body having a very small dimensional change in a high temperature and high humidity environment.
- the laminated optical body of the present invention comprises a long polarizing film having an absorption axis in the short direction and comprising a base material layer and a hydrophilic polymer layer to which a dichroic substance is adsorbed; A long retardation film having a phase axis.
- This laminated optical body has a long shape.
- the hydrophilic polymer layer has a thickness of 1 ⁇ m to 10 ⁇ m.
- the base material layer also serves as a protective layer for the hydrophilic polymer layer.
- the retardation film includes molecules oriented in a tilted manner.
- the laminated optical body has a slow axis in the short direction on the side opposite to the hydrophilic polymer layer of the retardation film, and the refractive index ellipsoid is nx> ny. It further includes a long second retardation film having a relationship of> nz.
- the in-plane retardation value Re 2 [590] of the second retardation film is 80 to 160 nm, and the Nz coefficient is 1.1 to 1.8.
- the in-plane retardation value Re 1 [590] of the retardation film is 100 nm or less, and the thickness direction retardation value Rth 1 [590] is 50 nm to 200 nm.
- the laminated optical body further includes an elongated second retardation film, and the in-plane retardation value Re 2 [590] of the second retardation film is less than 100 nm, The thickness direction retardation value Rth 2 [590] is less than 200 nm.
- the total Re 1 + 2 [590] of the in-plane retardation values of the retardation film and the second retardation film is 10 nm or more and less than 200 nm, and the total retardation value Rth 1 + 2 [thickness direction] 590] is 50 nm to 300 nm.
- the manufacturing method of an elongate laminated optical body is provided. In this production method, a thin film is formed by applying a composition containing a hydrophilic polymer to a long base material; the thin film is stretched together with the base material; and the stretched thin film is dyed.
- the method stretches the thin film in the lateral direction together with the substrate.
- an optical film is provided. This optical film is obtained by cutting or punching the laminated optical body.
- a liquid crystal display device is provided. The liquid crystal display device includes the optical film and a liquid crystal cell.
- the present invention by using a polarizing film that is very thin and has an absorption axis in the short direction, it can be laminated with a phase difference film having a slow axis in the longitudinal direction and a roll-to-roll. Therefore, it is possible to obtain a laminated optical body having a very small axial shift of the slow axis of the retardation film. Furthermore, since the very thin polarizing film as described above has a very small dimensional change rate (particularly under high temperature and high humidity environment), the distortion of the retardation film due to the dimensional change of the polarizing film in the laminated optical body is also extremely small. Become. As a result, the retardation unevenness of the laminated optical body is extremely reduced.
- the laminated optical body of the present invention can realize a liquid crystal display device with extremely small display unevenness when incorporated in a liquid crystal display device.
- the laminated optical body of the present invention can be manufactured by roll-to-roll, it is excellent in manufacturing efficiency.
- FIG. 3 is an image showing a luminance distribution of a display screen of the liquid crystal display device obtained in Example 1.
- FIG. 4 is a photograph of a display screen (black image) of a liquid crystal display device obtained in Example 2.
- FIG. 6 is an image showing a luminance distribution of a display screen of a liquid crystal display device obtained in Example 2.
- 4 is a photograph of a display screen (black image) of a liquid crystal display device obtained in Comparative Example 1.
- FIG. 6 is an image showing a luminance distribution of a display screen of a liquid crystal display device obtained in Comparative Example 1.
- 4 is a photograph of a display screen (black image) of a liquid crystal display device obtained in Comparative Example 2.
- 10 is an image showing a luminance distribution of a display screen of a liquid crystal display device obtained in Comparative Example 2.
- A. 1 is a schematic cross-sectional view of a laminated optical body according to a preferred embodiment of the present invention.
- the laminated optical body 10 is formed by laminating a polarizing film 11 and a retardation film 12.
- the polarizing film 11 is a laminate of a base material layer 11a and a hydrophilic polymer layer 11b (sometimes referred to as a polarizing thin film in this specification).
- a dichroic substance is adsorbed on the hydrophilic polymer layer 12.
- the laminated optical body 10 has a long shape.
- “long shape” means that the length (longitudinal direction) is 10 times or more with respect to the width (short direction).
- the laminated optical body of the present invention has a roll shape.
- the polarizing film 11 (substantially, the hydrophilic polymer layer 11b) has an absorption axis in the short direction.
- the retardation film 12 has a slow axis in the longitudinal direction. Therefore, the absorption axis of the polarizing film and the slow axis of the retardation film are substantially orthogonal.
- the roll-to-roll bonding can significantly reduce the variation in the slow axis direction as compared to the case of bonding one sheet at a time. Furthermore, since a retardation film having a slow axis in the longitudinal direction can be employed, production of a long retardation film is much easier, and control of the slow axis direction of the retardation film is easy. . In addition, since a long polarizing film having an absorption axis in the short direction can be produced wide, it can be suitably applied to a large liquid crystal display device and the like. One of the major achievements of the present invention is that a long polarizing film having optical properties that are practically acceptable and having an absorption axis in the short direction is actually produced.
- the “short direction” includes a direction substantially parallel to the short direction
- the “longitudinal direction” includes a direction substantially parallel to the long direction.
- “Substantially parallel” includes the case where the angle between the two directions is 0 ° ⁇ 1 °, and preferably 0 ° ⁇ 0.5 °.
- substantially orthogonal includes the case where the angle formed by the two directions is 90 ° ⁇ 1 °, and preferably 90 ° ⁇ 0.5 °.
- the base material layer 11a can function as a protective film for the hydrophilic polymer layer 11b.
- the hydrophilic polymer layer 11b and the retardation film 12 are bonded together via any appropriate adhesive layer or pressure-sensitive adhesive layer (not shown). Between the base material layer 11a and the hydrophilic polymer layer 11b and / or between the hydrophilic polymer layer 11b and the adhesive layer or the pressure-sensitive adhesive layer, any appropriate easy adhesion layer (for example, acrylic resin) May be provided).
- a protective film also referred to as an inner protective film: not shown
- any appropriate surface treatment layer (not shown) is provided on the side of the base material layer 11a opposite to the hydrophilic polymer layer 11b (that is, outside the base material layer 11a) according to the purpose. May be.
- the surface treatment layer include a treatment layer subjected to a hard coat treatment, an antireflection treatment, an antisticking treatment, a diffusion treatment (antiglare treatment), and the like.
- the retardation film 12 any appropriate retardation film can be adopted as long as it has a slow axis in the longitudinal direction and the effect of the present invention can be obtained.
- the retardation film 12 is a so-called O-plate containing molecules that are tilt-oriented. Details of the retardation film 12 will be described in the section A-2 described later.
- the laminated optical body of the present invention may further include a second retardation film.
- the optical characteristics and arrangement position of the second retardation film can be appropriately set according to the purpose, the optical characteristics of the retardation film 12 (hereinafter, sometimes referred to as “first retardation film” for convenience), and the like.
- the second retardation film 13 may be disposed on the opposite side of the first retardation film 12 from the hydrophilic polymer layer 11b in the laminated optical body 10, as shown in FIG. 1B.
- the retardation film 12 and the hydrophilic polymer layer 11b may be disposed (not shown). Details of the second retardation film 13 will be described later in section A-3.
- the laminated optical body of the present invention may further include a brightness enhancement film on the side opposite to the hydrophilic polymer layer 11b of the base material layer 11a (that is, the outside of the base material layer 11a). (Not shown).
- a brightness enhancement film may be directly laminated on the opposite side of the hydrophilic polymer layer 11b from the retardation film 12 (that is, after the base material layer 11a is peeled off, the hydrophilic polymer layer 11b).
- a brightness enhancement film may be laminated on the layer 11b (not shown).
- the laminated optical body provided with the brightness enhancement film can be suitably used, for example, as a polarizing plate on the backlight side.
- the laminated optical body is typically arranged so that the brightness enhancement film is on the backlight side.
- the brightness enhancement film is laminated on the laminated optical body via any appropriate pressure-sensitive adhesive or adhesive.
- the pressure-sensitive adhesive or adhesive is filled and disposed without a gap between the brightness enhancement film and the laminated optical body (substantially, the base material layer 11a or the hydrophilic polymer layer 11b).
- the brightness enhancement film for example, two or more multilayer thin film laminates made of two or more materials having a refractive index difference, or two or more resin laminates using two or more resins having a refractive index were stretched. And bi-refractive layer multilayer thin film laminates of two or more layers made of two or more materials having a refractive index.
- the brightness enhancement film can be, for example, a reflective polarizer commercially available under the trade name DBEF manufactured by 3M. When a reflective polarizer is used as the brightness enhancement film, the reflective polarizer is arranged so that the polarization transmission axis and the absorption axis of the polarizing film 11 are orthogonal to each other.
- the long brightness enhancement film and the long laminated optical body can be bonded together by roll-to-roll. That is, in the conventional polarizing plate, since the absorption axis is in the original MD, the polarization transmission axis of the brightness enhancement film to be bonded needs to be expressed in TD. On the other hand, according to the present invention, since the absorption axis of the polarizing film is in the short direction, it is possible to bond the long luminance enhancement film and the long laminated optical body by roll-to-roll. .
- the thickness of the brightness enhancement film that can be used in the present invention is typically about 50 to 200 ⁇ m.
- the dimensional change rate of the laminated optical body 10 is preferably 0.2% or less, and more preferably 0.1% or less, under the condition of being stored in a constant temperature environment test chamber at 80 ° C. for 500 hours. Further, it is preferably 0.12% or less, more preferably 0.08% or less under the condition of being stored in a constant temperature / humidity test chamber at 60 ° C. and 90% RH for 500 hours.
- the polarizing film 11 is a laminate of the base material layer 11a and the hydrophilic polymer layer 11b. Typically, the base material layer 11a and the hydrophilic polymer layer 11b are adhered and laminated without an adhesive layer or an adhesive layer interposed therebetween.
- the thickness of the polarizing film is that the thickness of the base material layer 11a is dominant because the hydrophilic polymer layer 11b is very thin, preferably 10 ⁇ m to 90 ⁇ m, more preferably 21 ⁇ m to 90 ⁇ m, and particularly preferably 21 ⁇ m to 80 ⁇ m. .
- the dimensional change rate of the polarizing film 11 is preferably 2% or less, and more preferably 0.5% or less, under the condition of being stored in a constant temperature environment test chamber at 80 ° C. for 500 hours. Normally, the dimensional change rate of the polarizing plate is dominated by the dimensional change of the polarizer that is most easily expanded and contracted. According to the polarizing film used in the present invention, since the hydrophilic polymer layer (detailed in the section A-1-2) is much thinner than a normal polarizer, the dimensional change of the hydrophilic polymer layer is very large. As a result, the dimensional change rate of the entire polarizing film becomes very small. Further, it is presumed that the manufacturing method of the polarizing film described in the section A-1-2 acts in a complex manner and the dimensional change rate becomes small.
- the base material layer 11a any appropriate polymer film can be adopted as long as the effects of the present invention can be obtained.
- the base material layer is preferably composed of a polymer film excellent in stretchability, and more preferably composed of a polymer film that can be stretched at a stretch ratio of 5 times or more. With such a film, it can be satisfactorily stretched in a state in which the composition for forming the hydrophilic polymer layer is in close contact.
- the base material layer is preferably composed of a film having excellent smoothness. If it is such a film, the composition for forming a hydrophilic polymer layer can be apply
- the base material layer is composed of a polymer film having positive intrinsic birefringence.
- the absorption axis of the hydrophilic polymer layer (polarizing thin film) and the slow axis (when developed) of the base material layer can be made substantially parallel by stretching.
- the substrate layer is composed of a polymer film having negative intrinsic birefringence. If such a film is used, the absorption axis of the hydrophilic polymer layer and the slow axis (when developed) of the base material layer can be made substantially orthogonal by stretching.
- the polymer constituting the base layer as described above include (meth) acrylic resins, olefin resins, cyclic olefin resins (for example, norbornene resins), polyester resins, and polycarbonate resins. It is done. Preferred are norbornene resins and polyester resins, and more preferred are norbornene resins. Norbornene-based resins and polyester-based resins have excellent stretchability and excellent transparency. Furthermore, since films formed from these resins have low moisture permeability, they can be used as they are as protective films for polarizers. it can. The norbornene resin is particularly excellent in the dimensional stability of the film.
- the above polymers may be used alone or in combination.
- Examples of the (meth) acrylic resin include poly (meth) acrylic esters such as polymethyl methacrylate, methyl methacrylate- (meth) acrylic acid copolymer, methyl methacrylate- (meth) acrylic acid ester copolymer.
- Polymer methyl methacrylate-acrylic ester- (meth) acrylic acid copolymer, (meth) methyl acrylate-styrene copolymer (MS resin, etc.), polymer having an alicyclic hydrocarbon group (for example, Methyl methacrylate-cyclohexyl methacrylate copolymer, methyl methacrylate- (meth) acrylate norbornyl copolymer, etc.), (meth) acrylic resin having glutaric anhydride structure, (meth) acrylic having lactone ring structure And (meth) acrylic resins having a glutarimide structure.
- a (meth) acrylic resin having a lactone ring structure is preferable. This is because a film having high heat resistance, high transparency, and high mechanical strength can be obtained.
- the olefin resin examples include (co) polymers composed of ethylene or a linear or branched ⁇ -olefin having 3 to 20 carbon atoms.
- the ⁇ -olefin include polypropylene, 1-butene, 1-pentene, 1-hexene, poly (1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1- Tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene, 1-nonadecene, 1-eicocene, 3-methyl-1-butene, 3-methyl-1-pentene, 4-methyl- 1-pentene, 2-ethyl-1-hexene, 2,2,4-trimethyl-1-pentene, etc.
- the olefin resin is preferably poly (3-methyl-1-pentene
- norbornene resin examples include ring-opening (co) polymers of norbornene monomers, addition polymers of norbornene monomers, and copolymers of norbornene monomers and ⁇ -olefins such as ethylene and propylene (typically Are random copolymers), graft modified products in which these are modified with an unsaturated carboxylic acid or a derivative thereof, and hydrides thereof.
- norbornene-based monomer examples include norbornene and alkyl and / or alkylidene substituted products thereof such as 5-methyl-2-norbornene, 5-dimethyl-2-norbornene, 5-ethyl-2-norbornene, 5-butyl- 2-Norbornene, 5-ethylidene-2-norbornene and the like, polar group-substituted products such as halogens; dicyclopentadiene, 2,3-dihydrodicyclopentadiene, etc .; dimethanooctahydronaphthalene, alkyl and / or alkylidene substitution thereof And polar group substituents such as halogen, for example, 6-methyl-1,4: 5,8-dimethano-1,4,4a, 5,6,7,8,8a-octahydronaphthalene, 6-ethyl -1,4: 5,8-dimethano-1,4,4a, 5,6,7,
- polyester-based resin examples include PET (polyethylene terephthalate), PAR (polyarylate), PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), modified products and copolymers thereof, and these and other resins.
