WO2011045991A1 - 光学フィルム - Google Patents
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- WO2011045991A1 WO2011045991A1 PCT/JP2010/065291 JP2010065291W WO2011045991A1 WO 2011045991 A1 WO2011045991 A1 WO 2011045991A1 JP 2010065291 W JP2010065291 W JP 2010065291W WO 2011045991 A1 WO2011045991 A1 WO 2011045991A1
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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
- G02B5/3083—Birefringent or phase retarding elements
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
- C08L1/08—Cellulose derivatives
- C08L1/10—Esters of organic acids, i.e. acylates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
- C08L1/08—Cellulose derivatives
- C08L1/10—Esters of organic acids, i.e. acylates
- C08L1/14—Mixed esters, e.g. cellulose acetate-butyrate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L33/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
- C08L33/04—Homopolymers or copolymers of esters
- C08L33/06—Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
- C08L33/08—Homopolymers or copolymers of acrylic acid esters
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
- C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
- C08F220/10—Esters
- C08F220/12—Esters of monohydric alcohols or phenols
- C08F220/14—Methyl esters, e.g. methyl (meth)acrylate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2301/00—Characterised by the use of cellulose, modified cellulose or cellulose derivatives
- C08J2301/08—Cellulose derivatives
- C08J2301/10—Esters of organic acids
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2333/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
- C08J2333/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters
- C08J2333/06—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2333/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers
- C08J2333/04—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters
- C08J2333/06—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Derivatives of such polymers esters of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C08J2333/10—Homopolymers or copolymers of methacrylic acid esters
- C08J2333/12—Homopolymers or copolymers of methyl methacrylate
Definitions
- the present invention relates to an optical film used for a liquid crystal display device or the like.
- PMMA Polymethyl methacrylate
- the PMMA film has poor heat resistance and has a problem that its shape changes when used at high temperatures or for long-term use.
- This problem was an important issue not only as a physical property of a single film but also in a polarizing plate and a display device using such a film. That is, in the liquid crystal display device, because the polarizing plate curls with the deformation of the film, the entire panel is warped, and the design phase difference changes even when used at the position on the viewing side surface. There has been a problem that the viewing angle fluctuates or the color changes.
- Patent Document 1 proposes a method of adding polycarbonate (hereinafter abbreviated as PC) to an acrylic resin in order to improve heat resistance.
- PC polycarbonate
- solvent there is a limit to the solvent that can be used, and the compatibility between resins is insufficient. Therefore, it is easy to become cloudy and use as an optical film is difficult.
- PMMA film is originally inferior in brittleness and has the property of being easily broken during production and use.
- Patent Document 2 In order to improve both heat resistance and brittleness simultaneously, a method of blending a cellulose ester resin with a specific acrylic resin has been proposed.
- Patent Document 2 Even in this method, when a thin film having a film thickness of 40 ⁇ m is manufactured, when the film is peeled off from the peeling roll, the film strength is weak and the film extends in the conveying direction. Since the force required for peeling is not uniform, when the film is stretched in the subsequent process, the retardation value is uneven (variation) and the optical slow axis direction (orientation angle) is largely misaligned. There was a problem caused by the lack.
- An object of the present invention is to improve retardation unevenness and misalignment of an orientation angle in a thin film optical film caused by inferior heat resistance and brittleness peculiar to an acrylic resin.
- the object of the present invention has been achieved by the following constitution.
- An optical film comprising an acrylic resin (A) having a weight average molecular weight Mw of 70,000 to less than 1,000,000, an acrylic resin (B) having a weight average molecular weight of 1,000,000 to 10,000,000, and a cellulose ester resin (C).
- a thin acrylic resin film having high heat resistance and improved brittleness can be provided.
- the optical film of the present invention contains an acrylic resin (A) having a weight average molecular weight Mw of 70,000 to less than 1,000,000, an acrylic resin (B) having a weight average molecular weight of Mw of 100 to 10,000,000, and a cellulose ester resin (C). And ⁇ Acrylic resin (A) having a weight average molecular weight Mw of 70,000 or more and less than 1,000,000>
- the acrylic resin (A) used in the present invention includes a methacrylic resin.
- the resin is not particularly limited, but a resin comprising 50 to 99% by mass of methyl methacrylate units and 1 to 50% by mass of other monomer units copolymerizable therewith is preferable.
- Examples of other copolymerizable monomers include alkyl methacrylates having 2 to 18 alkyl carbon atoms, alkyl acrylates having 1 to 18 carbon atoms, alkyl acrylates such as acrylic acid and methacrylic acid.
- Examples thereof include unsaturated nitrile, maleic anhydride, maleimide, N-substituted maleimide, and glutaric anhydride, and these can be used alone or in combination of two or more.
- methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, s-butyl acrylate, 2-ethylhexyl acrylate, and the like are preferable from the viewpoint of thermal decomposition resistance and fluidity of the copolymer.
- n-Butyl acrylate is particularly preferably used.
- the acrylic resin (A) used in the optical film of the present invention preferably has a weight average molecular weight (Mw) of 100,000 or more and less than 1,000,000 from the viewpoint of mechanical strength as a film and fluidity when producing the film.
- Mw weight average molecular weight
- the weight average molecular weight of the acrylic resin (A) of the present invention can be measured by gel permeation chromatography.
- the measurement conditions are as follows.
- the production method of the acrylic resin (A) in the present invention is not particularly limited, and any known method such as suspension polymerization, emulsion polymerization, bulk polymerization, or solution polymerization may be used.
- a polymerization initiator a normal peroxide type and an azo type can be used, and a redox type can also be used.
- the polymerization temperature may be 30 to 100 ° C. for suspension or emulsion polymerization, and 80 to 160 ° C. for bulk or solution polymerization. Furthermore, in order to control the reduced viscosity of the produced copolymer, polymerization can be carried out using alkyl mercaptan or the like as a chain transfer agent.
- a commercially available thing can be used as an acrylic resin (A) of this invention.
- the acrylic resin (B) of the present invention has a monomer composition similar to that of the acrylic resin (A) of the present invention and has a large weight average molecular weight.
- the acrylic resin (B) of the present invention can be produced by a known method, and commercially available products can also be used.
- the difference in weight average molecular weight between the acrylic resins (A) and (B) is 100,000 or more and 9 million or less, and preferably 500,000 or more and 5 million or less.
- ⁇ Cellulose ester resin (C)> The cellulose ester resin (C) of the present invention may be substituted with either an aliphatic acyl group or an aromatic acyl group, but is preferably substituted with an acetyl group.
- the aliphatic acyl group has 2 to 20 carbon atoms, specifically acetyl, propionyl, butyryl, isobutyryl, valeryl, pivaloyl, hexanoyl, Examples include octanoyl, lauroyl, stearoyl and the like.
- the aliphatic acyl group is meant to include those further having a substituent.
- the aromatic ring is a benzene ring in the above-described aromatic acyl group
- the substituent of the benzene ring are exemplified.
- the number of substituents X substituted on the aromatic ring is 0 or 1 to 5, preferably 1 to 3, and particularly preferably One or two.
- substituents substituted on the aromatic ring may be the same or different from each other, but they may be linked together to form a condensed polycyclic compound (eg, naphthalene, indene, indane, phenanthrene, quinoline) , Isoquinoline, chromene, chroman, phthalazine, acridine, indole, indoline, etc.).
- a condensed polycyclic compound eg, naphthalene, indene, indane, phenanthrene, quinoline
- Isoquinoline chromene, chroman, phthalazine, acridine, indole, indoline, etc.
- the cellulose ester resin has a structure having a structure selected from at least one of a substituted or unsubstituted aliphatic acyl group and a substituted or unsubstituted aromatic acyl group. Used, these may be single or mixed acid esters of cellulose.
- the degree of substitution of the cellulose ester resin of the present invention is such that the total acyl group substitution degree (T) is 2.00 to 3.00, of which the acetyl group substitution degree (ac) is 0 to 2.50. More preferably, the acyl group substitution degree (r) other than the acetyl group is 1.50 to 2.90.