- PET polyethylene terephthalate
- PAR polyarylate
- PEN polyethylene naphthalate
- PBT polybutylene terephthalate
- modified products and copolymers thereof and these and other resins.
- Polymer alloy A mixture of amorphous PET, PET / PC, PAR / PC, or the like is preferable.
- an aromatic polycarbonate is preferably used as the polycarbonate resin.
- the aromatic polycarbonate can be typically obtained by a reaction between a carbonate precursor and an aromatic dihydric phenol compound.
- Specific examples of the carbonate precursor include phosgene, bischloroformate of dihydric phenols, diphenyl carbonate, di-p-tolyl carbonate, phenyl-p-tolyl carbonate, di-p-chlorophenyl carbonate, dinaphthyl carbonate and the like. Can be mentioned. Among these, phosgene and diphenyl carbonate are preferable.
- aromatic dihydric phenol compounds include 2,2-bis (4-hydroxyphenyl) propane, 2,2-bis (4-hydroxy-3,5-dimethylphenyl) propane, and bis (4-hydroxyphenyl).
- Methane 1,1-bis (4-hydroxyphenyl) ethane, 2,2-bis (4-hydroxyphenyl) butane, 2,2-bis (4-hydroxy-3,5-dimethylphenyl) butane, 2, 2-bis (4-hydroxy-3,5-dipropylphenyl) propane, 1,1-bis (4-hydroxyphenyl) cyclohexane, 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethyl And cyclohexane. You may use these individually or in combination of 2 or more types.
- 2,2-bis (4-hydroxyphenyl) propane, 1,1-bis (4-hydroxyphenyl) cyclohexane, 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane are used.
- 2,2-bis (4-hydroxyphenyl) propane and 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane are used.
- the thickness of the base material layer before stretching is preferably 50 ⁇ m to 200 ⁇ m, more preferably 100 ⁇ m to 200 ⁇ m.
- the thickness after stretching is preferably 20 ⁇ m to 80 ⁇ m, and more preferably 30 ⁇ m to 60 ⁇ m.
- the hydrophilic polymer layer 11b can function as a polarizer.
- the hydrophilic polymer layer 11b forms a thin film by applying a composition containing a vinyl alcohol resin (hereinafter also referred to as a vinyl alcohol composition) to a base material (resulting in a base material layer). Is obtained together with the base material, and the stretched thin film is dyed (substantially, a polarizing film in which the base material layer / hydrophilic polymer layer is integrated is obtained).
- Examples of the vinyl alcohol resin include polyvinyl alcohol and ethylene-vinyl alcohol copolymer.
- Polyvinyl alcohol is obtained by saponifying polyvinyl acetate.
- the ethylene-vinyl alcohol copolymer can be obtained by saponifying an ethylene-vinyl acetate copolymer.
- the saponification degree of the vinyl alcohol resin is preferably 95.0 mol% to 99.95 mol%, more preferably 99.0 mol% to 99.93 mol%.
- the degree of saponification can be determined according to JIS K 6726-1994. By using a vinyl alcohol resin having a saponification degree in the above range, a polarizer having excellent durability can be obtained.
- the average degree of polymerization of the vinyl alcohol resin can be appropriately selected according to the purpose.
- the average degree of polymerization is preferably 1200 to 4500, more preferably 1600 to 4300.
- the average degree of polymerization can be determined according to JIS K 6726-1994.
- the vinyl alcohol composition is typically a solution in which a vinyl alcohol resin is dissolved in an appropriate solvent.
- Typical examples of the solvent include water, warm water, and hot water.
- the concentration of the vinyl alcohol resin in the solution is 3% by weight to 20% by weight. With such a resin concentration, a uniform coating film in close contact with the substrate can be formed.
- the vinyl alcohol composition preferably contains a plasticizer and / or a surfactant.
- the plasticizer include polyhydric alcohols such as ethylene glycol and glycerin.
- a nonionic surfactant is mentioned, for example.
- the plasticizer and surfactant are used for the purpose of further improving the dyeability and stretchability of the resulting thin film.
- the vinyl alcohol composition may further contain any appropriate additive depending on the purpose.
- any appropriate method can be adopted as a method for applying the vinyl alcohol composition.
- Specific examples include a roll coating method, a spin coating method, a wire bar coating method, a dip coating method, an extrusion method, a curtain coating method, and a spray coating method.
- the base material and the thin film can be adhered and laminated without applying the adhesive layer or the pressure-sensitive adhesive layer only by applying the vinyl alcohol composition.
- the dimensional change rate of the obtained polarizing film can be reduced.
- a vinyl alcohol composition may be primed.
- a thin film is formed by drying the applied vinyl alcohol composition. Drying may be natural drying, heat drying, or a combination thereof.
- the thickness of the thin film after drying and before stretching is preferably 2 ⁇ m to 50 ⁇ m.
- the base material / thin film is stretched together.
- Any appropriate stretching method can be adopted as a method of stretching the substrate / thin film.
- Specific examples include a longitudinal uniaxial stretching method, a transverse uniaxial stretching method, a longitudinal and transverse simultaneous biaxial stretching method, and a longitudinal and transverse sequential biaxial stretching method.
- any suitable stretching machine such as a roll stretching machine, a tenter stretching machine, and a biaxial stretching machine can be used.
- the draw ratio and the draw temperature can be appropriately set according to the optical properties desired for the resulting hydrophilic polymer layer.
- the draw ratio is preferably 3 to 7 times, and the draw temperature is preferably ⁇ 20 ° C. or 100 ° C. to 180 ° C. of the glass transition temperature of the substrate.
- the stretch direction is the short direction of the elongated substrate / thin film. By stretching in the short direction, an absorption axis can be expressed in the short direction, and a wide polarizing film that can be suitably applied to a large screen liquid crystal display device can be obtained.
- the stretched base material / thin film is subjected to a dyeing process and, if necessary, a swelling process, a cross-linking process, a water washing process, and a drying process (moisture content adjustment process).
- a polarizing film having a molecular layer configuration is obtained.
- the dyeing treatment is typically wet dyeing that is immersed in a dyeing bath containing a dichroic substance (typically iodine or a dichroic dye).
- the total time for immersing the substrate / thin film in the dyeing bath is preferably 5 to 240 seconds.
- the stretched substrate / film is dry-drawn at a high temperature (eg, 130 ° C. to 180 ° C.) and then wet dyed.
- a high temperature eg, 130 ° C. to 180 ° C.
- the thickness of the obtained hydrophilic polymer layer is preferably 1 ⁇ m to 10 ⁇ m, more preferably 1 ⁇ m to 6 ⁇ m, and particularly preferably 1 ⁇ m to 4 ⁇ m.
- the hydrophilic polymer layer used in the present invention is much thinner than a normal polarizer (a polarizer obtained by stretching and dyeing a vinyl alcohol film: typical thickness of about 10 ⁇ m to 25 ⁇ m).
- a normal polarizer a polarizer obtained by stretching and dyeing a vinyl alcohol film: typical thickness of about 10 ⁇ m to 25 ⁇ m.
- the dimensional change of the conductive polymer layer itself is very small.
- the transmittance at a wavelength of 550 nm (also referred to as single transmittance) measured at 23 ° C. of the hydrophilic polymer layer (polarizing thin film) is preferably 39% to 46%, more preferably 42% to 46%. .
- the polarization degree of the hydrophilic polymer layer is preferably 99.0% or more.
- the theoretical upper limit of the degree of polarization is 100%.
- the hue of the hydrophilic polymer layer according to National Bureau of Standards (NBS); b value (single b value) is preferably 4.2 or less, more preferably 4.0 or less. Note that the ideal value of the b value is zero.
- a polarizing thin film (hydrophilic polymer layer) that is much thinner (and therefore has a smaller dimensional change rate) than conventional polarizers and has practically acceptable optical characteristics as described above, and as a result, a polarizing film This is one of the great achievements in the present invention.
- the retardation film 12 has a slow axis in the longitudinal direction.
- any appropriate retardation film can be adopted depending on the purpose as long as it has a slow axis in the longitudinal direction and can be laminated with the polarizing film 11.
- typical examples of the retardation film used in the present invention will be described.
- the relationship of> nz is shown.
- nx is the refractive index in the direction in which the refractive index is maximum in the film plane (slow axis direction)
- ny is the refractive index in the direction perpendicular to the slow axis direction (fast axis direction) in the film plane
- nz refers to the refractive index in the thickness direction of the film.
- Re [590] of the retardation film is preferably 20 nm to 150 nm, more preferably 30 nm to 130 nm, and particularly preferably 40 nm to 120 nm.
- the in-plane retardation value refers to an in-plane retardation value at a wavelength ⁇ (nm) at 23 ° C.
- the thickness direction retardation value (Rth [ ⁇ ]) refers to the thickness direction retardation value at 23 ° C. and the wavelength ⁇ (nm).
- the thickness of the retardation film can be appropriately set according to the purpose and desired in-plane retardation and thickness direction retardation. In one embodiment, the thickness of the retardation film is preferably 20 to 150 ⁇ m.
- the retardation film can be formed by stretching a polymer film. Specifically, by appropriately selecting the type of polymer, stretching conditions (for example, stretching temperature, stretching ratio, stretching direction), stretching method, and the like, desired optical properties (for example, refractive index ellipsoid, in-plane position) A retardation film having a retardation and a retardation in the thickness direction can be obtained.
- the stretching temperature is preferably 110 to 170 ° C.
- the stretching ratio is preferably 1.10 to 1.67 times.
- Examples of the stretching method include longitudinal uniaxial stretching. By using such a stretching method, a long retardation film having a slow axis in the longitudinal direction can be obtained.
- any appropriate polymer can be adopted as the resin for forming the polymer film.
- resins having positive intrinsic birefringence such as norbornene resins, polycarbonate resins, cellulose resins, polyvinyl alcohol resins, polysulfone resins, and the like.
- norbornene resins, polycarbonate resins, and cellulose resins are preferable, and norbornene resins are particularly preferable. Details of the norbornene resin and the polycarbonate resin are as described in the section A-1-1.
- any appropriate cellulose resin (typically, ester of cellulose and acid) can be adopted as the cellulose resin.
- the cellulosic resin is substituted with an acetyl group and a propionyl group.
- Substitution degree of cellulose resin “DSac (acetyl substitution degree) + DSpr (propionyl substitution degree)” (how many three hydroxyl groups present in the repeating unit of cellulose are substituted with acetyl group or propionyl group on average) Is preferably 2 or more, more preferably 2.3 or more, and even more preferably 2.6 or more.
- the upper limit of “DSac + DSpr” is preferably 3 or less, more preferably 2.9 or less, and even more preferably 2.8 or less.
- the lower limit of the DSpr (propionyl substitution degree) is preferably 1 or more, more preferably 2 or more, and further preferably 2.5 or more.
- the upper limit of DSpr is preferably 3 or less, more preferably 2.9 or less, and even more preferably 2.8 or less.
- the DSac (degree of acetyl substitution) and DSpr (degree of propionyl substitution) can be determined by the method described in JP-A No. 2003-315538 [0016] to [0019].
- Arbitrary appropriate methods can be employ
- cellulose is treated with a strong caustic soda solution to obtain alkali cellulose, which is acylated with a mixture of a predetermined amount of acetic anhydride and propionic anhydride.
- the substitution degree “DSac + DSpr” is adjusted by partially hydrolyzing the acyl group.
- the cellulosic resin may have other substituents other than acetyl groups and propionyl groups.
- substituents include ester groups such as butyrate; ether groups such as alkyl ether groups and aralkylene ether groups.
- the retardation film 12 has a refractive index ellipsoid of nx> ny> nz.
- the Nz coefficient is preferably 1.1 to 3.0, and more preferably 1.1 to 2.0.
- the in-plane retardation value (Re [590]) at a wavelength of 590 nm of the retardation film in which the refractive index ellipsoid shows a relationship of nx> ny> nz can be set to any appropriate value depending on the purpose.
- Re [590] of the retardation film is preferably 20 nm to 150 nm, more preferably 30 nm to 130 nm, and particularly preferably 40 nm to 120 nm.
- the retardation value in the thickness direction (Rth [590]) at a wavelength of 590 nm of the retardation film in which the refractive index ellipsoid shows a relationship of nx> ny> nz can also be set to any appropriate value depending on the purpose.
- Rth [590] of the retardation film is preferably 22 nm to 300 nm, more preferably 40 nm to 200 nm, and particularly preferably 50 nm to 150 nm.
- a retardation film having a refractive index ellipsoid showing a relationship of nx> ny> nz can be formed by stretching a polymer film.
- stretching conditions for example, stretching temperature, stretching ratio, stretching direction
- stretching method etc.
- desired optical properties for example, refractive index ellipsoid, in-plane retardation, thickness direction
- a retardation film having a retardation can be obtained.
- the stretching method include fixed-end biaxial stretching and sequential biaxial stretching.
- the retardation film may be formed by applying a non-liquid crystal polymer solution and removing the solvent.
- a process for example, a stretching process for imparting optical biaxiality (nx> ny> nz) is performed.
- the non-liquid crystal polymer include polyamide, polyimide, polyester, polyetherketone, polyamideimide, and polyesterimide. Polyimide is preferred. Note that specific examples of the polyimide and details of the method of forming the retardation film are described in JP-A-2004-46065.
- the thickness is typically 0.1 to 10 ⁇ m, more preferably 0.1 to 8 ⁇ m, and particularly preferably 0.1 to 5 ⁇ m.
- the retardation film 12 may be a so-called O plate containing molecules that are tilted.
- the tilted molecules as a whole can compensate for the birefringence of the entire liquid crystal molecules in the liquid crystal cell.
- the tilt-aligned molecules can preferably compensate for the birefringence of the liquid crystal molecules at the substrate interface of the liquid crystal cell.
- the “O plate” includes not only those in which the angle of tilted orientation of molecules is constant but also hybrid orientation.
- “Hybrid orientation” means that the tilt angle (tilt angle) of a molecule increases or decreases continuously or intermittently along the thickness direction, and the tilt angle ( ⁇ A ) on the polarizing film side is the opposite side (in the illustrated example) This is different from the tilt angle ( ⁇ B ) on the air interface side.
- the tilt angle ( ⁇ ) represents an angle formed by an adjacent layer surface and a molecule, and 0 ° when the molecule is arranged in parallel in the plane.
- FIG. 2A schematically shows a typical arrangement state of molecules in the tilted orientation
- FIG. 2B schematically shows a typical arrangement state of molecules in the hybrid orientation.
- the upper side is the polarizing film side.
- the tilt angle is set in Journal of Applied Phisics Vol. 38 (1999) p. 748, the pre-measured ne, no, and phase difference values (in the direction parallel to the slow axis, 5 ° to polar angle ⁇ 40 ° to + 40 ° (normal direction is 0 °)) It can be obtained by substituting each value measured in steps.
- ⁇ air represents the tilt angle on one side (for example, the air interface) of the tilted alignment molecule
- ⁇ AL represents the tilt angle on the other side (for example, the substrate or the alignment film).
- d represents the thickness of the retardation film containing inclined alignment molecules.
- ne represents the extraordinary refractive index of the molecule, and no represents the ordinary refractive index of the molecule.
- the average tilt angle is preferably 10 ° to 40 ° in one embodiment.
- the average tilt angle means an average of tilt angles of the whole molecule as viewed statistically.
- the tilt angle ( ⁇ A ) on the polarizing film side (hydrophilic polymer layer side) is preferably the opposite tilt angle ( ⁇ Larger than B ).
- the tilt angle ( ⁇ A ) on the polarizing film side is preferably 20 ° to 90 °, more preferably 25 ° to 35 °.
- the tilt angle ( ⁇ B ) on the opposite side is preferably 19 ° to 50 °, and particularly preferably 24 ° to 34 °.
- ⁇ is preferably 20 ° to 70 °, more preferably 40 ° to 65 °.
- ⁇ A is preferably 20 ° to 90 °, and more preferably 40 ° to 85 °.
- ⁇ B is preferably 0 ° to 20 °, more preferably 0 ° to 10 °, and particularly preferably 0 ° to 5 °.
- retardation film 12 has a direction in which the direction of the inclined alignment of molecules is projected in the retardation film plane is slow. It is substantially parallel to the phase axis.
- the molecules constituting the film exhibit a refractive index ellipsoid of nx> ny ⁇ nz, and the molecules are tilted.
- Such a retardation film can be obtained, for example, by subjecting a retardation film showing a refractive index ellipsoid of nx> ny ⁇ nz to a tilt orientation treatment (a method for tilt orientation will be described later).
- the refractive index ratio of the molecules constituting the retardation film 12 is preferably 0.9 to 4.
- the refractive index ratio of a molecule is a parameter related to the shape of the molecule, and is represented by the formula: (nx-nz) / (nx-ny).
- nx is the long axis direction of the molecule
- ny is the long axis direction of the molecule in the plane including the long axis of the molecule ( (nz direction) orthogonal direction
- nz means a direction orthogonal to both the nx direction and the ny direction.
- nx is the direction in which the refractive index is maximum in the film plane (slow axis direction).
- Ny is the direction (fast axis direction) perpendicular to the slow axis direction in the film plane
- nz is the thickness direction of the film.
- the long axis direction (nx direction) of a molecule when it is called “molecular refractive index ellipsoid” or “molecular refractive index ratio” is a statistical average of all molecules constituting the film.
- the refractive index ellipsoid of the molecule and the refractive index ratio of the molecule can be calculated from the in-plane retardation value, the thickness direction retardation value, and the average inclination angle of the inclined alignment film.
- the in-plane retardation value (Re [590]) at a wavelength of 590 nm of the retardation film can be set to any appropriate value depending on the purpose.
- Re [590] of the retardation film is preferably 20 nm to 150 nm, more preferably 30 nm to 130 nm, and particularly preferably 40 nm to 120 nm.
- the retardation value in the thickness direction (Rth [590]) at a wavelength of 590 nm of the retardation film can be set to any appropriate value depending on the purpose.
- Rth [590] of the retardation film is preferably 45 nm to 800 nm, more preferably 60 nm to 720 nm, and particularly preferably 80 nm to 640 nm.
- the refractive index ratio of the molecules constituting the retardation film 12 is preferably 0.9 to 4, and more preferably 2 to 3.5.
- the refractive index ratio is in such a range, the optical compensation of the liquid crystal molecules of the liquid crystal cell can be performed appropriately, and a liquid crystal display device having a high contrast in the oblique direction can be obtained.
- any suitable compound that shows a refractive index ellipsoid of nx> ny ⁇ nz before the tilt alignment treatment and can form a film that can be subjected to the tilt alignment treatment described later is used.
- a material is a thermoplastic resin in one embodiment and a liquid crystal compound in another embodiment.
- the thermoplastic resin include norbornene resin, polycarbonate resin, cellulose resin, polyvinyl alcohol resin, and polysulfone resin. Of these, norbornene resins are preferable. Details of the norbornene-based resin are as described in the above section A-1-1.
- the thermoplastic resin may be a resin having positive intrinsic birefringence or a resin having negative intrinsic birefringence.
- the retardation film When the retardation film is composed of a thermoplastic resin, the retardation film can be obtained by applying different shearing forces to the respective surfaces of the polymer film formed from the thermoplastic resin.
- the polymer film is preferably a retardation film, more preferably a retardation film showing a refractive index ellipsoid of nx> ny ⁇ nz.
- a method of applying different shearing force to each surface of the film for example, rolling with a pair of rolls of different materials (for example, a pair of rolls with different friction coefficients), rolling with a pair of rolls with different diameters,
- One example is rolling with a pair of rolls having different rotation speeds.
- the rolling can be performed under heating (preferably heating near the Tg of the polymer film).
- the difference in the friction coefficient of the roll, the ratio of the roll diameter, the ratio of the rotation speed of the roll, the nip pressure of the roll, the heating temperature, the type of resin constituting the polymer film, etc., the average inclination angle and The tilt direction can be controlled. For example, using an unstretched norbornene-based resin film, when the heating temperature of the roll is 120 ° C.
- the film has a slow axis in the longitudinal direction
- a phase difference film can be obtained in which the refractive index ratio of the molecules constituting the film is 3, and the film is inclined and oriented at an average inclination angle of 30 ° so that the downstream side in the flow direction of the film faces upward.
- the refractive index ratio of the molecules constituting the film is different before and after the tilt alignment treatment. That is, in the tilted alignment treatment, not only the resin molecules constituting the polymer film are simply tilted, but also the resin molecules are stretched along with the tilted orientation to change the molecular shape itself.
- the refractive index ratio of the molecules constituting the retardation film 12 does not change before and after the tilted alignment, but the molecules change before and after the tilted orientation treatment.
- the refractive index ratio of can be different values. For example, as described above, when the roll heating temperature is 120 ° C. and the rotation speed ratio of the lower roll / upper roll is 1.1, an inclined alignment retardation film having a molecular refractive index ratio of 3 will be obtained. In this case, the refractive index ratio of the molecules constituting the polymer film used can be 1 to 1.35, and the Nz coefficient of the polymer film can be 1 to 1.35.
- the thickness of the retardation film is appropriately set according to the purpose and desired in-plane retardation and thickness direction retardation, and preferably 60 to 150 ⁇ m. is there.
- the liquid crystal compound can be a rod-shaped liquid crystal compound.
- the “rod-like liquid crystal compound” has a mesogenic group in the molecular structure, and the refractive index in the major axis direction of the mesogenic group is larger than that in the minor axis direction.
- the rod-like liquid crystal compound exhibits a crystal or glass state at room temperature, and develops a nematic liquid crystal phase at a high temperature.
- the rod-like liquid crystal compound exhibits a liquid crystal phase before film formation, but after film formation, for example, a network structure may be formed by a crosslinking reaction and no liquid crystal phase may be exhibited. If the rod-like liquid crystal compound having the above properties is used, for example, after forming a hybrid arrangement in a state showing a liquid crystal phase, the arrangement state can be fixed by cooling or crosslinking.
- the mesogenic group is a structural part necessary for forming a liquid crystal phase and usually contains a cyclic unit.
- Specific examples of the mesogenic group include, for example, a biphenyl group, a phenylbenzoate group, a phenylcyclohexane group, an azoxybenzene group, an azomethine group, an azobenzene group, a phenylpyrimidine group, a diphenylacetylene group, a diphenylbenzoate group, a bicyclohexane group, and a cyclohexyl group.
- Examples thereof include a benzene group and a terphenyl group.
- the terminal of these cyclic units may have substituents, such as a cyano group, an alkyl group, an alkoxy group, a halogen group, for example.
- substituents such as a cyano group, an alkyl group, an alkoxy group, a halogen group, for example.
- a mesogenic group which consists of a cyclic unit etc. what has a biphenyl group and a phenylbenzoate group is used preferably.
- the rod-like liquid crystal compound preferably has at least one crosslinkable functional group in a part of the molecular structure. This is because the cross-linking reaction increases the mechanical strength and provides a retardation layer having excellent durability.
- the crosslinkable functional group include an acryloyl group, a methacryloyl group, an epoxy group, and a vinyl ether group.
- a commercially available rod-like liquid crystal compound can be used as it is.
- other liquid crystal compounds and arbitrary additives such as a polymerization initiator and a leveling agent may be added to a commercially available or synthesized rod-shaped liquid crystal compound to be used as a liquid crystalline composition.
- Examples of commercially available rod-like liquid crystal compounds having a crosslinkable functional group include BASF Corporation trade name “Pariocolor LC242”, HUNTSMAN Corporation trade name “CB483”, and the like.
- the retardation film When the retardation film is composed of a liquid crystal compound, the retardation film can be obtained by orienting a rod-like liquid crystal compound and solidifying or curing it while fixing the alignment state. Specifically, a liquid crystalline composition containing a rod-like liquid crystal compound is applied on the surface of a long alignment substrate subjected to alignment treatment to form a coating layer, and the coating layer is dried. In addition, the liquid crystal solidified layer having a tilted orientation can be formed, and the liquid crystal solidified layer can be formed by irradiating the liquid crystal with ultraviolet rays to form a tilted liquid crystal cured layer. That is, the retardation film can be a liquid crystal cured layer.
- the refractive index ratio of the molecules also does not change before and after the tilt alignment treatment.
- the “solidified layer” refers to a softened, melted or solution-state liquid crystalline composition that has been cooled and solidified
- the “cured layer” refers to a part of the liquid crystalline composition or All of them are cross-linked by heat, catalyst, light and / or radiation to be insoluble or insoluble or hardly soluble.
- the alignment substrate any appropriate substrate can be adopted as long as the liquid crystalline composition can be developed.
- the alignment substrate is a polymer substrate.
- the alignment substrate may be a single layer or a laminate composed of a plurality of layers (for example, a laminate of a substrate and an alignment film).
- the surface of the base material is subjected to any appropriate orientation treatment.
- the alignment treatment include mechanical alignment treatment, physical alignment treatment, and chemical alignment treatment.
- Specific examples of the mechanical alignment treatment include rubbing treatment and stretching treatment.
- Specific examples of the physical alignment process include a magnetic field alignment process and an electric field alignment process.
- Specific examples of the chemical alignment treatment include oblique vapor deposition and photo-alignment treatment. A rubbing process is preferred.
- arbitrary appropriate conditions may be employ
- the liquid crystalline composition may further contain a polymer liquid crystal compound (liquid crystal polymer).
- the polymer liquid crystal compound is used for the purpose of improving the orientation of the rod-like liquid crystal compound.
- the content of the polymer liquid crystal compound is preferably 10 to 40 parts by weight, more preferably 15 to 30 parts by weight with respect to 100 parts by weight of the total solid content in the liquid crystal composition.
- Examples of the polymer liquid crystal compound include compounds represented by the following general formula (III). (In the formula, h is an integer of 14 to 20, and m is 50 to 70 and n is 30 to 50 when the sum of m and n is 100.)
- the coating layer is formed by coating the liquid crystalline composition on the alignment substrate by any appropriate method.
- the thickness of the coating layer is preferably 1 ⁇ m to 50 ⁇ m, more preferably 1 ⁇ m to 30 ⁇ m.
- the liquid crystal solidified layer is formed by drying the coating layer.
- the drying time is preferably 20 seconds to 20 minutes, more preferably 1 minute to 10 minutes, and particularly preferably 1 minute to 5 minutes.
- the drying temperature is preferably 30 ° C. or higher and a liquid crystal phase-isotropic phase transition temperature (Ti) or lower, more preferably 30 ° C. to 120 ° C.
- the liquid crystal phase-isotropic phase transition temperature (Ti) can be known by observing a sample of a liquid crystalline composition containing a liquid crystal compound with a polarizing microscope while heating.
- a tilted and aligned liquid crystal cured layer is formed.
- Dose at a wavelength 365nm of the ultraviolet rays is preferably 400mJ / cm 2 ⁇ 1500mJ / cm 2.
- the thickness of the liquid crystal cured layer is appropriately set according to the purpose and desired in-plane retardation and thickness direction retardation, and is preferably 1 ⁇ m to 5 ⁇ m, more preferably 1 ⁇ m to 3 ⁇ m.
- the liquid crystal cured layer is one in which a liquid crystal compound is tilted and aligned, and preferably in a hybrid alignment.
- retardation film 12 has a direction in which the direction of the inclined alignment of molecules is projected in the retardation film plane is slow. It is substantially orthogonal to the phase axis. That is, the tilted orientation direction of the tilted molecules is the short direction of the retardation film.
- the molecule can be a thermoplastic resin. In another embodiment, the molecule can be a discotic liquid crystal compound.
- thermoplastic resin examples include norbornene resins and cellulose resins such as triacetyl cellulose (TAC).
- TAC triacetyl cellulose
- a norbornene resin is preferable. Details of the norbornene-based resin are as described in the above section A-1-1.
- the discotic liquid crystal compound generally has a linear mother group such as benzene, 1,3,5-triazine, calixarene, etc. arranged at the center of the molecule, a linear alkyl group, alkoxy group, substituted A liquid crystal compound having a discotic molecular structure in which a benzoyloxy group or the like is radially substituted as its side chain.
- Typical examples of discotic liquid crystals include C.I. Destrade et al., Mol. Cryst. Liq. Cryst. 71, 111 (1981), benzene derivatives, triphenylene derivatives, truxene derivatives, phthalocyanine derivatives, B.I. Kohne et al., Angew.
- the in-plane retardation value (Re [590]) at a wavelength of 590 nm of the retardation film can be set to any appropriate value depending on the purpose.
- Re [590] of the retardation film is preferably 100 nm or less, more preferably 5 nm to 80 nm, and particularly preferably 5 nm to 60 nm.
- the retardation value in the thickness direction (Rth [590]) at a wavelength of 590 nm of the retardation film can be set to any appropriate value depending on the purpose.
- Rth [590] of the retardation film is preferably 50 nm to 200 nm, more preferably 60 nm to 180 nm, and particularly preferably 80 nm to 160 nm.
- the retardation film is composed of a thermoplastic resin
- the retardation film is different on each surface of the polymer film formed from the thermoplastic resin by using the method described in the section A-2-2-1. It can be obtained by applying a shearing force and then stretching in the lateral direction. Examples of the stretching method in the short direction include a lateral uniaxial stretching method.
- the specific example of the manufacturing method of retardation film is shown below. That is, using an unstretched norbornene-based resin film, when the heating temperature of the roll is 120 ° C.
- the film has a slow axis in the longitudinal direction
- a retardation film containing molecules tilted and oriented so that the downstream side in the flow direction of the film faces upward can be obtained.
- the thickness of the retardation film is appropriately set according to the purpose and desired in-plane retardation and thickness direction retardation, and preferably 60 to 150 ⁇ m. is there.