- the acyl group other than the acetyl group preferably has 3 to 7 carbon atoms.
- cellulose ester resin of the present invention those having an acyl group having 2 to 7 carbon atoms as a substituent, that is, cellulose acetate, cellulose propionate, cellulose butyrate, cellulose acetate propionate, cellulose acetate butyrate, cellulose acetate It is preferably at least one selected from benzoate and cellulose benzoate.
- particularly preferable cellulose ester resins include cellulose acetate, cellulose propionate, cellulose butyrate, cellulose acetate propionate, and cellulose acetate butyrate.
- the mixed fatty acid is a lower fatty acid ester of cellulose acetate propionate or cellulose acetate butyrate having an acyl group having 2 to 4 carbon atoms as a substituent.
- the portion not substituted with an acyl group usually exists as a hydroxyl group. These can be synthesized by known methods.
- substitution degree of the acetyl group and the substitution degree of other acyl groups were determined by the method prescribed in ASTM-D817-96.
- the object of the present invention can be achieved even if the weight average molecular weight is about 1000000, but considering productivity, it is 75000 to 280000. Those of 100,000 to 240,000 are more preferred.
- the optical film does not cause ductile fracture in the present invention.
- the ductile fracture is caused by applying a stress larger than the strength of a certain material, and is defined as a fracture accompanied by significant elongation or drawing of the material before the final fracture.
- the fracture surface is characterized by numerous indentations called dimples.
- an optical film that does not cause ductile fracture is characterized in that fracture such as fracture is not observed even when a large stress is applied such that the film is folded in two.
- the demand for the brittleness of optical films is increasing from the viewpoint of reworkability and productivity as optical films become larger and thinner with the recent increase in liquid crystal display devices, and the above ductile fracture does not occur. Is required.
- optical film that does not cause ductile fracture can be achieved by selecting the material configuration of the acrylic resin, cellulose ester, and other additives used as described above.
- the optical film of the present invention has a tension softening point of 105 ° C. or lower when considering use in a high-temperature environment such as a projector having a high haze and a high temperature such as a projector or a vehicle-mounted display device.
- the temperature is preferably 145 ° C, and more preferably controlled at 110 ° C to 130 ° C.
- the tension softening point temperature of the optical film for example, a Tensilon tester (ORIENTEC Co., RTC-1225A) is used, and the optical film is cut out by 120 mm (length) ⁇ 10 mm (width).
- the temperature can be increased at a rate of temperature increase of 30 ° C./min while pulling with a tension of 30 ° C., and the temperature at 9 N is measured three times, and the average value can be obtained.
- the optical film of the present invention preferably has a glass transition temperature (Tg) of 110 ° C. or higher. More preferably, it is 120 ° C. or higher. Especially preferably, it is 150 degreeC or more.
- Tg glass transition temperature
- the glass transition temperature referred to here is an intermediate value determined according to JIS K7121 (1987) using a differential scanning calorimeter (DSC-7 model manufactured by Perkin Elmer) at a heating rate of 20 ° C./min. Point glass transition temperature (Tmg).
- the optical film of the present invention has a defect with a diameter of 5 ⁇ m or more in the film plane of 1 piece / 10 cm square or less. More preferably, it is 0.5 piece / 10 cm square or less, more preferably 0.1 piece / 10 cm square or less.
- the diameter of the defect indicates the diameter when the defect is circular, and when it is not circular, the range of the defect is determined by observing with a microscope according to the following method, and the maximum diameter (diameter of circumscribed circle) is determined.
- the range of the defect is the size of the shadow when the defect is observed with the transmitted light of the differential interference microscope when the defect is a bubble or a foreign object. If the defect is a change in surface shape, such as transfer of a roll flaw or an abrasion, the size is confirmed by observing the defect with the reflected light of a differential interference microscope.
- the film breaks with the defect as a starting point, and the productivity may be significantly reduced.
- the diameter of a defect becomes 5 micrometers or more, it can confirm visually by polarizing plate observation etc., and when used as an optical member, a bright spot may arise.
- the coating agent may not be formed uniformly, resulting in defects (coating defects).
- the defect is a void in the film (foaming defect) generated due to the rapid evaporation of the solvent in the drying process of the solution casting, a foreign matter in the film forming stock solution, or a foreign matter mixed in the film forming. This refers to the foreign matter (foreign matter defect) in the film.
- the optical film of the present invention preferably has a breaking elongation in at least one direction of 10% or more, more preferably 20% or more in the measurement based on JIS-K7127-1999.
- the upper limit of the elongation at break is not particularly limited, but is practically about 250%. In order to increase the elongation at break, it is effective to suppress defects in the film caused by foreign matter and foaming.
- the thickness of the optical film of the present invention is preferably 20 ⁇ m or more. More preferably, it is 30 ⁇ m or more.
- the upper limit of the thickness is not particularly limited, but in the case of forming a film by a solution casting method, the upper limit is about 250 ⁇ m from the viewpoint of applicability, foaming, solvent drying and the like.
- the thickness of the film can be appropriately selected depending on the application.
- the optical film of the present invention preferably has a total light transmittance of 90% or more, more preferably 93% or more. Moreover, as a realistic upper limit, it is about 99%. In order to achieve such excellent transparency expressed by the total light transmittance, it is necessary not to introduce an additive or a copolymer component that absorbs visible light, or to accurately filter foreign substances in the polymer. It is effective to reduce the diffusion and absorption of light inside the film.
- the optical film of the present invention is characterized in that the haze value (turbidity), which is one of the indices indicating transparency, is 1.0% or less.
- the luminance and contrast when incorporated in a liquid crystal display device are characteristic. From the point, it is preferably 0.5% or less.
- the total light transmittance and haze value of the optical film are values measured according to JIS-K7361-1-1997 and JIS-K7136-2000.
- the optical film of the present invention can be preferably used as an optical film as long as the above physical properties are satisfied, but a film excellent in workability and heat resistance can be obtained by using the following composition. be able to.
- the optical film contains acrylic resin (A), (B) and cellulose ester resin in a mass ratio of 95: 5 to 30:70, and the cellulose ester resin (C)
- the acyl group has a total substitution degree (T) of 2.00 to 3.00, an acetyl group substitution degree (ac) of 0 to 2.50, and the acyl group other than the acetyl group has 3 to 7 carbon atoms.
- the weight average molecular weight (Mw) is preferably 75,000 to 280000.
- the acrylic resin component When the acrylic resin component is increased, for example, the dimensional change under high temperature and high humidity is suppressed, and curling of the polarizing plate and warping of the panel when used as a polarizing plate can be remarkably reduced. Furthermore, in the composition in which the acrylic resin component is more than half, the above physical properties can be maintained for a longer time.
- the acrylic resin (A) and the cellulose ester resin (C) are preferably mixed at a mass ratio of 95: 5 to 30:70.
- the total amount of the acrylic resin (A) and the cellulose ester resin (C) is an acrylic resin. With respect to (B), it is preferably 99: 1 to 80:20.
- the optical film of the present invention may contain a resin other than acrylic resins (A), (B) and cellulose ester resin (C).
- the total mass of the acrylic resins (A) and (B) and the cellulose ester resin (C) is 55 to 100% by mass, preferably 60 to 99% by mass of the optical film.
- the retardation control agent (D) can be added to the optical film.
- the retardation control agent (D) compounds described in JP-A No. 2002-296421 and various ester plasticizers can be used. Hereinafter, preferred ester compounds will be described in detail.
- a compound having a structure in which aromatic rings are arranged in a plane when added as an additive and stretched is preferable.
- a compound having an aromatic ring as a block in the main chain or at the end is preferable.
- the polyester polyol used in the present invention includes a dehydration condensation reaction between a glycol having an average carbon number of 2 to 3.5 and a dibasic acid having an average carbon number of 4 to 5.5, or the glycol. It is preferably one produced by a conventional method by addition of a dibasic anhydride having an average carbon number of 4 to 5.5 and a dehydration condensation reaction.
- glycol used in the polyester polyol examples include ethylene glycol, diethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 2-methyl-1,3-propanediol, 1,4-butylene glycol, and neopentyl.
- ethylene glycol or a mixture of ethylene glycol and diethylene glycol Is particularly preferably used.
- the average carbon number of the glycol is preferably in the range of 2 to 3.5 from the viewpoint of production of polyester polyol, compatibility with cellulose, transparency, and the like.
- the ethylene glycol / diethylene glycol molar ratio is preferably 25 to 100/75 to 0, and for cellulose esters having excellent compatibility with cellulose esters.
- a modifier can be obtained. Further, it is more preferably 25 to 40/75 to 60, and 60 to 95/40 to 5, and by adjusting to such a range, the crystallinity and melting point of the polyester polyol are close to conventional ones, Productivity is also improved.
- examples of the dibasic acid constituting the polyester polyol used in the present invention include succinic acid, glutaric acid, adipic acid, and sebacic acid.
- succinic acid or a mixture of succinic acid and terephthalic acid is particularly preferably used.
- the average number of carbon atoms of the dibasic acid is preferably in the range of 4 to 5.5 from the viewpoint of production of polyester polyol, compatibility with cellulose, transparency, and the like. .
- the succinic acid / terephthalic acid molar ratio is preferably 25 to 100/75 to 0, and has excellent compatibility with the cellulose ester.
- a cellulose ester modifier can be obtained.
- the crystallinity and melting point of the polyester polyol are close to conventional ones, Productivity is also improved.
- the glycol and dibasic acid constituting the polyester polyol used in the present invention include combinations other than the above, but the total of the average number of carbon atoms of the glycol and the average number of carbon atoms of the dibasic acid is 6-7. A combination of .5 is preferred.
- the polyester polyol obtained from the glycol and the dibasic acid may have a number average molecular weight in the range of 1,000 to 200,000, more preferably a polyester having a hydroxyl group (hydroxyl group) terminal of 1000 to 5000, Those having a number average molecular weight of 1200 to 4000 are particularly preferably used.
- a phase difference control agent (a modifier for cellulose ester) excellent in compatibility with the cellulose ester can be obtained by a solid phase reaction.
- the polyester polyol having a number average molecular weight of 1000 or more is contained in the film in an amount of 2 to 30% by mass. More preferably, it is 10 to 20% by mass.
- the content of the polymer in the film depends on the type of polymer and the weight average molecular weight, and the performance such as dimensional stability, retentivity, and transmittance is within the range in which dope, web, and phase separation do not occur after film formation. It is decided accordingly.
- the content of the carboxyl group terminal in the polyester polyol used in the present invention is preferably 1/20 or less of the hydroxyl group (hydroxyl group) terminal from the viewpoint of the effect of the present invention. Furthermore, it is more preferable to stop at 1/40 or less.
- esterification catalysts such as metal organic acid salts or metal chelate compounds such as titanium, zinc, lead and zirconium, or antimony oxide can be used.
- esterification catalyst for example, tetraisopropyl titanate, tetrabutyl titanate and the like are preferably used, and 0.0005 to 0.005 per 100 parts by mass in total of glycol (a) and dibasic acid (b) used. 02 parts by weight are preferably used.
- Polyester polyol polycondensation is carried out by conventional methods.
- a direct reaction of the above dibasic acid and glycol, the above dibasic acid or an alkyl ester thereof for example, a polyesterification reaction or transesterification reaction between a dibasic acid methyl ester and a glycol, or a hot melt condensation method
- a direct reaction for example, a polyesterification reaction or transesterification reaction between a dibasic acid methyl ester and a glycol, or a hot melt condensation method
- it can be easily synthesized by any method of dehydrohalogenation reaction between acid chlorides of these acids and glycols, but polyester polyols whose number average molecular weight is not so large are preferably by direct reaction.
- the polyester polyol having a high distribution on the low molecular weight side has a very good compatibility with the cellulose ester, and after forming the film, a moisture permeability is small and a cellulose ester film having a high transparency can be obtained.
- the conventional method can be used as the molecular weight adjustment method without any particular limitation.
- the amount of these monovalent compounds can be controlled by a method of blocking the molecular ends with a monovalent acid or monovalent alcohol.
- a monovalent acid is preferable from the viewpoint of polymer stability.
- acetic acid, propionic acid, butyric acid, pivalic acid, benzoic acid and the like can be mentioned, but during the polycondensation reaction, such monovalent acid is not removed from the system but stopped and removed from the reaction system. Those which are easy to be distilled off when being removed from the system are selected, but these may be mixed and used.
- the number average molecular weight can also be adjusted by measuring the timing of stopping the reaction according to the amount of water distilled off during the reaction. In addition, it can be adjusted by biasing the number of moles of glycol or dibasic acid to be charged or by controlling the reaction temperature.
- Aromaatic terminal ester plasticizer As the phase difference controlling agent according to the present invention, an aromatic terminal ester plasticizer represented by the following general formula (I) can be used.
- B is a benzene monocarboxylic acid residue
- G is an alkylene glycol residue having 2 to 12 carbon atoms, an aryl glycol residue having 6 to 12 carbon atoms, or an oxyalkylene glycol residue having 4 to 12 carbon atoms
- A represents an alkylene dicarboxylic acid residue having 4 to 12 carbon atoms or an aryl dicarboxylic acid residue having 6 to 12 carbon atoms
- n represents an integer of 1 or more.
- benzene monocarboxylic acid component of the aromatic terminal ester plasticizer for example, benzoic acid, para-tert-butylbenzoic acid, orthotoluic acid, metatoluic acid, p-toluic acid, dimethylbenzoic acid, ethylbenzoic acid, normal propylbenzoic acid, There are aminobenzoic acid, acetoxybenzoic acid and the like, and these can be used as one kind or a mixture of two or more kinds, respectively.
- alkylene glycol component having 2 to 12 carbon atoms of the aromatic terminal ester plasticizer examples include ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,2-butanediol, and 1,3-butanediol.
- Examples of the oxyalkylene glycol component having 4 to 12 carbon atoms of the aromatic terminal ester include diethylene glycol, triethylene glycol, tetraethylene glycol, dipropylene glycol, tripropylene glycol, and the like. Or it can be used as a mixture of two or more.
- aryl glycol component having 6 to 12 carbon atoms of the aromatic terminal ester examples include hydroquinone, resorcin, bisphenol A, bisphenol F, and bisphenol. These glycols are used as one kind or a mixture of two or more kinds. Can be used.
- alkylene dicarboxylic acid component having 4 to 12 carbon atoms of the aromatic terminal ester examples include succinic acid, maleic acid, fumaric acid, glutaric acid, adipic acid, azelaic acid, sebacic acid, and dodecanedicarboxylic acid. These are used as one kind or a mixture of two or more kinds.
- aryl dicarboxylic acid component having 6 to 12 carbon atoms examples include phthalic acid, terephthalic acid, 1,5 naphthalenedicarboxylic acid, 1,4 naphthalenedicarboxylic acid and the like.
- the number average molecular weight of the aromatic terminal ester plasticizer is preferably 300 to 2000, and more preferably 500 to 1500.
- the acid value is 0.5 mgKOH / g or less, the hydroxyl group (hydroxyl group) value is 25 mgKOH / g or less, more preferably the acid value is 0.3 mgKOH / g or less, and the hydroxyl group (hydroxyl group) value is 15 mgKOH / g or less. Those are preferred.
- Acid value refers to the number of milligrams of potassium hydroxide necessary to neutralize the acid (carboxyl group present at the molecular terminal) contained in 1 g of a sample.
- the acid value and the hydroxyl group (hydroxyl group) value are measured in accordance with JIS K0070.
- the content of the aromatic terminal ester plasticizer is preferably 1 to 20% by mass, more preferably 3 to 11% by mass in the cellulose ester film.