- the retardation film When the retardation film is composed of a liquid crystal compound, the retardation film can be obtained using a discotic liquid crystal compound in the same manner as described in the section A-2-2-1.
- the tilted alignment state of the liquid crystal compound can be controlled by adjusting the type and molecular structure of the compound, the type of alignment film, additives (for example, a plasticizer, a binder, and a surfactant).
- the thickness of the retardation film is preferably 1 ⁇ m to 5 ⁇ m.
- the laminated optical body of the present invention may further include a second retardation film.
- the optical characteristics and arrangement position of the second retardation film can be appropriately set according to the purpose, the optical characteristics of the retardation film 12, and the like.
- the retardation film 12 is referred to as a first retardation film.
- the subscript 1 represents the first retardation film
- the subscript 2 represents the second retardation film.
- the second retardation film 13 is delayed in the short direction. It has a phase axis (that is, substantially perpendicular to the slow axis of the first retardation film), and the refractive index ellipsoid has a relationship of nx>ny> nz.
- the second retardation film 13 is disposed on the opposite side of the retardation film 12 from the hydrophilic polymer layer 11b in the laminated optical body of the present invention.
- the in-plane retardation value Re 2 [590] of the second retardation film is preferably 80 to 160 nm, more preferably 90 to 150 nm, and particularly preferably 100 to 140 nm.
- the second retardation film can compensate the optical axis of the polarizing film.
- the Nz coefficient (Rth / Re) is preferably 1.1 to 1.8, and more preferably 1.2 ⁇ Nz ⁇ 1.7.
- the second retardation film can be formed of any appropriate material. Specific examples include stretched films of polymer films.
- the resin forming the polymer film is preferably a norbornene resin or a polycarbonate resin. Details of the norbornene resin and the polycarbonate resin are as described in the section A-1-1.
- any appropriate method can be adopted as a method for producing the stretched film.
- the stretching method include lateral uniaxial stretching, fixed end biaxial stretching, and sequential biaxial stretching.
- a specific example of the fixed-end biaxial stretching includes a method of stretching a polymer film in the short direction (lateral direction) while running in the longitudinal direction. This method can be apparently lateral uniaxial stretching.
- the stretching temperature is preferably 135 to 165 ° C, more preferably 140 to 160 ° C.
- the draw ratio is preferably 1.2 to 3.2 times, more preferably 1.3 to 3.1 times.
- the thickness is typically 20 to 80 ⁇ m, preferably 25 to 75 ⁇ m, more preferably 30 to 60 ⁇ m.
- Non-liquid crystalline material includes a non-liquid crystalline material.
- a non-liquid crystalline polymer is preferable.
- polymers such as polyamide, polyimide, polyester, polyetherketone, polyamideimide, and polyesterimide are preferable. These polymers may be used alone or in a mixture of two or more. Among these, polyimide is particularly preferable because of high transparency, high orientation, and high stretchability.
- the second retardation film can be typically formed by coating the base film with the non-liquid crystalline polymer solution and removing the solvent.
- a treatment for example, a stretching treatment
- optical biaxiality nx> ny> nz
- a difference in refractive index nx> ny
- the thickness is typically 0.1 to 10 ⁇ m, more preferably 0.1 to 8 ⁇ m, and particularly preferably 0.1 to 5 ⁇ m.
- the second retardation film is the laminated optical body of the present invention.
- the retardation film 12 may be disposed on the opposite side of the hydrophilic polymer layer 11b, or may be disposed between the retardation film 12 and the hydrophilic polymer layer 11b.
- a retardation film having appropriate optical characteristics can be used depending on the purpose and the arrangement position.
- the second retardation film 13 may be a single layer film or a film in which two or more layers are laminated.
- the in-plane retardation value (Re 2 [590]) at a wavelength of 590 nm of the second retardation film can be set to any appropriate value depending on the purpose.
- the in-plane retardation value Re 2 [590] is preferably less than 100 nm, more preferably less than 80 nm.
- the retardation value (Rth 2 [590]) in the thickness direction at a wavelength of 590 nm of the second retardation film can be set to any appropriate value depending on the purpose.
- the thickness direction retardation value Rth 2 [590] is preferably less than 200 nm, more preferably 50 nm to 180 nm.
- the total Re 1 + 2 [590] of the in-plane retardation values of the first retardation film and the second retardation film is preferably 10 nm or more and less than 200 nm, and more preferably 10 nm to 160 nm. Further, the total Rth 1 + 2 [590] of the retardation values in the thickness direction is preferably 50 nm to 300 nm, more preferably 100 nm to 280 nm.
- the second retardation film may have any suitable refractive index ellipsoidal relationship as long as the preferable Re 2 [590] and Rth 2 [590] are obtained.
- thermoplastic resin is preferred.
- the thermoplastic resin may be a resin having positive intrinsic birefringence or a resin having negative intrinsic birefringence.
- the liquid crystal material for example, a liquid crystal polymer or a liquid crystal monomer can be used.
- the liquid crystal material may exhibit a liquid crystallinity mechanism either lyotropic or thermotropic.
- the alignment state of the liquid crystal is preferably homogeneous alignment.
- the liquid crystal polymer and the liquid crystal monomer may be used alone or in combination.
- Specific examples of the method for forming the liquid crystal monomer and the second retardation film include a monomer and a method for forming described in JP-A-2006-178389.
- the thickness is preferably 0.5 to 10 ⁇ m, more preferably 0.5 to 8 ⁇ m, and particularly preferably 0.5 to 5 ⁇ m.
- thermoplastic resin examples include norbornene resin, polycarbonate resin, cellulose resin, polyvinyl alcohol resin, and polysulfone resin. Of these, norbornene resins and polycarbonate resins are preferable.
- the norbornene resin and the polycarbonate resin are as described above.
- stretching a polymer film formed from such a resin by appropriately selecting stretching conditions (for example, stretching temperature, stretching ratio, stretching direction), stretching method, and the like according to the type of the resin, A second retardation film having desired optical properties (for example, in-plane retardation, thickness direction retardation) can be obtained.
- the thickness is preferably 5 to 55 ⁇ m, more preferably 10 to 50 ⁇ m, and particularly preferably 15 to 45 ⁇ m.
- the second retardation film can be a cholesteric alignment solidified layer.
- the cholesteric alignment solidified layer include a cholesteric layer described in JP-A No. 2003-287623.
- the thickness is preferably 0.5 to 10 ⁇ m, more preferably 0.5 to 8 ⁇ m, and particularly preferably 0.5 to 5 ⁇ m.
- the second retardation film which is a negative C plate
- the second retardation film may be formed of a non-liquid crystalline polymer such as polyamide, polyimide, polyester, polyetherketone, polyamideimide, or polyesterimide.
- polyimide is particularly preferable because of high transparency, high orientation, and high stretchability.
- Specific examples of polyimide and a specific example of the method of forming the second retardation film include a method for producing a polymer and an optical compensation film described in JP-A-2004-46065.
- the thickness is preferably 0.5 to 10 ⁇ m, more preferably 0.5 to 8 ⁇ m, and particularly preferably 0.5 to 5 ⁇ m.
- the second retardation film which is a negative C plate
- TAC triacetyl cellulose
- the cellulose resin and norbornene resin are as described above.
- Examples of the stretching method include biaxial stretching (longitudinal and transverse equal magnification stretching).
- the thickness is preferably 45 to 105 ⁇ m, more preferably 55 to 95 ⁇ m, and particularly preferably 50 to 90 ⁇ m.
- the second retardation film that is a negative C plate may be a laminate having the cholesteric alignment solidified layer and a plastic film layer.
- the resin forming the plastic film layer include the cellulose resin and the norbornene resin.
- the protective film preferably has optical isotropy.
- the thickness direction retardation Rth [550] of the inner protective film is preferably ⁇ 20 nm to +20 nm, more preferably ⁇ 10 nm to +10 nm, particularly preferably ⁇ 6 nm to +6 nm, and most preferably ⁇ 3 nm to +3 nm. It is.
- the in-plane retardation Re [550] of the inner protective film is preferably 0 nm or more and 10 nm or less, more preferably 0 nm or more and 6 nm or less, and particularly preferably 0 nm or more and 3 nm or less. Details of such an optically isotropic protective film are described in Japanese Patent Application Laid-Open No. 2008-180961, which description is incorporated herein by reference.
- the laminated optical body 10 of the present invention is continuous with the longitudinal direction aligned while transporting the elongated polarizing film 11 and the elongated retardation film 12 in the longitudinal direction. It is produced by bonding together (so-called roll-to-roll).
- the said elongate polarizing film 11 and the said elongate phase difference film 12 are each stored as a roll, they are used for the bonding process.
- the long polarizing film 11 is subjected to a laminating process continuously from the manufacturing process described in the section A-1-2, and the long retardation film 12 is Then, it is subjected to the bonding step continuously from the manufacturing step described in the above section A-2.
- the polarizing film 11 and the retardation film 12 are bonded together via a pressure-sensitive adhesive composition or an adhesive composition.
- a pressure-sensitive adhesive composition or an adhesive composition is applied to one side of either a polarizing film or a retardation film, and then the polarizing film and the retardation film are bonded and dried.
- the pressure-sensitive adhesive composition is preferably an acrylic pressure-sensitive adhesive composition. This is because it is excellent in transparency, low cost and easy to obtain.
- the adhesive composition preferably includes a polyvinyl alcohol resin and a crosslinking agent.
- the polyvinyl alcohol resin is preferably an acetoacetyl group-containing polyvinyl alcohol resin. This is because the adhesion between the polarizing film and the retardation film can be further improved and the durability can be improved. Details of the polyvinyl alcohol-based resin and the crosslinking agent are described in, for example, Japanese Patent Application Laid-Open No. 2008-180961, and the description thereof is incorporated herein by reference.
- Examples of the application method of the pressure-sensitive adhesive composition or the adhesive composition include a roll method, a spray method, and an immersion method.
- the thickness of the coating film can be set so that the thickness after drying is preferably 10 ⁇ m to 60 ⁇ m.
- the thickness of the coating film can be set so that the thickness after drying is preferably 20 nm to 150 nm. By setting it as such thickness, sufficient adhesive force can be obtained.
- the drying temperature is typically 5 to 150 ° C., preferably 30 to 120 ° C.
- the drying time is typically 120 seconds or longer, preferably 400 seconds or longer.
- FIG. 3 shows one process in an example of the method for producing a laminated optical body of the present invention.
- the polarizing film 11 and the retardation film 12 coated with the pressure-sensitive adhesive composition or adhesive composition are fed in the direction of the arrows, and the respective longitudinal directions are aligned. Paste together. That is, the polarizing film 11 and the retardation film 12 are continuously bonded by roll-to-roll to obtain the laminated optical body 10.
- reference numerals 111 and 112 denote rolls for winding the long polarizing film and the retardation film, respectively, and reference numeral 113 denotes a guide roll for bonding the polarizing film and the retardation film together.
- the retardation film is typically formed by coating on any appropriate base material, and then can be transferred to a polarizing film (not shown). .
- the laminated optical body 10 of the present invention further includes the second retardation film 13
- the laminated optical body 10 includes the elongated polarizing film 11 and the elongated retardation. While the film 12 and the long second retardation film 13 are respectively transported in the longitudinal direction, the film 12 and the long second retardation film 13 are manufactured by aligning the longitudinal direction and continuously bonding them.
- a long laminate is obtained by laminating the long first retardation film 12 and the long second retardation film 13 by roll-to-roll, Subsequently, it can produce by bonding this laminated body and the elongate polarizing film 11 by roll-to-roll.
- the long polarizing film 11 and the long retardation film 12 are bonded together by roll-to-roll to obtain a long laminated body, and then the laminated body and It can be produced by laminating the second retardation film 13 by roll-to-roll.
- the optical film of the present invention is obtained by cutting or punching the laminated optical body obtained as described above.
- the cutting or punching may employ any appropriate method. Since the laminated optical body of the present invention is wide due to the manufacturing method of the polarizing film, it is easy to punch or cut an optical film for a large-sized liquid crystal display device and reduce waste materials due to punching or the like. This is advantageous in terms of cost.
- the obtained laminated optical body is cut into a size corresponding to the size of the applied liquid crystal display device, it is preferable from the viewpoint of manufacturing efficiency that two or more laminated optical bodies are cut and stacked.
- the conventional laminated optical body (polarizing plate) having the same configuration has a large thickness, it is necessary to apply a large force to cut two or more laminated optical bodies in a stacked manner. As a result, the stacked laminated optical bodies are easily displaced from each other, and the dimensional accuracy of the obtained optical film may be insufficient.
- the laminated optical body of the present invention is very thin, it can be cut with high accuracy even when two or more sheets are stacked and cut, which is very preferable in terms of manufacturing efficiency.
- FIG. 4 is a schematic cross-sectional view of a liquid crystal display device according to a preferred embodiment of the present invention.
- the liquid crystal display device 100 includes a liquid crystal cell 20 and an optical film 10 ′ disposed on at least one side of the liquid crystal cell 20.
- Optical film 10 ' is arrange
- a normal polarizing plate is disposed on the other side. Any appropriate drive mode can be adopted as the drive mode of the liquid crystal cell 20.
- Typical driving modes include STN (Super Twisted Nematic) mode, TN (Twisted Nematic) mode, IPS (In-Plane Switching) mode, VA (Vertical Aligned HB), OCB (Optically HB).
- Examples include an aligned nematic (ASM) mode and an ASM (axially aligned microcell) mode.
- the drive mode is preferably the VA mode.
- the driving mode is preferably the TN mode. This is because very good optical compensation is realized by the retardation film of the optical film 10 ′.
- the optical film 10 ′ is disposed on both sides of the liquid crystal cell 20 as shown in FIG. More preferably, the optical films 10 ′ and 10 ′ disposed on both sides of the liquid crystal cell are cut or punched from the same original fabric (laminated optical body). By cutting or punching from the same original fabric (laminated optical body), a pair of optical films having a very small optical axis deviation and having substantially the same degree of axial deviation even if there is an axial deviation can be obtained. Therefore, a liquid crystal display device having very excellent display characteristics can be obtained.
- Optical film 10 ', 10' may be arrange
- the absorption axes are arranged so as to be orthogonal to each other. Therefore, when the liquid crystal cell is in the TN mode, the light state (white display) is obtained when no voltage is applied (normally white mode), and when the liquid crystal cell is in the VA mode, the dark state (black) is applied when no voltage is applied. Display) (normally black mode).
- the present invention will be specifically described by way of examples, but the present invention is not limited to these examples.
- the measuring method in an Example is as follows. In the examples, when an angle other than the tilt angle is expressed, the longitudinal direction of the film is 0 °, and the counterclockwise direction from the longitudinal direction is positive.
- Retardation value (Re [590], Rth [590]) and variation
- the retardation of the retardation film produced in the reference example was measured at a wavelength of 590 nm and 23 ° C. using a product name “Axoscan” manufactured by Axiometric. It was measured. The difference between the maximum value and the minimum value of the phase difference values in a predetermined direction was regarded as variation.