- a polyhydric alcohol ester plasticizer can be further used as the retardation control agent.
- the polyhydric alcohol ester used in the present invention is preferably an ester of a divalent or higher aliphatic polyhydric alcohol and a monocarboxylic acid, and preferably has an aromatic ring or a cycloalkyl ring in the molecule.
- the polyhydric alcohol used in the present invention is represented by the following general formula (1).
- R1- (OH) n represents an n-valent organic group
- n represents a positive integer of 2 or more
- the OH group represents an alcoholic or phenolic hydroxyl group (hydroxyl group).
- Examples of preferable polyhydric alcohols include the following.
- triethylene glycol triethylene glycol
- tetraethylene glycol dipropylene glycol
- tripropylene glycol tripropylene glycol
- sorbitol trimethylolpropane
- xylitol trimethylolpropane
- monocarboxylic acid used for polyhydric alcohol ester there is no restriction
- alicyclic monocarboxylic acid or aromatic monocarboxylic acid is preferable in terms of improving moisture permeability and retention.
- preferred monocarboxylic acids include the following, but the present invention is not limited thereto.
- aliphatic monocarboxylic acid a fatty acid having a straight chain or a side chain having 1 to 32 carbon atoms can be preferably used.
- acetic acid More preferably, it has 1 to 20 carbon atoms, and particularly preferably 1 to 10 carbon atoms.
- the use of acetic acid is preferred because the compatibility with the cellulose ester increases, and it is also preferred to use a mixture of acetic acid and another monocarboxylic acid.
- Preferred aliphatic monocarboxylic acids include acetic acid, propionic acid, butyric acid, valeric acid, caproic acid, enanthic acid, caprylic acid, pelargonic acid, capric acid, 2-ethyl-hexanecarboxylic acid, undecylic acid, lauric acid, tridecylic acid , Saturated fatty acids such as myristic acid, pentadecylic acid, palmitic acid, heptadecylic acid, stearic acid, nonadecanoic acid, arachidic acid, behenic acid, lignoceric acid, serotic acid, heptacosanoic acid, montanic acid, melicic acid, laccelic acid, undecylenic acid, Examples thereof include unsaturated fatty acids such as oleic acid, sorbic acid, linoleic acid, linolenic acid and arachidonic acid.
- Examples of preferred alicyclic monocarboxylic acids include cyclopentane carboxylic acid, cyclohexane carboxylic acid, cyclooctane carboxylic acid, and derivatives thereof.
- aromatic monocarboxylic acids examples include those in which an alkyl group is introduced into the benzene ring of benzoic acid such as benzoic acid and toluic acid, and two or more benzene rings such as biphenyl carboxylic acid, naphthalene carboxylic acid, and tetralin carboxylic acid.
- benzoic acid which has, or derivatives thereof can be mentioned.
- benzoic acid is preferred.
- the molecular weight of the polyhydric alcohol ester is not particularly limited, but is preferably in the range of 300 to 1500, and more preferably in the range of 350 to 750.
- a larger molecular weight is preferable because it is less likely to evaporate, and a smaller one is preferable in terms of moisture permeability and compatibility with cellulose ester.
- the carboxylic acid used for the polyhydric alcohol ester may be one kind or a mixture of two or more kinds. Moreover, all the OH groups in the polyhydric alcohol may be esterified, or a part of the OH groups may be left as they are.
- the retardation control agent is preferably an optical film containing a saccharide ester compound obtained by esterifying a hydroxyl group (hydroxyl group) of a saccharide compound in which 1 to 12 at least one structure selected from a furanose structure and a pyranose structure is bonded. .
- sugar compound examples include glucose, galactose, mannose, fructose, xylose, arabinose, lactose, sucrose, cellobiose, cellotriose, maltotriose, and raffinose, and those having both a furanose structure and a pyranose structure are particularly preferable.
- the ester compound is a monosaccharide ( ⁇ -glucose, ⁇ -fructose) benzoate, or a monosaccharide represented by the following general formula (A): —OR 12 , —OR 15 , —OR 22 , —OR 25
- the sugar ester compound is a compound in which part or all of the hydroxyl group (hydroxyl group) of the sugar compound is esterified or a mixture thereof.
- the benzoic acid in the above general formula may further have a substituent, for example, an alkyl group, an alkenyl group, an alkoxyl group, and a phenyl group, and these alkyl group, alkenyl group, and phenyl group have a substituent. You may have.
- the optical film according to the present invention preferably contains 1 to 30% by mass of the sugar ester compound based on the total amount of the resin constituting the optical film in order to suppress the fluctuation of the retardation value and stabilize the display quality.
- the sugar ester compound is commercially available as Monopet SB (Daiichi Kogyo Seiyaku Co., Ltd.).
- phase difference controlling agent those containing bisphenol A in the molecule are also preferred.
- a compound in which ethylene oxide or propylene oxide is added to both ends of bisphenol A can be used.
- BP series such as New Paul BP-2P, BP-3P, BP-23P, BP-5P, BPE-20 (F), BPE-20NK, BPE-20T, BPE-40, BPE-60, BPE-100
- BPE series manufactured by Sanyo Chemical Co., Ltd.
- BPX series manufactured by Adeka Co., Ltd.
- Adeka Polyether BPX-11, BPX-33, BPX-55 Adeka Polyether BPX-11, BPX-33, BPX-55.
- Diallyl bisphenol A dimethallyl bisphenol A, tetrabromobisphenol A in which bisphenol A is substituted with bromine, oligomers and polymers obtained by polymerizing this, bisphenol A bis (diphenyl phosphate) substituted with diphenyl phosphate, etc. Can be used.
- Polycarbonate obtained by polymerizing bisphenol A polyarylate obtained by polymerizing bisphenol A with a dibasic acid such as terephthalic acid, and an epoxy oligomer or polymer polymerized with an epoxy-containing monomer can also be used.
- Modiper CL130D or L440-G obtained by graft polymerization of bisphenol A and styrene or styrene acrylic can also be used.
- the optical film according to the present invention may contain two or more retardation control agents. In this case, by optimizing the combination, elution of the phase difference controlling agent can be reduced.
- the optical film may contain acrylic particles (E).
- the acrylic particles (E) of the present invention are characterized by being present in the state of particles in the optical film with the acrylic resins (A) and (B) and the cellulose ester resin (C) (also referred to as incompatible state). is there.
- the acrylic particles (E) are obtained, for example, by collecting a predetermined amount of the produced optical film, dissolving in a solvent, stirring, and sufficiently dissolving / dispersing, so that the pore size is less than the average particle size of the acrylic particles (E). It is preferable that the weight of the insoluble matter filtered and collected using the PTFE membrane filter is 90% by mass or more of the acrylic particles (E) added to the optical film.
- the acrylic particles (E) used in the present invention are not particularly limited, but are preferably acrylic particles (E) having a layer structure of two or more layers, particularly the following multilayer structure acrylic granular composite. It is preferable.
- the multilayer structure acrylic granular composite is formed by laminating an innermost hard layer polymer, a cross-linked soft layer polymer exhibiting rubber elasticity, and an outermost hard layer polymer from the center to the outer periphery.
- Preferred embodiments of the multilayer structure acrylic granular composite used in the acrylic resin composition of the present invention include the following.
- A Monomer comprising 80 to 98.9% by weight of methyl methacrylate, 1 to 20% by weight of alkyl acrylate having 1 to 8 carbon atoms in the alkyl group, and 0.01 to 0.3% by weight of polyfunctional grafting agent
- B 75 to 98.5% by mass of an alkyl acrylate having 4 to 8 carbon atoms in the presence of the innermost hard layer polymer in the presence of the innermost hard layer polymer, A crosslinked soft layer polymer obtained by polymerizing a monomer mixture comprising 0.01 to 5% by mass of a multifunctional crosslinking agent and 0.5 to 5% by mass of a multifunctional grafting agent;
- the innermost hard In the presence of a polymer comprising a layer and a crosslinked soft layer, a monomer mixture comprising 80 to 99% by mass of methyl methacrylate and 1 to 20% by mass of alkyl acrylate having 1 to 8 carbon atoms in the alkyl group is polymerized.
- Outermost hard layer And the obtained three-layer structure polymer is 5 to 40% by mass of the innermost hard layer polymer (a), 30 to 60% by mass of the soft layer polymer (b), and The outermost hard layer polymer (c) comprising 20 to 50% by mass, having an insoluble part when fractionated with acetone, and an acrylic granular composite having a methyl ethyl ketone swelling degree of 1.5 to 4.0 at the insoluble part .
- the innermost hard layer polymer (a) constituting the multilayer structure acrylic granular composite is 80 to 98.9% by mass of methyl methacrylate and 1 to 20 mass of alkyl acrylate having 1 to 8 carbon atoms in the alkyl group. % And a monomer mixture consisting of 0.01 to 0.3% by mass of a polyfunctional grafting agent is preferred.
- examples of the alkyl acrylate having 1 to 8 carbon atoms in the alkyl group include methyl acrylate, ethyl acrylate, n-propyl acrylate, n-butyl acrylate, s-butyl acrylate, 2-ethylhexyl acrylate, and the like. And n-butyl acrylate are preferably used.
- the proportion of the alkyl acrylate unit in the innermost hard layer polymer (a) is 1 to 20% by mass.
- the thermal decomposability of the polymer is increased, while the unit is 20% by mass. If it exceeds 50%, the glass transition temperature of the innermost hard layer polymer (c) is lowered, and the impact resistance imparting effect of the three-layer structure acrylic granular composite is lowered.
- polyfunctional grafting agent examples include polyfunctional monomers having different polymerizable functional groups, such as allyl esters of acrylic acid, methacrylic acid, maleic acid, and fumaric acid, and allyl methacrylate is preferably used. .
- the polyfunctional grafting agent is used to chemically bond the innermost hard layer polymer and the soft layer polymer, and the ratio used during the innermost hard layer polymerization is 0.01 to 0.3% by mass. .
- the crosslinked soft layer polymer (b) constituting the acrylic granular composite is an alkyl acrylate having from 9 to 8 carbon atoms having an alkyl group of 1 to 8 in the presence of the innermost hard layer polymer (a). What is obtained by polymerizing a monomer mixture consisting of 10% by mass, 0.01 to 5% by mass of a multifunctional crosslinking agent and 0.5 to 5% by mass of a multifunctional grafting agent is preferred.
- n-butyl acrylate or 2-ethylhexyl acrylate is preferably used as the alkyl acrylate having 4 to 8 carbon atoms in the alkyl group.
- Examples of other monofunctional monomers that can be copolymerized include styrene and substituted styrene derivatives. As the ratio of the alkyl acrylate having 4 to 8 carbon atoms in the alkyl group and styrene increases, the glass transition temperature of the produced polymer (b) decreases as the former increases, that is, it can be softened.
- the refractive index of the soft layer polymer (b) at room temperature is set to the innermost hard layer polymer (a), the outermost hard layer polymer (c), and the hard heat. It is more advantageous to make it closer to the plastic acrylic resin, and the ratio between them is selected in consideration of these.
- polyfunctional grafting agent those mentioned in the section of the innermost layer hard polymer (a) can be used.
- the polyfunctional grafting agent used here is used to chemically bond the soft layer polymer (b) and the outermost hard layer polymer (c), and the proportion used during the innermost hard layer polymerization is impact resistance. From the viewpoint of the effect of imparting properties, 0.5 to 5% by mass is preferable.
- polyfunctional crosslinking agent generally known crosslinking agents such as divinyl compounds, diallyl compounds, diacrylic compounds, dimethacrylic compounds and the like can be used, but polyethylene glycol diacrylate (molecular weight 200 to 600) is preferably used.
- the polyfunctional cross-linking agent used here is used to generate a cross-linked structure during the polymerization of the soft layer (b) and to exhibit the effect of imparting impact resistance.
- the polyfunctional crosslinking agent is not an essential component because the crosslinked structure of the soft layer (b) is generated to some extent. Is preferably 0.01 to 5% by weight from the viewpoint of imparting impact resistance.
- the outermost hard layer polymer (c) constituting the multi-layer structure acrylic granular composite has a methyl methacrylate of 80 to 99 mass in the presence of the innermost hard layer polymer (a) and the soft layer polymer (b). % And a monomer mixture comprising 1 to 20% by mass of an alkyl acrylate having 1 to 8 carbon atoms in the alkyl group is preferred.
- the acrylic alkylate those described above are used, but methyl acrylate and ethyl acrylate are preferably used.
- the proportion of the alkyl acrylate unit in the outermost hard layer (c) is preferably 1 to 20% by mass.
- an alkyl mercaptan or the like can be used as a chain transfer agent to adjust the molecular weight for the purpose of improving the compatibility with the acrylic resin (A).
- the outermost hard layer with a gradient such that the molecular weight gradually decreases from the inside toward the outside in order to improve the balance between elongation and impact resistance.
- the monomer mixture for forming the outermost hard layer is divided into two or more, and the molecular weight is increased from the inside by a method of sequentially increasing the amount of chain transfer agent added each time. It is possible to make it smaller toward the outside.
- the molecular weight formed at this time can also be examined by polymerizing the monomer mixture used each time under the same conditions, and measuring the molecular weight of the obtained polymer.
- the particle diameter of the acrylic granular composite which is a multilayer structure polymer preferably used in the present invention is not particularly limited, but is preferably 10 nm or more and 1000 nm or less, and more preferably 20 nm or more and 500 nm or less. More preferably, it is most preferably 50 nm or more and 400 nm or less.
- the mass ratio of the core and the shell is not particularly limited, but when the entire multilayer structure polymer is 100 parts by mass,
- the core layer is preferably 50 parts by mass or more and 90 parts by mass or less, and more preferably 60 parts by mass or more and 80 parts by mass or less.
- Examples of such commercially available multilayered acrylic granular composites include, for example, “Metablene” manufactured by Mitsubishi Rayon Co., “Kane Ace” manufactured by Kaneka Chemical Co., Ltd., “Paralloid” manufactured by Kureha Chemical Co., Ltd., Rohm and Haas “Acryloid” manufactured by KK, “Staffyroid” manufactured by Ganz Kasei Kogyo Co., Ltd., “Parapet SA” manufactured by Kuraray Co., Ltd., and the like can be used alone or in combination of two or more.
- acrylic particles (E-1) which are graft copolymers preferably used as the acrylic particles (E) preferably used in the present invention include unsaturated carboxylic acids in the presence of a rubbery polymer.
- a monomer mixture comprising an acid ester monomer, an unsaturated carboxylic acid monomer, an aromatic vinyl monomer, and, if necessary, other vinyl monomers copolymerizable therewith A polymerized graft copolymer may be mentioned.
- the rubbery polymer used for the acrylic particles (E-1) which are graft copolymers is not particularly limited, but diene rubber, acrylic rubber, ethylene rubber, and the like can be used. Specific examples include polybutadiene, styrene-butadiene copolymer, block copolymer of styrene-butadiene, acrylonitrile-butadiene copolymer, butyl acrylate-butadiene copolymer, polyisoprene, butadiene-methyl methacrylate copolymer.
- the refractive indexes of the acrylic resins (A), (B) and the acrylic particles (E) are approximate because the transparency of the optical film of the present invention can be obtained.
- the refractive index difference between the acrylic particles (E) and the acrylic resins (A) and (B) is preferably 0.05 or less, more preferably 0.02 or less, especially 0.01 or less. It is preferable.
- the refractive index difference can be reduced by a method of adjusting the composition ratio of monomers, and an optical film excellent in transparency can be obtained.