- Nz coefficient, molecular refractive index ratio, molecular refractive index ellipsoid Nz coefficient was calculated from Re [590] and Rth [590] measured as described in (4) above. Further, the refractive index ratio of the molecule and the refractive index ellipsoid were calculated from Re [590] and Rth [590] and the average inclination angle.
- Contrast Optical characteristics of all optical members used in the liquid crystal display device including the retardation film, polarizing film and liquid crystal cell produced in the reference example were measured by a usual method.
- the contrast of the liquid crystal display device was simulated using these actual measurement values and using the product name “LCD Master” manufactured by Shintech.
- the substrate / thin film laminate thus obtained was stretched in the lateral direction at a stretching temperature of 140 ° C. and a stretch ratio of 4.5 times.
- the total thickness of the stretched laminate was 60 ⁇ m, and the thickness of the polyvinyl alcohol thin film was 3 ⁇ m.
- aqueous potassium iodide solution (5% by weight) for 10 seconds to dye and crosslink the polyvinyl alcohol thin film. This was dried at 80 ° C. for 4 minutes to obtain a roll-shaped polarizing film having a structure of base material layer / hydrophilic polymer layer.
- the transmittance of the obtained polarizing film was 41.5%, and the degree of polarization was 99%.
- the obtained polarizing film had the absorption axis in the transversal direction (TD).
- the substrate / thin film laminate thus obtained was stretched in the lateral direction at a stretching temperature of 140 ° C. and a stretch ratio of 4.5 times.
- the total thickness of the stretched laminate was 60 ⁇ m, and the thickness of the polyvinyl alcohol thin film was 3 ⁇ m.
- aqueous potassium iodide solution (4% by weight) for 10 seconds to dye and crosslink the polyvinyl alcohol thin film. This was dried at 60 ° C. for 4 minutes to obtain a roll-shaped polarizing film having a structure of a base material / polarizing thin film.
- the transmittance of the obtained polarizing film was 41.5%, and the degree of polarization was 99%. Further, the obtained polarizing film had an absorption axis in the short direction.
- [Reference Example 4] [Production of retardation film] 150 ° C. by a roll-type longitudinal uniaxial stretching method while sequentially feeding the film from a roll-shaped wound body of a norbornene-based resin film (manufactured by JSR, trade name “Arton”, thickness 100 ⁇ m, width 1.2 m, length 500 m) Then, the film was stretched 1.3 times in the length direction and then cut into a width of 1 m to obtain a long retardation film. The obtained retardation film had a slow axis in the longitudinal direction (MD).
- MD longitudinal direction
- the thickness of the obtained retardation film was 70 ⁇ m, the in-plane retardation Re [590] was 55 nm, the variation of Re [590] in the width direction was 5 nm, and the axial accuracy of the slow axis was 0.5 °.
- the thickness of the obtained retardation film was 94 ⁇ m
- the in-plane retardation Re [590] was 64 nm
- the variation of Re [590] in the width direction was 4 nm
- the axial accuracy of the slow axis was 0.8 °.
- the thickness of the obtained retardation film was 72 ⁇ m, the in-plane retardation Re [590] was 53 nm, the variation of Re [590] in the width direction was 8 nm, and the axial accuracy of the slow axis was 1.5 °.
- the thickness of the obtained retardation film was 94 ⁇ m
- the in-plane retardation Re [590] was 60 nm
- the variation of Re [590] in the width direction was 4.5 nm
- the axial accuracy of the slow axis was 1.8 °.
- a polyethylene terephthalate film (trade name “RC06” manufactured by Toray Industries, Inc.) was rubbed in the film longitudinal direction to obtain an alignment substrate.
- the solidified layer was cured by irradiating with ultraviolet rays in an air atmosphere so that the irradiation amount of the solidified layer surface at a wavelength of 365 nm was 500 mJ / cm 2 .
- substrate was formed.
- the in-plane retardation value Re [590] of the obtained retardation film A was 90 nm, the average inclination angle was 35 °, and the slow axis direction was 0 ° (all center values).
- retardation film B A commercially available long norbornene-based resin film (trade name “ZEONOR” manufactured by Nippon Zeon Co., Ltd.) that has already been stretched was used as the retardation film B.
- the in-plane retardation value Re [590] of the retardation film B was 130 nm, the Nz coefficient was 1.5, and the slow axis direction was 90 ° (all center values).
- the refractive index ellipsoid had a relationship of nx>ny> nz.
- the in-plane retardation value Re [590] of the obtained retardation film is 50 nm
- the thickness direction retardation value Rth [590] is 150 nm
- the average tilt angle is 18 °
- the slow axis direction is 0 ° (longitudinal direction).
- Example 1 [Production of laminated optical body]
- the polarizing film obtained in Reference Example 1 and the retardation film obtained in Reference Example 4 are bonded with roll-to-roll as shown in FIG. 3 via an acrylic adhesive (thickness: 20 ⁇ m).
- a roll-shaped laminated optical body was obtained.
- the axial accuracy of the retardation film used, the total thickness and the dimensional change rate of the obtained laminated optical body are shown in Table 1 below together with the luminance unevenness of the liquid crystal display device described later.
- the roll-shaped laminated optical body (original fabric) obtained as described above was cut to correspond to the size of the liquid crystal cell of Reference Example 13 to obtain an optical film.
- the optical film was cut so that its longitudinal direction and the absorption axis of the polarizing film were orthogonal to each other.
- Two optical films were cut out from the same raw fabric, and each was attached to the top and bottom of the liquid crystal cell of Reference Example 13 via an acrylic adhesive (thickness: 20 ⁇ m) to obtain a liquid crystal panel.
- This liquid crystal panel was combined with the backlight unit of the liquid crystal display device from which the liquid crystal cell was taken out to obtain a liquid crystal display device.
- the luminance unevenness of the obtained liquid crystal display device is shown in Table 1 below, a photograph of the display screen (black image) taken is shown in FIG.
- the luminance distribution is obtained by measuring in-plane luminance from a black image and color-coding it according to the luminance range.
- Example 2 A roll-shaped laminated optical body was obtained in the same manner as in Example 1 except that the retardation film obtained in Reference Example 5 was used as the retardation film.
- a liquid crystal display device was produced in the same manner as in Example 1 except that this laminated optical body (original fabric) was used.
- Table 1 shows the axial accuracy of the retardation film used, the total thickness and dimensional change rate of the obtained laminated optical body, and the luminance unevenness of the liquid crystal display device. Furthermore, the photograph which image
- Example 3 [Production of laminated optical body]
- the polarizing film obtained in Reference Example 2 and the retardation film obtained in Reference Example 8 are bonded with roll-to-roll as shown in FIG. 3 via an acrylic adhesive (thickness: 20 ⁇ m).
- a roll-shaped laminated optical body was obtained.
- the outline of the laminated optical body is shown in Table 2 below.
- Example 3 A roll-shaped laminated optical body was obtained in the same manner as in Example 3 except that the commercially available polarizing plate of Reference Example 3 was used instead of the polarizing film.
- the outline of the laminated optical body is shown in Table 2 below.
- Example 3 except that the commercially available polarizing plate of Reference Example 3 was used instead of the polarizing film, and the retardation film obtained in Reference Example 9 was used instead of the retardation film obtained in Reference Example 8. Similarly, a roll-shaped laminated optical body was obtained. The outline of the laminated optical body is shown in Table 2 below.
- Example 4 [Production of liquid crystal display devices]
- the roll-shaped laminated optical body (raw material) obtained in Example 3 was cut so as to correspond to the size of the liquid crystal cell of Reference Example 14 to obtain an optical film.
- the optical film was cut so that the angle formed between the longitudinal direction and the absorption axis of the polarizing film was 45 °.
- Two optical films were cut out from the same raw fabric, and each was attached to the top and bottom of the liquid crystal cell of Reference Example 14 via an acrylic adhesive (thickness: 20 ⁇ m) to obtain a liquid crystal panel.
- This liquid crystal panel was combined with the backlight unit of the liquid crystal display device from which the liquid crystal cell was taken out to obtain a liquid crystal display device.
- the positional relationship of the optical axis of each layer in the liquid crystal display device is shown in Table 3 below.
- Example 6 A liquid crystal display device was obtained in the same manner as in Example 4 except that the laminated optical body obtained in Comparative Example 3 was used instead of the laminated optical body obtained in Example 3. The positional relationship of the optical axis of each layer in the liquid crystal display device is shown in Table 3 below.
- Example 7 A liquid crystal display device was obtained in the same manner as in Example 4 except that the laminated optical body obtained in Comparative Example 4 was used instead of the laminated optical body obtained in Example 3. The positional relationship of the optical axis of each layer in the liquid crystal display device is shown in Table 3 below.
- Example 8 A liquid crystal display device was obtained in the same manner as in Example 4 except that the laminated optical body obtained in Comparative Example 5 was used instead of the laminated optical body obtained in Example 3. The positional relationship of the optical axis of each layer in the liquid crystal display device is shown in Table 3 below.
- the liquid crystal display device using the optical film of the example of the present invention has a significantly larger contrast in all directions than the liquid crystal display device of Comparative Example 6.
- Comparative Example 6 since roll-to-roll cannot make the slow axis of the retardation film and the absorption axis of the polarizing film orthogonal to each other, viewing angle compensation is insufficient.
- the laminated optical body of Example 3 has a significantly smaller degree of axial misalignment than the laminated optical body of Comparative Example 5. Since the laminated optical body of Comparative Example 5 uses a normal polarizing plate (having an absorption axis in the longitudinal direction), in order to make the absorption axis and the slow axis of the retardation film (O plate) orthogonal to each other. The slow axis of the O plate must be developed in the short direction. It can be seen that the process of developing the slow axis of the O plate in the short direction is very difficult, and even if it can be expressed, the axis deviation increases as shown in Table 6.
- Laminate A obtained in Reference Example 10 and the polarizing film obtained in Reference Example 2 are attached with a roll-to-roll as shown in FIG. 3 via an acrylic adhesive (thickness: 20 ⁇ m). Combined. Thereafter, the alignment substrate (PET film) was removed, and a roll-shaped laminate B in which the retardation film A was transferred to the polarizing film was obtained. Next, the laminate B and the retardation film B of Reference Example 11 are rolled to an adhesive with an acrylic adhesive (thickness: 20 ⁇ m) so that the retardation film A and the retardation film B face each other. A laminated optical body was obtained by laminating with a roll. The summary of the obtained laminated optical body is shown in Table 7 below.
- Example 9 A roll-shaped laminated optical body was obtained in the same manner as in Example 5 except that the commercially available polarizing plate of Reference Example 3 was used instead of the polarizing film.
- the outline of the laminated optical body is shown in Table 7 below.
- Example 6 [Production of liquid crystal display devices]
- the roll-shaped laminated optical body (original fabric) obtained in Example 5 was cut so as to correspond to the size of the liquid crystal cell of Reference Example 14 to obtain an optical film.
- the optical film was cut so that the angle formed between the longitudinal direction and the absorption axis of the polarizing film was 45 °.
- Two optical films were cut out from the same raw fabric, and each was attached to the top and bottom of the liquid crystal cell of Reference Example 14 via an acrylic adhesive (thickness: 20 ⁇ m) to obtain a liquid crystal panel.
- This liquid crystal panel was combined with the backlight unit of the liquid crystal display device from which the liquid crystal cell was taken out to obtain a liquid crystal display device.
- Table 8 shows the positional relationship of the optical axes of the respective layers in the liquid crystal display device.
- Comparative Example 11 The laminated optical body obtained in Comparative Example 9 was used in place of the laminated optical body obtained in Example 5, and the angle between the longitudinal direction of the optical film and the absorption axis of the polarizing film was 135 °.
- a liquid crystal display device was obtained in the same manner as in Example 6 except that the cutting was performed. Table 8 below shows the positional relationship of the optical axes of the respective layers in the liquid crystal display device.
- Example 12 A liquid crystal display device was obtained in the same manner as in Example 6 except that the laminated optical body obtained in Comparative Example 10 was used instead of the laminated optical body obtained in Example 5.
- Table 8 shows the positional relationship of the optical axes of the respective layers in the liquid crystal display device.
- the liquid crystal display device of Example 6 has a markedly higher contrast in all directions than the liquid crystal display device of Comparative Example 11.
- Comparative Example 11 since the slow axis of the first retardation film cannot be orthogonal to the absorption axis of the polarizing film in roll-to-roll, viewing angle compensation is insufficient.
- the optical film of Example 5 using roll-to-roll has a significantly smaller degree of axial displacement than the optical film of Comparative Example 10 using single plate bonding.
- Example 7 [Production of laminated optical body]
- the phase difference film I obtained in Reference Example 12 and the polarizing film obtained in Reference Example 2 are bonded by roll-to-roll as shown in FIG. 3 through an aqueous adhesive (thickness: 80 nm).
- a roll-shaped laminated optical body was obtained.
- a summary of the laminated optical body is shown in Table 11 below.
- Example 13 A roll-shaped laminated optical body was obtained in the same manner as in Example 7 except that the commercially available polarizing plate of Reference Example 3 was used instead of the polarizing film. A summary of the laminated optical body is shown in Table 11 below.
- Example 8 [Production of liquid crystal display devices]
- the roll-shaped laminated optical body (original fabric) obtained in Example 7 was cut so as to correspond to the size of the liquid crystal cell of Reference Example 14 to obtain an optical film.
- the optical film was cut so that the angle formed between the longitudinal direction and the absorption axis of the polarizing film was 135 °.
- Two optical films were cut out from the same raw fabric, and each was attached to the top and bottom of the liquid crystal cell of Reference Example 14 via an acrylic adhesive (thickness: 20 ⁇ m) to obtain a liquid crystal panel.
- This liquid crystal panel was combined with the backlight unit of the liquid crystal display device from which the liquid crystal cell was taken out to obtain a liquid crystal display device.
- Table 12 shows the positional relationship of the optical axes of the respective layers in the liquid crystal display device.
- Comparative Example 15 The laminated optical body obtained in Comparative Example 13 was used in place of the laminated optical body obtained in Example 7, and the angle between the longitudinal direction of the optical film and the absorption axis of the polarizing film was 45 °.
- a liquid crystal display device was obtained in the same manner as in Example 8 except that the cutting was performed. Table 12 below shows the positional relationship of the optical axes of the respective layers in the liquid crystal display device.
- the liquid crystal display device of Example 8 has a markedly higher contrast in all directions than the liquid crystal display device of Comparative Example 15.
- Comparative Example 15 since the slow axis of the retardation film I and the absorption axis of the polarizing film cannot be orthogonal to each other in roll-to-roll, viewing angle compensation is insufficient.
- the optical film of Example 7 using roll-to-roll is found to have a significantly smaller degree of axial misalignment than the optical film of Comparative Example 14 using single plate bonding.