- the difference in refractive index referred to here is a solution in which the optical film of the present invention is sufficiently dissolved in a solvent in which the acrylic resins (A) and (B) are soluble under suitable conditions, and this is centrifuged. By separating the solvent-soluble part and the insoluble part by the above operation, and purifying the soluble part (acrylic resins (A) and (B)) and the insoluble part (acrylic particles (E)), respectively, the measured refractive index was measured. The difference of (23 degreeC, measurement wavelength: 550nm) is shown.
- the method of blending the acrylic particles (E) with the acrylic resins (A) and (B) is not particularly limited, and after the acrylic resins (A) and (B) and other optional components are previously blended.
- a method of uniformly kneading at 200 to 350 ° C. with a single screw or twin screw extruder while adding acrylic particles (E) is preferably used.
- acrylic particles (E) are dispersed in advance is added to and mixed with a solution (dope solution) in which acrylic resins (A), (B) and cellulose ester resin (C) are dissolved, and acrylic particles (
- a method such as in-line addition of a solution obtained by dissolving and mixing E) and other optional additives can be used.
- acrylic particles can also be used as the acrylic particles of the present invention.
- metabrene W-341 (manufactured by Mitsubishi Rayon Co., Ltd.)
- Chemisnow MR-2G (E3)
- MS-300X (E4) (manufactured by Soken Chemical Co., Ltd.) and the like can be mentioned.
- the optical film of the present invention preferably contains 0.5 to 45% by mass of acrylic particles (E) based on the total mass of the resin constituting the film.
- a plasticizer can be used in combination in order to improve the fluidity and flexibility of the composition.
- the plasticizer include phthalate ester, fatty acid ester, trimellitic ester, phosphate ester, polyester, and epoxy.
- polyester-based and phthalate-based plasticizers are preferably used.
- Polyester plasticizers are superior in non-migration and extraction resistance compared to phthalate ester plasticizers such as dioctyl phthalate, but are slightly inferior in plasticizing effect and compatibility.
- the polyester plasticizer is a reaction product of a monovalent or tetravalent carboxylic acid and a monovalent or hexavalent alcohol, and is mainly obtained by reacting a divalent carboxylic acid with a glycol.
- Representative divalent carboxylic acids include glutaric acid, itaconic acid, adipic acid, phthalic acid, azelaic acid, sebacic acid and the like.
- glycol examples include glycols such as ethylene, propylene, 1,3-butylene, 1,4-butylene, 1,6-hexamethylene, neopentylene, diethylene, triethylene, and dipropylene. These divalent carboxylic acids and glycols may be used alone or in combination.
- the ester plasticizer may be any of ester, oligoester and polyester types, and the molecular weight is preferably in the range of 100 to 10000, but preferably in the range of 600 to 3000, the plasticizing effect is large.
- the viscosity of the plasticizer has a correlation with the molecular structure and molecular weight, but in the case of an adipic acid plasticizer, the range of 200 to 5000 mPa ⁇ s (25 ° C.) is preferable because of compatibility and plasticization efficiency. Furthermore, some polyester plasticizers may be used in combination.
- the plasticizer is preferably added in an amount of 0.5 to 30 parts by mass with respect to 100 parts by mass of the composition containing the acrylic resins (A) and (B).
- the composition containing the acrylic resins (A) and (B) of the present invention preferably contains an ultraviolet absorber, and examples of the ultraviolet absorber used include benzotriazole, 2-hydroxybenzophenone, and salicylic acid phenyl ester. And the like.
- 2- (5-methyl-2-hydroxyphenyl) benzotriazole 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2H-benzotriazole
- 2- (3 Triazoles such as 5-di-t-butyl-2-hydroxyphenyl) benzotriazole, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-octoxybenzophenone, 2,2′-dihydroxy-4-methoxybenzophenone And benzophenones.
- ultraviolet absorbers having a molecular weight of 400 or more are less likely to volatilize at a high boiling point and are difficult to disperse even during high-temperature molding, so that the weather resistance is effectively improved with a relatively small amount of addition. be able to.
- the transition from the thin coating layer to the substrate layer is particularly small and hardly precipitates on the surface of the laminate, the amount of contained UV absorber is maintained for a long time, and the durability of the weather resistance improvement effect is excellent. From the point of view, it is preferable.
- Examples of the ultraviolet absorber having a molecular weight of 400 or more include 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2-benzotriazole, 2,2-methylenebis [4- (1, 1,3,3-tetrabutyl) -6- (2H-benzotriazol-2-yl) phenol], bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, bis ( Hindered amines such as 1,2,2,6,6-pentamethyl-4-piperidyl) sebacate and 2- (3,5-di-t-butyl-4-hydroxybenzyl) -2-n-butylmalonic acid Bis (1,2,2,6,6-pentamethyl-4-piperidyl), 1- [2- [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionyloxy] Such as til] -4- [3- (3,5-di-tert-butyl
- 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2-benzotriazole and 2,2-methylenebis [4- (1,1,3,3- Tetrabutyl) -6- (2H-benzotriazol-2-yl) phenol] is particularly preferred.
- antioxidants may be added to the acrylic resins (A) and (B) used in the optical film of the present invention in order to improve the thermal decomposability and thermal colorability during molding. It is also possible to add an antistatic agent to give the optical film antistatic performance.
- a flame retardant acrylic resin composition containing a phosphorus flame retardant may be used.
- Phosphorus flame retardants used here include red phosphorus, triaryl phosphate ester, diaryl phosphate ester, monoaryl phosphate ester, aryl phosphonate compound, aryl phosphine oxide compound, condensed aryl phosphate ester, halogenated alkyl phosphorus. Examples thereof include one or a mixture of two or more selected from acid esters, halogen-containing condensed phosphates, halogen-containing condensed phosphonates, halogen-containing phosphites, and the like.
- triphenyl phosphate 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, phenylphosphonic acid, tris ( ⁇ -chloroethyl) phosphate, tris (dichloropropyl) Examples thereof include phosphate and tris (tribromoneopentyl) phosphate.
- a production method such as an inflation method, a T-die method, a calendar method, a cutting method, a casting method, an emulsion method, or a hot press method can be used. From the standpoint of suppressing optical defects such as die lines and optical defects such as die lines, solution casting by casting is preferred.
- Organic solvent useful for forming the dope when the optical film of the present invention is produced by the solution casting method is acrylic resin (A), (B), cellulose ester resin (C), and other additives at the same time. Any material that can be dissolved can be used without limitation.
- methylene chloride as a non-chlorinated organic solvent, methyl acetate, ethyl acetate, amyl acetate, acetone, tetrahydrofuran, 1,3-dioxolane, 1,4-dioxane, cyclohexanone, ethyl formate, 2,2,2-trifluoroethanol, 2,2,3,3-hexafluoro-1-propanol, 1,3-difluoro-2-propanol, 1,1,1,3,3,3-hexafluoro- 2-methyl-2-propanol, 1,1,1,3,3,3-hexafluoro-2-propanol, 2,2,3,3,3-pentafluoro-1-propanol, nitroethane, etc.
- Methylene chloride, methyl acetate, ethyl acetate and acetone can be preferably used.
- the dope preferably contains 1 to 40% by mass of a linear or branched aliphatic alcohol having 1 to 4 carbon atoms.
- a linear or branched aliphatic alcohol having 1 to 4 carbon atoms.
- a solvent containing methylene chloride and a linear or branched aliphatic alcohol having 1 to 4 carbon atoms is added to acrylic resins (A), (B), cellulose ester resin (C), acrylic particles (E 3) is preferably a dope composition in which at least 15 to 45 mass% in total is dissolved.
- linear or branched aliphatic alcohol having 1 to 4 carbon atoms examples include methanol, ethanol, n-propanol, iso-propanol, n-butanol, sec-butanol, and tert-butanol. Ethanol is preferred because of the stability of these dopes, the relatively low boiling point, and good drying properties.
- a method carried out at normal pressure a method carried out below the boiling point of the main solvent, a method carried out under pressure above the boiling point of the main solvent, Various methods such as a method using a cooling dissolution method as described in JP-A-9-95544, JP-A-9-95557, or JP-A-9-95538, a method using a high pressure as described in JP-A-11-21379, etc.