- the laminated optical body and optical film of the present invention can be suitably used for a liquid crystal display device.
- the laminated optical body and optical film of the present invention can be particularly suitably used for a liquid crystal display device for large screen applications.
- the liquid crystal display device of the present invention is, for example, an OA device such as a personal computer monitor, a notebook personal computer, a copy machine, a mobile phone, a clock, a digital camera, a portable information terminal (PDA), a portable device such as a portable game machine, a video camera, and a television.
- PDA portable information terminal
- Household electrical equipment such as microwave ovens, back monitors, car navigation system monitors, in-vehicle equipment such as car audio, display equipment such as information monitors for commercial stores, security equipment such as monitoring monitors, nursing care monitors, It can be suitably used for care / medical devices such as medical monitors.
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Abstract
Description
好ましい実施形態においては、上記親水性高分子層の厚みは1μm~10μmである。
好ましい実施形態においては、上記基材層は、上記親水性高分子層の保護層を兼ねる。
好ましい実施形態においては、上記位相差フィルムは、傾斜配向した分子を含む。好ましい実施形態においては、上記位相差フィルムに含まれる分子は該位相差フィルムの厚み方向に沿って連続的または間欠的に傾斜し、該分子が面内に平行に配列されている場合の傾斜角を0°として、上記親水性高分子層側の傾斜角は該親水性高分子層と反対側の傾斜角よりも20°~70°大きい。好ましい実施形態においては、上記傾斜配向した分子の平均傾斜角は10°~40°である。
好ましい実施形態においては、上記位相差フィルムにおける上記分子の屈折率楕円体はnx>ny=nzの関係を有する。好ましい実施形態においては、上記積層光学体は、上記位相差フィルムの上記親水性高分子層とは反対側に、短手方向に遅相軸を有し、かつ、屈折率楕円体がnx>ny>nzの関係を有する長尺状の第2の位相差フィルムをさらに備える。好ましい実施形態においては、上記第2の位相差フィルムの面内位相差値Re2[590]は80~160nmであり、Nz係数は1.1~1.8である。
好ましい実施形態においては、上記位相差フィルムにおける上記分子の屈折率楕円体はnx=ny>nzの関係を有する。好ましい実施形態においては、上記位相差フィルムの面内位相差値Re1[590]は100nm以下であり、厚み方向の位相差値Rth1[590]は50nm~200nmである。好ましい実施形態においては、上記積層光学体は、長尺状の第2の位相差フィルムをさらに備え、該第2の位相差フィルムの面内位相差値Re2[590]が100nm未満であり、厚み方向の位相差値Rth2[590]が200nm未満である。好ましい実施形態においては、上記位相差フィルムと上記第2の位相差フィルムの面内位相差値の合計Re1+2[590]は10nm以上200nm未満であり、厚み方向の位相差値の合計Rth1+2[590]は50nm~300nmである。
本発明の別の局面によれば、長尺状の積層光学体の製造方法が提供される。この製造方法は、長尺状の基材に親水性高分子を含む組成物を塗布して薄膜を形成すること;該薄膜を該基材と一緒に延伸すること;該延伸された薄膜を染色して、基材層と親水性高分子層とを含む長尺状の偏光フィルムを得ること;および、該偏光フィルムと長尺状の位相差フィルムとを、長手方向を揃えて連続的に貼り合わせること; を含む。
好ましい実施形態においては、上記方法は、上記薄膜を上記基材と一緒に短手方向に延伸する。
本発明のさらに別の局面によれば、光学フィルムが提供される。この光学フィルムは、上記の積層光学体を裁断または打ち抜いて得られる。
本発明のさらに別の局面によれば、液晶表示装置が提供される。この液晶表示装置は、上記の光学フィルムと液晶セルとを備える。
A.積層光学体の全体構成
図1は、本発明の好ましい実施形態による積層光学体の概略断面図である。積層光学体10は、偏光フィルム11と位相差フィルム12とが積層されてなる。偏光フィルム11は、基材層11aと親水性高分子層11b(本明細書においては偏光薄膜と称する場合もある)との積層体である。親水性高分子層12には二色性物質が吸着されている。積層光学体10は長尺状とされている。本明細書において「長尺状」とは、幅(短手方向)に対して長さ(長手方向)が10倍以上であるものをいう。好ましくは、本発明の積層光学体はロール状とされている。
上記のように、偏光フィルム11は、基材層11aと親水性高分子層11bとの積層体である。代表的には、基材層11aと親水性高分子層11bとは、接着剤層も粘着剤層も介することなく、密着積層されている。偏光フィルムの厚みは、親水性高分子層11bが非常に薄いので基材層11aの厚みが支配的であり、好ましくは10μm~90μm、さらに好ましくは21μm~90μm、特に好ましくは21μm~80μmである。
基材層11aとしては、本発明の効果が得られる限りにおいて、任意の適切な高分子フィルムが採用され得る。基材層は、好ましくは延伸性に優れた高分子フィルムで構成され、さらに好ましくは5倍以上の延伸倍率で延伸可能な高分子フィルムで構成される。このようなフィルムであれば、親水性高分子層を形成するための組成物を密着させた状態で良好に延伸することができる。また、基材層は、好ましくは優れた平滑性を有するフィルムで構成される。このようなフィルムであれば、親水性高分子層を形成するための組成物を均一に塗布することができる。1つの実施形態においては、基材層は、正の固有複屈折を有する高分子フィルムで構成される。このようなフィルムを用いれば、延伸により親水性高分子層(偏光薄膜)の吸収軸と基材層の遅相軸(発現する場合)とを実質的に平行とすることができる。別の実施形態においては、基材層は、負の固有複屈折を有する高分子フィルムで構成される。このようなフィルムを用いれば、延伸により親水性高分子層の吸収軸と基材層の遅相軸(発現する場合)とを実質的に直交させることができる。
親水性高分子層11bは、偏光子として機能し得る。親水性高分子層11bは、基材(結果的に基材層となる)にビニルアルコール系樹脂を含む組成物(以下、ビニルアルコール組成物とも称する)を塗布して薄膜を形成し、当該薄膜を基材と一緒に延伸し、当該延伸された薄膜を染色することにより得られる(実質的には、基材層/親水性高分子層が一体化した偏光フィルムが得られる)。
上記のように、位相差フィルム12は、長手方向に遅相軸を有する。位相差フィルム12としては、長手方向に遅相軸を有し、かつ、上記偏光フィルム11と積層可能である限り、目的に応じて任意の適切な位相差フィルムが採用され得る。以下、本発明に用いられる位相差フィルムの代表例を説明する。
1つの実施形態においては、位相差フィルム12は、屈折率楕円体がnx>ny=nzまたはnx>ny>nzの関係を示す。ここで、nxはフィルム面内において屈折率が最大となる方向(遅相軸方向)の屈折率、nyはフィルム面内において遅相軸方向に直交する方向(進相軸方向)の屈折率、nzはフィルムの厚み方向の屈折率をいう。
上記位相差フィルム12は、傾斜配向した分子を含む、いわゆるOプレートであってもよい。傾斜配向した分子が全体として、液晶セル中の液晶分子全体の複屈折を補償し得る。なかでも、傾斜配向した分子は、液晶セルの基板界面の液晶分子の複屈折を好適に補償し得る。本明細書において「Oプレート」とは、分子の傾斜配向の角度が一定のもののみならず、ハイブリッド配向も含む。「ハイブリッド配向」とは、分子の傾斜角度(チルト角)が、厚み方向に沿って連続的または間欠的に増加または減少し、偏光フィルム側のチルト角(θA)が反対側(図示例では空気界面側)のチルト角(θB)と異なるものをいう。ここで、チルト角(θ)とは、隣接する層面と分子とのなす角度を表し、当該分子が面内に平行に配列されている場合を0°とする。傾斜配向における分子の代表的な配列状態を図2(a)に、ハイブリッド配向における分子の代表的な配列状態を図2(b)に模式的に示す。図2(a)および図2(b)においては、上側が偏光フィルム側である。
1つの実施形態においては、位相差フィルム12は、分子の傾斜配向の方向を位相差フィルム面内に投影した方向は、遅相軸と実質的に平行である。このような位相差フィルムにおいては、当該フィルムを構成する分子がnx>ny≧nzの屈折率楕円体を示し、かつ、当該分子が傾斜配向している。このような位相差フィルムは、例えば、nx>ny≧nzの屈折率楕円体を示す位相差フィルムを傾斜配向処理することにより得られ得る(傾斜配向させる方法については後述する)。1つの実施形態においては、位相差フィルム12を構成する分子の屈折率比は、好ましくは0.9~4である。分子の屈折率比は、分子の形状に関連するパラメーターであり、式:(nx-nz)/(nx-ny)で表される。本明細書において、「分子の屈折率楕円体」または「分子の屈折率比」というときは、nxは分子の長軸方向、nyは分子の長軸を含む面内において分子の長軸方向(nx方向)に直交する方向、nzはnx方向およびny方向のいずれにも直交する方向をいう。「位相差フィルムの屈折率楕円体」というとき、およびフィルムの光学特性(例えば、面内位相差)を表すときは、nxはフィルム面内において屈折率が最大となる方向(遅相軸方向)、nyはフィルム面内において遅相軸方向に直交する方向(進相軸方向)、nzはフィルムの厚み方向をいう。言うまでもなく、「分子の屈折率楕円体」または「分子の屈折率比」というときの分子の長軸方向(nx方向)は、フィルムを構成する分子全体の統計的平均である。分子の屈折率楕円体および分子の屈折率比は、傾斜配向フィルムの面内位相差値、厚み方向位相差値および平均傾斜角から算出することができる。
別の実施形態においては、位相差フィルム12は、分子の傾斜配向の方向を位相差フィルム面内に投影した方向が、遅相軸と実質的に直交している。すなわち、傾斜配向した分子の傾斜配向方向は、位相差フィルムの短手方向である。このような位相差フィルムにおいては、当該フィルムを構成する分子がnx=ny>nzの屈折率楕円体を示し、かつ、当該分子が傾斜配向している。本明細書においては、「nx=ny」は、nxとnyが厳密に等しい場合のみならず、nxとnyが実質的に等しい場合も包含する。具体的には、nx-ny<0.005であり得、好ましくはnx-ny<0.001である。このような屈折率楕円体の関係を有する分子が傾斜配向して、黒表示時の液晶セル内の正の一軸性液晶分子と鏡面対称の状態となるので、全方位での光学的な補償が可能となり、視野角特性が向上し得る。なお、上記位相差フィルムにおいては、傾斜配向した分子が上記屈折率楕円体の関係を示すので、位相差フィルムの屈折率楕円体の関係は、nx=ny>nzを満たさない場合がある。
上記のように、本発明の積層光学体は、第2の位相差フィルムをさらに備えてもよい。第2の位相差フィルムの光学特性および配置位置は、目的、位相差フィルム12の光学特性等に応じて適切に設定され得る。以下、代表例について説明する。なお、本項においては、便宜上、位相差フィルム12を第1の位相差フィルムと称する。また、添え字の1は第1の位相差フィルムを表し、添え字の2は第2の位相差フィルムを表すものとする。
この場合、第2の位相差フィルム13は、短手方向に遅相軸を有し(すなわち、第1の位相差フィルムの遅相軸と実質的に直交し)、屈折率楕円体がnx>ny>nzの関係を有する。この場合、第2の位相差フィルム13は、本発明の積層光学体において位相差フィルム12の親水性高分子層11bとは反対側に配置される。
この場合、第2の位相差フィルムは、本発明の積層光学体において位相差フィルム12の親水性高分子層11bとは反対側に配置されてもよく、位相差フィルム12と親水性高分子層11bとの間に配置されてもよい。目的や配置位置に応じて、適切な光学特性を有する位相差フィルムが用いられ得る。第2の位相差フィルム13は、単層のフィルムであってもよく、2以上の層が積層されたフィルムであってもよい。
上記保護フィルム(内側保護フィルム)は、光学的に等方性を有することが好ましい。具体的には、内側保護フィルムの厚み方向の位相差Rth[550]は、好ましくは-20nm~+20nm、さらに好ましくは-10nm~+10nm、特に好ましくは-6nm~+6nm、最も好ましくは-3nm~+3nmである。内側保護フィルムの面内位相差Re[550]は、好ましくは0nm以上10nm以下、さらに好ましくは0nm以上6nm以下、特に好ましくは0nm以上3nm以下である。このような光学的に等方性を有する保護フィルムの詳細は、特開2008-180961号公報に記載されており、その記載は本明細書に参考として援用される。
本発明の積層光学体10は、上記長尺状の偏光フィルム11と上記長尺状の位相差フィルム12とをそれぞれ長手方向に搬送させながら、長手方向を揃えて連続的に貼り合わせること(いわゆる、ロール・トゥ・ロール)により作製される。1つの実施形態においては、上記長尺状の偏光フィルム11および上記長尺状の位相差フィルム12は、それぞれロールとして保管された後、貼り合わせ工程に供される。別の実施形態においては、上記長尺状の偏光フィルム11は、上記A-1-2項に記載の製造工程から連続して貼り合わせ工程に供され、上記長尺状の位相差フィルム12は、上記A-2項に記載の製造工程から連続して貼り合わせ工程に供される。
本発明の光学フィルムは、上記のようにして得られた積層光学体を裁断または打ち抜いて得られる。裁断または打ち抜きは、任意の適切な方法を採用し得る。本発明の積層光学体は、偏光フィルムの製造方法に起因して幅広であるので、大型の液晶表示装置用の光学フィルムの打ち抜きまたは裁断が容易であり、かつ、打ち抜き等による廃材を少なくすることができるので、コスト的に有利である。得られた積層光学体を、適用される液晶表示装置の寸法に応じた寸法に裁断する際には、2枚以上の積層光学体を重ねて裁断加工することが製造効率の点から好ましい。同様の構成を有する従来の積層光学体(偏光板)では、厚みが大きいので、2枚以上の積層光学体を重ねて裁断するには大きな力を加える必要がある。その結果、重ねた積層光学体同士がずれやすく、得られる光学フィルムの寸法精度が不十分であるおそれがある。一方、本発明の積層光学体は厚みが非常の薄いので、2枚以上を重ねて裁断しても精度よく裁断することが可能であり、製造効率の面で非常に好ましい。