- a method of pressurizing at a temperature equal to or higher than the boiling point of the main solvent is preferable.
- the acrylic resins (A) and (B) and the cellulose ester resin (C) in the dope are preferably in the range of 15 to 45% by mass.
- An additive is added to the dope during or after dissolution to dissolve and disperse, then filtered through a filter medium, defoamed, and sent to the next step with a liquid feed pump.
- a filter medium having a collected particle diameter of 0.5 to 5 ⁇ m and a drainage time of 10 to 25 sec / 100 ml.
- agglomerates remaining at the time of particle dispersion and agglomerates generated upon addition of the main dope are only aggregated by using a filter medium having a collected particle diameter of 0.5 to 5 ⁇ m and a drainage time of 10 to 25 sec / 100 ml. Can be removed.
- the concentration of particles is sufficiently thinner than that of the additive solution, so that aggregates do not stick together at the time of filtration and the filtration pressure does not increase suddenly.
- FIG. 1 is a diagram schematically showing a dope preparation step, a casting step, and a drying step of a solution casting film forming method preferable for the present invention.
- the main dope solution is filtered by the main filter 3, and an ultraviolet absorbent additive solution is added in-line from 16 to this.
- the main dope may contain about 10 to 50% by weight of recycled material.
- the return material may contain acrylic particles. In that case, it is preferable to control the addition amount of the acrylic particle addition liquid in accordance with the addition amount of the return material.
- the additive liquid containing acrylic particles preferably contains 0.5 to 10% by mass of acrylic particles, more preferably 1 to 10% by mass, and more preferably 1 to 5% by mass. Most preferably.
- the return material is a product obtained by finely pulverizing the optical film, which is generated when the optical film is formed, and is obtained by cutting off both sides of the film, or by using an optical film original that has been speculated out due to scratches, etc. .
- an acrylic resin, a cellulose ester resin, and in some cases, acrylic particles kneaded into pellets can be preferably used.
- An endless metal belt 31 such as a stainless steel belt or a rotating metal drum, which feeds the dope through a liquid feed pump (for example, a pressurized metering gear pump) to the pressure die 30 and transfers it infinitely. This is a step of casting the dope from the pressure die slit to the casting position on the support.
- a liquid feed pump for example, a pressurized metering gear pump
- the pressure die includes a coat hanger die and a T die, and any of them is preferably used.
- the surface of the metal support is a mirror surface.
- two or more pressure dies may be provided on the metal support, and the dope amount may be divided and stacked. Or it is also preferable to obtain the film of a laminated structure by the co-casting method which casts several dope simultaneously.
- Solvent evaporation step In this step, the web (the dope is cast on the casting support and the formed dope film is called a web) is heated on the casting support to evaporate the solvent.
- the web on the support after casting is preferably dried on the support in an atmosphere of 40 to 100 ° C. In order to maintain the atmosphere at 40 to 100 ° C., it is preferable to apply hot air at this temperature to the upper surface of the web or heat by means such as infrared rays.
- Peeling process It is the process of peeling the web which the solvent evaporated on the metal support body in a peeling position. The peeled web is sent to the next process.
- the temperature at the peeling position on the metal support is preferably 10 to 40 ° C, more preferably 11 to 30 ° C.
- the amount of residual solvent at the time of peeling of the web on the metal support at the time of peeling is preferably 50 to 120% by mass depending on the strength of drying conditions, the length of the metal support, and the like.
- the amount of residual solvent is determined.
- the amount of residual solvent in the web is defined by the following formula.
- Residual solvent amount (%) (mass before web heat treatment ⁇ mass after web heat treatment) / (mass after web heat treatment) ⁇ 100 Note that the heat treatment for measuring the residual solvent amount represents performing heat treatment at 115 ° C. for 1 hour.
- the peeling tension at the time of peeling the metal support and the film is usually 196 to 245 N / m. However, if wrinkles easily occur at the time of peeling, it is preferable to peel with a tension of 190 N / m or less. It is preferable to peel at a minimum tension of ⁇ 166.6 N / m, and then peel at a minimum tension of ⁇ 137.2 N / m, and particularly preferable to peel at a minimum tension of ⁇ 100 N / m.
- the temperature at the peeling position on the metal support is preferably ⁇ 50 to 40 ° C., more preferably 10 to 40 ° C., and most preferably 15 to 30 ° C.
- a drying device 35 that alternately conveys the web through a plurality of rolls arranged in the drying device and / or a tenter stretching device 34 that clips and conveys both ends of the web with a clip are used. And dry the web.
- the drying means is generally to blow hot air on both sides of the web, but there is also a means to heat by applying microwaves instead of wind. Too rapid drying tends to impair the flatness of the finished film. Drying at a high temperature is preferably performed from about 8% by mass or less of the residual solvent. Throughout the drying is generally carried out at 40-250 ° C. It is particularly preferable to dry at 40 to 160 ° C.
- tenter stretching apparatus When using a tenter stretching apparatus, it is preferable to use an apparatus capable of independently controlling the film gripping length (distance from the start of gripping to the end of gripping) by the left and right gripping means of the tenter. In the tenter process, it is also preferable to intentionally create compartments having different temperatures in order to improve planarity.
- the stretching operation may be performed in multiple stages, and it is also preferable to perform biaxial stretching in the casting direction and the width direction.
- biaxial stretching When biaxial stretching is performed, simultaneous biaxial stretching may be performed or may be performed stepwise.
- stepwise means that, for example, stretching in different stretching directions can be sequentially performed, stretching in the same direction is divided into multiple stages, and stretching in different directions is added to any one of the stages. Is also possible. That is, for example, the following stretching steps are possible.
- Simultaneous biaxial stretching includes stretching in one direction and contracting the other while relaxing the tension.
- the preferred draw ratio for simultaneous biaxial stretching can be in the range of x1.01 to x1.5 in both the width direction and the longitudinal direction.
- the amount of residual solvent in the web is preferably 20 to 100% by mass at the start of the tenter, and drying is preferably performed while the tenter is applied until the amount of residual solvent in the web is 10% by mass or less. More preferably, it is 5% by mass or less.
- the drying temperature is preferably 30 to 150 ° C, more preferably 50 to 120 ° C, and most preferably 70 to 100 ° C.
- the temperature distribution in the width direction of the atmosphere is small from the viewpoint of improving the uniformity of the film.
- the temperature distribution in the width direction in the tenter process is preferably within ⁇ 5 ° C, and within ⁇ 2 ° C. Is more preferable, and within ⁇ 1 ° C. is most preferable.
- Winding step This is a step of winding the optical film by the winder 37 after the residual solvent amount in the web is 2% by mass or less, and the dimensional stability is achieved by setting the residual solvent amount to 0.4% by mass or less. A film with good properties can be obtained.
- a generally used one may be used, and there are a constant torque method, a constant tension method, a taper tension method, a program tension control method with a constant internal stress, etc., and these may be used properly.
- the optical film of the present invention is preferably a long film.
- the optical film has a thickness of about 100 m to 5000 m, and is usually in the form of a roll.
- the film width is preferably 1.3 to 4 m, more preferably 1.4 to 2 m.
- the film thickness of the optical film of the present invention is not particularly limited, but when used for a polarizing plate protective film described later, it is preferably 20 to 200 ⁇ m, more preferably 25 to 100 ⁇ m, and 30 to 80 ⁇ m. It is particularly preferred.
- the polarizing plate used in the present invention can be produced by a general method. It is preferable that an adhesive layer is provided on the back side of the optical film of the present invention, and is bonded to at least one surface of a polarizer produced by immersion and stretching in an iodine solution.
- the film may be used on the other surface, or another polarizing plate protective film may be used.
- cellulose ester films for example, Konica Minoltack KC8UX, KC4UX, KC5UX, KC8UY, KC4UY, KC12UR, KC8UCR-3, KC8UCR-4, KC8UCR-5, KV8UY-HA, KV8UX-RHA, KV8UX-RHA Etc.