本発明の液晶表示装置は、上記本発明の光学フィルムと液晶セルとを備える。図4は、本発明の好ましい実施形態による液晶表示装置の概略断面図である。液晶表示装置100は、液晶セル20と、液晶セル20の少なくとも一方の側に配置された光学フィルム10´とを備える。光学フィルム10´は、基材層11aが外側となるように配置される。光学フィルム10´が液晶セルの一方の側のみに配置される場合、他方の側には通常の偏光板が配置される。液晶セル20の駆動モードとしては、任意の適切な駆動モードが採用され得る。駆動モードの代表例としては、STN(Super Twisted Nematic)モード、TN(Twisted Nematic)モード、IPS(In-Plane Switching)モード、VA(Vertical Aligned)モード、OCB(Optically Compensated Birefringence)モード、HAN(Hybrid Aligned Nematic)モードおよびASM(Axially Symmetric Aligned Microcell)モードが挙げられる。光学フィルム10´の位相差フィルムとして屈折率楕円体がnx>ny=nzまたはnx>ny>nzの関係を示す位相差フィルムを用いる場合には、駆動モードは、好ましくはVAモードである。光学フィルム10´の位相差フィルムとしてOプレートを用いる場合には、駆動モードは、好ましくはTNモードである。光学フィルム10´の位相差フィルムによって、非常に良好な光学補償が実現されるからである。
実施例および比較例で得られた積層光学体を10cm×10cmに切り出し、試験片とした。当該試験片の所定の位置に所定の間隔でマーキングした。マーキングした試験片をオーブン(ESPEC社製、製品名PH-201)に入れ、80℃で500時間放置した後取り出した。取り出した試験片のマーキングの間隔を測定し、以下の式から寸法変化率を求めた:
寸法変化率(%)={(DA-DB)/DA}×100
DA:オーブンに入れる前のマーキング距離
DB:オーブンに入れた後のマーキング距離
また、上記と同様にマーキングした試験片を恒温・恒湿オーブン(ESPEC社製、製品名PL-2KT)に入れ、60℃、90%RHの条件で500時間放置した後取り出した。取り出した試験片のマーキングの間隔を測定し、上記と同様の式を用いて寸法変化率を求めた。
参考例4~7で作製した位相差フィルムを5cm×3cmに切り出し、試験片とした。王子計測機器(株)製 製品名「KOBRA-21ADH」を用いて、試験片の遅相軸の角度を原反の幅方向に等間隔で15点測定した。15点の平均値を求め、当該平均値からの標準偏差を軸精度の指標とした。
実施例および比較例で得られた液晶表示装置について、23℃の暗室でバックライトを点灯させてから20分経過した後、測定を行った。具体的には、コニカ・ミノルタ製 2次元色分布測定装置「CA-1500」を用いて表示画面を撮影した。表示画面全面から無作為に選んだ24235ヶ所の輝度を上記装置で測定し、輝度の平均値を求め、当該平均値からの標準偏差を輝度ムラとした。
参考例で作製した位相差フィルムの位相差を、Axiometric社製 製品名「Axoscan」を用いて、波長590nm、23℃で測定した。所定の方向における位相差値の最大値と最小値との差をバラツキとした。
下記式(I)および(II)に示すように、Journal of Applied Phisics Vol.38(1999年)P.748に記載のWitteの式に、ne、no、及び位相差値(遅相軸と平行に、極角-40°~+40°(法線方向を0°とする)に5°きざみで測定したそれぞれの値)を代入して、θairおよびθALを求め、これらの平均値を平均傾斜角度とした。なお、位相差値は、Axiometric社製 製品名「Axoscan」を用いて、波長590nm、23℃で測定した値を用いた。また、ne及びnoは、アッベ屈折率計[アタゴ(株)製 製品名「DR-M4」]を用いて測定した値を用いた。
上記(4)のようにして測定したRe[590]およびRth[590]からNz係数を算出した。また、Re[590]およびRth[590]と上記平均傾斜角度とから分子の屈折率比および屈折率楕円体を算出した。
参考例で作製した位相差フィルム、偏光フィルムおよび液晶セルをはじめ、液晶表示装置に使用するすべての光学部材の光学特性を通常の方法で実測した。これらの実測値を用い、かつ、Shintech社製 製品名「LCD Master」を用いて、液晶表示装置のコントラストをシミュレーションした。
上記(2)の軸精度以外の軸角度については、王子計測機器(株)製 製品名「KOBRA21-WPR」を用いて測定した。
大塚電子社製 製品名「MCPD-3000」を用いて測定した。
[偏光フィルムの作製]
ポリビニルアルコール樹脂(日本合成化学社製、製品名「ゴーセノールNH-18」、ケン化度98~99%)を熱水溶解した後冷却し、7重量%のポリビニルアルコール水溶液を調製した。一方、基材としてノルボルネン系樹脂フィルム(JSR(株)製、製品名「アートン」、厚み100μm)を用意した。上記水溶液を、基材表面に塗布し、100℃で10分間乾燥して、基材上に厚み7μmのポリビニルアルコール薄膜を形成した。このようにして得られた基材/薄膜の積層体を、延伸温度140℃、延伸倍率4.5倍で短手方向に延伸した。延伸された積層体の全体厚みは60μm、ポリビニルアルコール薄膜の厚みは3μmであった。このようにして延伸された積層体を、30℃のヨウ素水溶液(ヨウ素:ヨウ化カリウム:水=1:10:200(重量比))に30秒間浸漬した後、55℃のホウ酸水溶液(5重量%)に60秒間浸漬し、さらに30℃のヨウ化カリウム水溶液(5重量%)に10秒間浸漬して、ポリビニルアルコール薄膜を染色および架橋した。これを80℃で4分間乾燥し、基材層/親水性高分子層の構成を有するロール状の偏光フィルムを得た。得られた偏光フィルムの透過率は41.5%、偏光度は99%であった。また、得られた偏光フィルムは、短手方向(TD)に吸収軸を有していた。
[偏光フィルムの作製]
ポリビニルアルコール樹脂(日本合成化学社製、製品名「ゴーセノールNH-18」、ケン化度98~99%)を熱水溶解した後冷却し、7重量%のポリビニルアルコール水溶液を調製した。一方、基材としてノルボルネン系樹脂フィルム(JSR(株)製、製品名「アートン」、厚み100μm)を用意した。上記水溶液を、基材表面に塗布し、100℃で10分間乾燥して、基材上に厚み7μmのポリビニルアルコール薄膜を形成した。このようにして得られた基材/薄膜の積層体を、延伸温度140℃、延伸倍率4.5倍で短手方向に延伸した。延伸された積層体の全体厚みは60μm、ポリビニルアルコール薄膜の厚みは3μmであった。このようにして延伸された積層体を、20℃のヨウ素水溶液(ヨウ素:ヨウ化カリウム:水=1:10:200(重量比))に60秒間浸漬した後、55℃のホウ酸水溶液(10重量%)に420秒間浸漬し、さらに30℃のヨウ化カリウム水溶液(4重量%)に10秒間浸漬して、ポリビニルアルコール薄膜を染色および架橋した。これを60℃で4分間乾燥し、基材/偏光薄膜の構成を有するロール状の偏光フィルムを得た。得られた偏光フィルムの透過率は41.5%、偏光度は99%であった。また、得られた偏光フィルムは、短手方向に吸収軸を有していた。
[偏光板]
保護フィルム/偏光子/保護フィルムの構成を有する市販の偏光板(日東電工(株)製、製品名「NPF-TEG1465DU」)を用いた。この偏光板は、液晶セル側の保護フィルムの面内位相差が実質的にゼロである。また、偏光板の単体透過率が約44%であり、長手方向(MD)に吸収軸を有している。
[位相差フィルムの作製]
ノルボルネン系樹脂フィルム(JSR社製、商品名「アートン」、厚み100μm、幅1.2m、長さ500m)のロール状巻回体からフィルムを順次繰り出しながら、ロール式縦一軸延伸法により、150℃で長さ方向に1.3倍に延伸した後、幅1mに裁断し、長尺状の位相差フィルムを得た。得られた位相差フィルムは、長手方向(MD)に遅相軸を有していた。得られた位相差フィルムの厚みは70μm、面内位相差Re[590]は55nm、幅方向のRe[590]のバラツキは5nm、遅相軸の軸精度は0.5°であった。得られた位相差フィルムの屈折率楕円体はnx>ny=nzの関係を有していた。
[位相差フィルムの作製]
ノルボルネン系樹脂フィルム(日本ゼオン社製、商品名「ゼオノア」、厚み100μm、幅1.3m、長さ1000m)のロール状巻回体からフィルムを順次繰り出しながら、ロール式縦一軸延伸法により、140℃で長さ方向に1.15倍に延伸した後、幅1mに裁断し、長尺状の位相差フィルムを得た。得られた位相差フィルムは、長手方向(MD)に遅相軸を有していた。得られた位相差フィルムの厚みは94μm、面内位相差Re[590]は64nm、幅方向のRe[590]のバラツキは4nm、遅相軸の軸精度は0.8°であった。得られた位相差フィルムの屈折率楕円体はnx>ny=nzの関係を有していた。
[位相差フィルムの作製]
ノルボルネン系樹脂フィルム(JSR社製、商品名「アートン」、厚み100μm、幅1.2m、長さ500m)のロール状巻回体からフィルムを順次繰り出しながら、テンター式横一軸延伸法により、150℃で横方向に1.3倍に延伸した後、幅1mに裁断し、長尺状の位相差フィルムを得た。得られた位相差フィルムは、短手方向(TD)に遅相軸を有していた。得られた位相差フィルムの厚みは72μm、面内位相差Re[590]は53nm、幅方向のRe[590]のバラツキは8nm、遅相軸の軸精度は1.5°であった。得られた位相差フィルムの屈折率楕円体はnx>ny=nzの関係を有していた。
[位相差フィルムの作製]
ノルボルネン系樹脂フィルム(日本ゼオン社製、商品名「ゼオノア」、厚み100μm、幅1.3m、長さ1000m)のロール状巻回体からフィルムを順次繰り出しながら、テンター式横一軸延伸法により、140℃で横方向に1.15倍に延伸した後、幅1mに裁断し、長尺状の位相差フィルムを得た。得られた位相差フィルムは、短手方向(TD)に遅相軸を有していた。得られた位相差フィルムの厚みは94μm、面内位相差Re[590]は60nm、幅方向のRe[590]のバラツキは4.5nm、遅相軸の軸精度は1.8°であった。得られた位相差フィルムの屈折率楕円体はnx>ny=nzの関係を有していた。
[位相差フィルム(Oプレート)の作製]
未延伸のノルボルネン系樹脂フィルム(日本ゼオン社製、「ゼオノア」フィルム)を、ロールを120℃に加熱し、下側ロール/上側ロールの回転速度比を1.1として圧延し、ロール状の位相差フィルムを得た。得られた位相差フィルムの面内位相差値は90nm、平均傾斜角度は30°、分子の屈折率比は3、遅相軸方向は長手方向であった。得られた傾斜配向位相差フィルムの分子の屈折率楕円体はnx>ny>nzの関係を有していた。
[位相差フィルム(Oプレート)の作製]
下側ロール/上側ロールの回転速度比を1.25としたこと以外は参考例8と同様の操作を行った。次いで、得られたフィルムを、延伸温度120℃、延伸倍率1.15倍でフィルムの短手方向(TD方向)に延伸し、ロール状の位相差フィルムを得た。得られた位相差フィルムの面内位相差値は30nm、平均傾斜角度は50°、分子の屈折率比は5.2、遅相軸方向は短手方向であった。得られた傾斜配向位相差フィルムの分子の屈折率楕円体はnx>ny>nzの関係を有していた。
[位相差フィルムA(Oプレート)の作製]
下記式(IV)で表わされる高分子液晶化合物(重量平均分子量:5,000) 20重量部と、重合性液晶化合物(BASF社製、商品名「PaliocolorLC242」、ne=1.654、no=1.523) 80重量部とを、シクロペンタノン 30重量部に溶解した。得られた溶液に表面調整剤(ビッグケミー社製、商品名「BYK375」) 0.3重量部を加え、次いで重合開始剤(Ciba社製、商品名「イルガキュア907」) 5重量部を加えた。さらに、固形分濃度が20重量%になるようにシクロペンタノンを加えて、塗工溶液を得た。
[位相差フィルムBの作製]
すでに延伸されてなる市販の長尺状ノルボルネン系樹脂フィルム(日本ゼオン社製、商品名「ゼオノア」)を位相差フィルムBとして用いた。位相差フィルムBの面内位相差値Re[590]は130nm、Nz係数は1.5、遅相軸方向は90°であった(すべて中心値)。当該フィルムは、屈折率楕円体がnx>ny>nzの関係を有していた。
[位相差フィルム(Oプレート)の作製]
未延伸のノルボルネン系樹脂フィルム(日本ゼオン社製、「ゼオノア」フィルム)を、ロールを120℃に加熱し、下側ロール/上側ロールの回転速度比を1.25として圧延してロール状のフィルムを得た。該フィルムを、延伸温度120℃、延伸倍率1.35倍でフィルムの短手方向(TD方向)に延伸し、ロール状の位相差フィルムIを得た。得られた位相差フィルムの面内位相差値Re[590]は50nm、厚み方向位相差値Rth[590]は150nm、平均傾斜角度は18°、遅相軸方向は0°(長手方向)であった(すべて中心値)。さらに、得られた傾斜配向位相差フィルムの分子の屈折率楕円体はnx=ny>nzの関係を有していた。
[液晶セル]
VAモードの液晶セルを含む液晶表示装置(SONY社製、32型液晶テレビ、型番S-2500)から液晶パネルを取り出し、液晶セルの上下に配置されていた光学フィルムをすべて取り除いた後、当該液晶セルの上下のガラス基板の表面を洗浄して用いた。
[液晶セル]
TNモードの液晶セルを含む液晶表示装置(BENQ社製、17型液晶モニター、型番「FP71+」)から液晶パネルを取り出し、液晶セルの上下に配置されていた光学フィルムをすべて取り除いた後、当該液晶セルの上下のガラス基板の表面を洗浄して用いた。
[積層光学体の作製]
参考例1で得られた偏光フィルムと参考例4で得られた位相差フィルムとを、アクリル系粘着剤(厚み:20μm)を介して、図3に示すようにしてロール・トゥ・ロールで貼り合わせ、ロール状の積層光学体を得た。用いた位相差フィルムの軸精度、得られた積層光学体の総厚みおよび寸法変化率を、後述の液晶表示装置の輝度ムラと併せて下記表1に示す。
上記のようにして得られたロール状の積層光学体(原反)を、参考例13の液晶セルのサイズに対応するよう裁断して、光学フィルムを得た。なお、光学フィルムは、その長手方向と偏光フィルムの吸収軸とが直交するようにして裁断した。同一原反から2つの光学フィルムを切り出し、それぞれを参考例13の液晶セルの上下にアクリル系粘着剤(厚み:20μm)を介して貼り付けて液晶パネルを得た。この液晶パネルを、上記液晶セルを取り出した液晶表示装置のバックライトユニットと結合し、液晶表示装置を得た。得られた液晶表示装置の輝度ムラを下記表1に、表示画面(黒画像)を撮影した写真を図5Aに、表示画面の輝度分布を図5Bに示す。なお、当該輝度分布は、黒画像から面内の輝度を測定し、輝度範囲によって色分けしたものである。
位相差フィルムとして参考例5で得られた位相差フィルムを用いたこと以外は実施例1と同様にしてロール状の積層光学体を得た。この積層光学体(原反)を用いたこと以外は実施例1と同様にして液晶表示装置を作製した。用いた位相差フィルムの軸精度、得られた積層光学体の総厚みおよび寸法変化率、ならびに液晶表示装置の輝度ムラを上記表1に示す。さらに、得られた液晶表示装置の表示画面(黒画像)を撮影した写真を図6Aに、表示画面の輝度分布を図6Bに示す。
参考例1の偏光フィルムの代わりに参考例3の市販の偏光板を用い、位相差フィルムとして参考例6で得られた位相差フィルムを用いたこと以外は実施例1と同様にしてロール状の積層光学体を得た。この積層光学体(原反)を用いたこと以外は実施例1と同様にして液晶表示装置を作製した。用いた位相差フィルムの軸精度、得られた積層光学体の総厚みおよび寸法変化率、ならびに液晶表示装置の輝度ムラを上記表1に示す。さらに、得られた液晶表示装置の表示画面(黒画像)を撮影した写真を図7Aに、表示画面の輝度分布を図7Bに示す。
参考例1の偏光フィルムの代わりに参考例3の市販の偏光板を用い、位相差フィルムとして参考例7で得られた位相差フィルムを用いたこと以外は実施例1と同様にしてロール状の積層光学体を得た。この積層光学体(原反)を用いたこと以外は実施例1と同様にして液晶表示装置を作製した。用いた位相差フィルムの軸精度、得られた積層光学体の総厚みおよび寸法変化率、ならびに液晶表示装置の輝度ムラを上記表1に示す。さらに、得られた液晶表示装置の表示画面(黒画像)を撮影した写真を図8Aに、表示画面の輝度分布を図8Bに示す。
表1から明らかなように、長手方向に遅相軸を有する位相差フィルムは、短手方向に遅相軸を有する位相差フィルムに比べて、遅相軸の軸精度に優れる。さらに、実施例1~2の積層光学体は、比較例1~2の積層光学体に比べて、寸法変化率が顕著に優れる。これらの特性に起因して、実施例1~2の液晶表示装置は、比較例1~2の液晶表示装置に比べて、輝度ムラが顕著に小さい。さらに、図5Aおよび図5B~図8Aおよび図8Bを比較すると明らかなように、実施例1~2の液晶表示装置は、比較例1~2の液晶表示装置に比べて、表示ムラが格段に改善されている。
[積層光学体の作製]
参考例2で得られた偏光フィルムと参考例8で得られた位相差フィルムとを、アクリル系粘着剤(厚み:20μm)を介して、図3に示すようにしてロール・トゥ・ロールで貼り合わせ、ロール状の積層光学体を得た。積層光学体の概要を下記表2に示す。
上記偏光フィルムの代わりに参考例3の市販の偏光板を用いたこと以外は実施例3と同様にしてロール状の積層光学体を得た。積層光学体の概要を下記表2に示す。
上記偏光フィルムの代わりに参考例3の市販の偏光板を用いた。この偏光板と参考例8で得られた位相差フィルムとを打ち抜き機で所定のサイズに打ち抜いた後、アクリル系粘着剤(厚み:20μm)を介して、単板貼り合わせ機を用いて貼り合わせ、積層光学体を得た。積層光学体の概要を下記表2に示す。
上記偏光フィルムの代わりに参考例3の市販の偏光板を用い、参考例8で得られた位相差フィルムの代わりに参考例9で得られた位相差フィルムを用いたこと以外は実施例3と同様にしてロール状の積層光学体を得た。積層光学体の概要を下記表2に示す。
[液晶表示装置の作製]
実施例3で得られたロール状の積層光学体(原反)を、参考例14の液晶セルのサイズに対応するよう裁断して、光学フィルムを得た。なお、光学フィルムは、その長手方向と偏光フィルムの吸収軸とのなす角度が45°になるようにして裁断した。同一原反から2つの光学フィルムを切り出し、それぞれを参考例14の液晶セルの上下にアクリル系粘着剤(厚み:20μm)を介して貼り付けて液晶パネルを得た。この液晶パネルを、上記液晶セルを取り出した液晶表示装置のバックライトユニットと結合し、液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表3に示す。
実施例3で得られた積層光学体の代わりに比較例3で得られた積層光学体を用いたこと以外は実施例4と同様にして液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表3に示す。
実施例3で得られた積層光学体の代わりに比較例4で得られた積層光学体を用いたこと以外は実施例4と同様にして液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表3に示す。
実施例3で得られた積層光学体の代わりに比較例5で得られた積層光学体を用いたこと以外は実施例4と同様にして液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表3に示す。
(1)コントラスト
実施例4の液晶表示装置および比較例6の液晶表示装置の上下左右方向における極角40°方向からのコントラストを算出した。結果を表4に示す。
実施例3で得られた積層光学体から裁断した光学フィルムと比較例4で得られた積層光学体(光学フィルム)とで、偏光フィルムの吸収軸と位相差フィルムの遅相軸との軸ズレを比較した。具体的には、実施例3および比較例4の光学フィルムをそれぞれ10枚作製し、それぞれの光学フィルムについて90°からのズレを測定した。ズレの平均値および最大値を表5に示す。
実施例3で得られたロール状の積層光学体(原反)と比較例5で得られたロール状の積層光学体(原反)とで、偏光フィルムの吸収軸と位相差フィルムの遅相軸との軸ズレを比較した。具体的には、それぞれのロール(原反)において50mmごとに90°からのズレを測定した。ズレの平均値、最大値、最小値および3σ(σは標準偏差)を表6に示す。
[積層光学体の作製]
参考例10で得られた積層体Aと参考例2で得られた偏光フィルムとを、アクリル系粘着剤(厚み:20μm)を介して、図3に示すようにしてロール・トゥ・ロールで貼り合わせた。その後、配向基板(PETフィルム)を除去して、偏光フィルムに位相差フィルムAが転写された、ロール状の積層体Bを得た。次いで、積層体Bと参考例11の位相差フィルムBとを、位相差フィルムAと位相差フィルムBとが対向するようにして、アクリル系粘着剤(厚み:20μm)を介してロール・トゥ・ロールで貼り合わせて積層光学体を得た。得られた積層光学体の概要を下記表7に示す。
上記偏光フィルムの代わりに参考例3の市販の偏光板を用いたこと以外は実施例5と同様にしてロール状の積層光学体を得た。積層光学体の概要を下記表7に示す。
参考例3の市販の偏光板と上記位相差フィルムAおよび位相差フィルムBとを打ち抜き機で所定のサイズに打ち抜いた後、アクリル系粘着剤(厚み:20μm)を介して、単板貼り合わせ機を用いて貼り合わせ、積層光学体を得た。積層光学体の概要を下記表7に示す。
[液晶表示装置の作製]
実施例5で得られたロール状の積層光学体(原反)を、参考例14の液晶セルのサイズに対応するよう裁断して、光学フィルムを得た。なお、光学フィルムは、その長手方向と偏光フィルムの吸収軸とのなす角度が45°になるようにして裁断した。同一原反から2つの光学フィルムを切り出し、それぞれを参考例14の液晶セルの上下にアクリル系粘着剤(厚み:20μm)を介して貼り付けて液晶パネルを得た。この液晶パネルを、上記液晶セルを取り出した液晶表示装置のバックライトユニットと結合し、液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表8に示す。
実施例5で得られた積層光学体の代わりに比較例9で得られた積層光学体を用いたこと、および光学フィルムを、その長手方向と偏光フィルムの吸収軸とのなす角度が135°になるようにして裁断したこと以外は実施例6と同様にして液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表8に示す。
実施例5で得られた積層光学体の代わりに比較例10で得られた積層光学体を用いたこと以外は実施例6と同様にして液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表8に示す。
(1)コントラスト
実施例6の液晶表示装置および比較例11の液晶表示装置の上下左右方向における極角40°方向からのコントラストを算出した。結果を表9に示す。
実施例5で得られた積層光学体から裁断した光学フィルムと比較例10で得られた積層光学体(光学フィルム)とで、偏光フィルム(偏光子)の吸収軸と位相差フィルムAおよび位相差フィルムBの遅相軸とのそれぞれの軸ズレを比較した。具体的には、実施例5および比較例10の光学フィルムをそれぞれ10枚作製し、それぞれの光学フィルムについて90°からのズレを測定した。ズレの平均値、最大値、最小値、および最大値と最小値との差(range)を表10に示す。
[積層光学体の作製]
参考例12で得られた位相差フィルムIと参考例2で得られた偏光フィルムとを、水系接着剤(厚み:80nm)を介して、図3に示すようにしてロール・トゥ・ロールで貼り合わせ、ロール状の積層光学体を得た。積層光学体の概要を下記表11に示す。
上記偏光フィルムの代わりに参考例3の市販の偏光板を用いたこと以外は実施例7と同様にしてロール状の積層光学体を得た。積層光学体の概要を下記表11に示す。
参考例12で得られた位相差フィルムIと参考例2で得られた偏光フィルムとを打ち抜き機で所定のサイズに打ち抜いた後、水系接着剤(厚み:80nm)を介して、単板貼り合わせ機を用いて貼り合わせ、積層光学体を得た。積層光学体の概要を下記表11に示す。
[液晶表示装置の作製]
実施例7で得られたロール状の積層光学体(原反)を、参考例14の液晶セルのサイズに対応するよう裁断して、光学フィルムを得た。なお、光学フィルムは、その長手方向と偏光フィルムの吸収軸とのなす角度が135°になるようにして裁断した。同一原反から2つの光学フィルムを切り出し、それぞれを参考例14の液晶セルの上下にアクリル系粘着剤(厚み:20μm)を介して貼り付けて液晶パネルを得た。この液晶パネルを、上記液晶セルを取り出した液晶表示装置のバックライトユニットと結合し、液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表12に示す。
実施例7で得られた積層光学体の代わりに比較例13で得られた積層光学体を用いたこと、および光学フィルムを、その長手方向と偏光フィルムの吸収軸とのなす角度が45°になるようにして裁断したこと以外は実施例8と同様にして液晶表示装置を得た。液晶表示装置における各層の光軸の位置関係を下記表12に示す。
(1)コントラスト
実施例8の液晶表示装置および比較例15の液晶表示装置の上下左右方向における極角40°方向からのコントラストを算出した。結果を表13に示す。
実施例7で得られた積層光学体から裁断した光学フィルムと比較例14で得られた積層光学体(光学フィルム)とで、偏光フィルムの吸収軸と位相差フィルムIの遅相軸との軸ズレを比較した。具体的には、実施例および比較例の光学フィルムをそれぞれ10枚作製し、それぞれの光学フィルムについて90°からのズレを測定した。ズレの平均値、最大値、最小値、および最大値と最小値との差(range)を表14に示す。
実施例1~8および比較例1~15から明らかなように、本発明の実施例によれば、製造効率に優れ、位相差フィルムの遅相軸の軸ズレおよび位相差ムラがきわめて小さく、かつ、高温・高湿環境下における寸法変化がきわめて小さい積層光学体が得られることがわかる。その結果、輝度ムラ、表示ムラおよびコントラストのいずれにも優れる液晶表示装置が得られることがわかる。
10´ 光学フィルム
11 偏光フィルム
11a 基材層
11b 親水性高分子層
12 位相差フィルム
13 第2の位相差フィルム
20 液晶セル
100 液晶表示装置
Claims (17)
- 短手方向に吸収軸を有し、基材層と二色性物質が吸着された親水性高分子層とを含む長尺状の偏光フィルムと、
長手方向に遅相軸を有する、長尺状の位相差フィルムと、
を備える、長尺状の積層光学体。 - 前記親水性高分子層の厚みが1μm~10μmである、請求項1に記載の積層光学体。
- 前記基材層が、前記親水性高分子層の保護層を兼ねる、請求項1または2に記載の積層光学体。
- 前記位相差フィルムが、傾斜配向した分子を含む、請求項1から3のいずれかに記載の積層光学体。
- 前記位相差フィルムに含まれる分子が該位相差フィルムの厚み方向に沿って連続的または間欠的に傾斜し、該分子が面内に平行に配列されている場合の傾斜角を0°として、前記親水性高分子層側の傾斜角が該親水性高分子層と反対側の傾斜角よりも20°~70°大きい、請求項4に記載の積層光学体。
- 前記傾斜配向した分子の平均傾斜角が10°~40°である、請求項4または5に記載の積層光学体。
- 前記位相差フィルムにおける前記分子の屈折率楕円体がnx>ny=nzの関係を有する、請求項4から6のいずれかに記載の積層光学体。
- 前記位相差フィルムの前記親水性高分子層とは反対側に、短手方向に遅相軸を有し、かつ、屈折率楕円体がnx>ny>nzの関係を有する長尺状の第2の位相差フィルムをさらに備える、請求項7に記載の積層光学体。
- 前記第2の位相差フィルムの面内位相差値Re2[590]が80~160nmであり、Nz係数が1.1~1.8である、請求項8に記載の積層光学体。
- 前記位相差フィルムにおける前記分子の屈折率楕円体がnx=ny>nzの関係を有する、請求項4から6のいずれかに記載の積層光学体。
- 前記位相差フィルムの面内位相差値Re1[590]が100nm以下であり、厚み方向の位相差値Rth1[590]が50nm~200nmである、請求項10に記載の積層光学体。
- 長尺状の第2の位相差フィルムをさらに備え、該第2の位相差フィルムの面内位相差値Re2[590]が100nm未満であり、厚み方向の位相差値Rth2[590]が200nm未満である、請求項10または11に記載の積層光学体。
- 前記位相差フィルムと前記第2の位相差フィルムの面内位相差値の合計Re1+2[590]が10nm以上200nm未満であり、厚み方向の位相差値の合計Rth1+2[590]が50nm~300nmである、請求項12に記載の積層光学体。
- 長尺状の基材に親水性高分子を含む組成物を塗布して薄膜を形成すること、
該薄膜を該基材と一緒に延伸すること、
該延伸された薄膜を染色して、基材層と親水性高分子層とを含む長尺状の偏光フィルムを得ること、および
該偏光フィルムと長尺状の位相差フィルムとを、長手方向を揃えて連続的に貼り合わせること
を含む、長尺状の積層光学体の製造方法。 - 前記薄膜を前記基材と一緒に短手方向に延伸する、請求項14に記載の方法。
- 請求項1から13のいずれかに記載の積層光学体を裁断または打ち抜いて得られる、光学フィルム。
- 請求項16に記載の光学フィルムと液晶セルとを備える、液晶表示装置。
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Also Published As
Publication number | Publication date |
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US20120003400A1 (en) | 2012-01-05 |
KR20110113747A (ko) | 2011-10-18 |
TW201038983A (en) | 2010-11-01 |
EP2397874A4 (en) | 2012-07-18 |
KR101319664B1 (ko) | 2013-10-17 |
EP2397874A1 (en) | 2011-12-21 |
CN102317821A (zh) | 2012-01-11 |
JPWO2010092926A1 (ja) | 2012-08-16 |
TWI485445B (zh) | 2015-05-21 |
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