- cellulose ester films for example, Konica Minoltack KC8UX, KC4UX, KC5UX, KC8UY, KC4UY, KC12UR, KC8UCR-3, KC8UCR-4, KC8UCR-5, KV8UY-HA, KV8UX-RHA, KV8UX-RHA Etc.
- a polarizer which is a main component of a polarizing plate, is an element that allows only light of a plane of polarization in a certain direction to pass.
- a typical polarizer currently known is a polyvinyl alcohol-based polarizing film, which is polyvinyl alcohol.
- iodine is dyed on a system film and one in which dichroic dye is dyed.
- the polarizer is formed by forming a polyvinyl alcohol aqueous solution into a film and dyeing the film by uniaxial stretching or dyeing or uniaxially stretching, and then performing a durability treatment with a boron compound.
- a pressure-sensitive adhesive having a storage elastic modulus at 25 ° C. in the range of 1.0 ⁇ 10 4 Pa to 1.0 ⁇ 10 9 Pa in at least a part of the pressure-sensitive adhesive layer is used. It is preferable to use a curable pressure-sensitive adhesive that forms a high molecular weight body or a crosslinked structure by various chemical reactions after the pressure-sensitive adhesive is applied and bonded.
- urethane adhesives examples include, for example, urethane adhesives, epoxy adhesives, aqueous polymer-isocyanate adhesives, curable adhesives such as thermosetting acrylic adhesives, moisture-curing urethane adhesives, polyether methacrylate types
- curable adhesives such as thermosetting acrylic adhesives, moisture-curing urethane adhesives, polyether methacrylate types
- anaerobic pressure-sensitive adhesives such as ester-based methacrylate type and oxidized polyether methacrylate, cyanoacrylate-based instantaneous pressure-sensitive adhesives, and acrylate-peroxide-based two-component instantaneous pressure-sensitive adhesives.
- the above-mentioned pressure-sensitive adhesive may be a one-component type or a type in which two or more components are mixed before use.
- the pressure-sensitive adhesive may be a solvent system using an organic solvent as a medium, or an aqueous system such as an emulsion type, a colloidal dispersion type, or an aqueous solution type that is a medium containing water as a main component. It may be a solvent type.
- the concentration of the pressure-sensitive adhesive liquid may be appropriately determined depending on the film thickness after adhesion, the coating method, the coating conditions, and the like, and is usually 0.1 to 50% by mass.
- ⁇ Liquid crystal display device> By incorporating the polarizing plate bonded with the optical film of the present invention into a liquid crystal display device, various liquid crystal display devices with excellent visibility can be produced.
- the polarizing plate according to the present invention is bonded to a liquid crystal cell via the adhesive layer or the like.
- the polarizing plate according to the present invention is a reflective type, transmissive type, transflective type LCD or TN type, STN type, OCB type, HAN type, VA type (PVA type, MVA type), IPS type, etc. Preferably used.
- a large-screen display device having a screen of 30 or more, especially 30 to 54 there is no white spot at the periphery of the screen and the effect is maintained for a long time.
- Example 1 The following acrylic resins (A) A1 to A6 and acrylic resins (B) B1 to B7 were prepared by known methods, and commercially available resins were obtained.
- Formation of acrylic resin film 1 The produced dope liquid was uniformly cast on a stainless steel band support at a temperature of 22 ° C. and a width of 2 m using a belt casting apparatus. With the stainless steel band support, the solvent was evaporated until the amount of residual solvent reached 100%, and peeling was performed from the stainless steel band support with a peeling tension of 162 N / m.
- the solvent was evaporated from the peeled acrylic resin web at 35 ° C., slit to 1.6 m width, and then dried at a drying temperature of 135 ° C. while stretching 1.1 times in the width direction with a tenter. At this time, the residual solvent amount when starting stretching with a tenter was 10%.
- drying was completed while transporting the drying zone at 120 ° C and 130 ° C with a number of rolls, slitting to a width of 1.5 m, and 10 mm wide at both ends of the film.
- a knurling process having a thickness of 5 ⁇ m was performed, and the film was wound around a core having an inner diameter of 6 inches with an initial tension of 220 N / m and a final tension of 110 N / m.
- the draw ratio in the MD direction calculated from the rotational speed of the stainless steel band support and the operating speed of the tenter was 1.1 times.
- the residual solvent amount of the optical film 1 described in Tables 1 and 2 was 0.1%, the film thickness was 40 ⁇ m, and the winding length was 4000 m.
- optical films were the same as the optical film 1 except that the types and composition ratios of the acrylic resins (A) and (B) cellulose ester resin (C) were changed as shown in Tables 2 and 3 below. A sample was prepared.
- An optical film conditioned for 24 hours in an air conditioning room at 23 ° C. and 55% RH is cut out at 120 mm (length) ⁇ 10 mm (width) under the same conditions, and pulled at a tension rate of 10 N at a rate of temperature increase of 30 ° C./min. The temperature was continuously increased, and the temperature at 9 N was measured three times, and the average was obtained.
- An optical film conditioned for 24 hours in an air-conditioned room at 23 ° C. and 55% RH is cut out at 100 mm (length) ⁇ 10 mm (width) under the conditions of 5 ° C. and 22% RH.
- the film was folded once into a mountain fold and a valley fold so that the film was exactly overlapped at 0 mm and a folding angle of 180 °, and this evaluation was measured 10 times and evaluated as follows.
- break by evaluation here represents that it broke and separated into two or more pieces.
- a polarizing plate using the optical film of the present invention as a polarizing plate protective film was prepared as follows.
- a 120- ⁇ m-thick long roll polyvinyl alcohol film was immersed in 100 parts by mass of an aqueous solution containing 1 part by mass of iodine and 4 parts by mass of boric acid, and stretched in the transport direction 5 times at 50 ° C. to produce a polarizer.
- the optical film 1 subjected to alkali saponification treatment was bonded to one side of the polarizer.
- KC8UCR-5 manufactured by Konica Minolta Opto Co., Ltd. which is an alkali saponified retardation film, was bonded to the other surface of the polarizer and dried to prepare a polarizing plate.
- polarizing plates were produced using other sample optical films.
- the obtained polarizing plate is carefully peeled off from the viewing side polarizing plate previously bonded to the Hitachi liquid crystal display device Woo W32L-H90, which is an IPS type liquid crystal display device, and aligned with the transmission axis of the polarizing plate originally applied. Then, a polarizing plate was attached so that the optical film of the present invention produced through the pressure-sensitive adhesive was on the viewing side, and a liquid crystal display device was produced.
- the present invention has excellent brittleness even in a thin film of 40 ⁇ m, and image unevenness is small.
- Example 2 In Example 1, samples having the same film thickness were prepared in the same manner except that the compounds shown in Table 4 were added as the retardation control agent (D) and acrylic particles (E), and the same evaluation was performed. The results are shown in Table 4.
- D1 Aromatic terminal ester plasticizer exemplified compound (14)
- D2 Sugar ester compound exemplified compound (3)
- D3 Polyhydric alcohol ester exemplary compound (16)
- D4 The following triazine compound
- the present invention has excellent brittleness even in a thin film of 40 ⁇ m and image unevenness is small.
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Abstract
Description
しかしながらこの方法でも、膜厚40μmという薄膜フィルムの製造時には、剥離ロールからのフィルムを剥離する際、フィルム強度が弱く、フィルムが搬送方向に伸びてしまうこと、また、フィルムが伸びることにより、フィルムの剥離にかかる力が均等でないため、後工程でのフィルムの延伸の際に、リタデーション値のムラ(ばらつき)、とともに光学的遅相軸の向き(配向角)のズレが大きいという、フィルムの脆性が不足していることを原因とする問題が発生した。
<重量平均分子量Mw7万以上100万未満のアクリル樹脂(A)>
本発明に用いられるアクリル樹脂(A)には、メタクリル樹脂も含まれる。樹脂としては特に制限されるものではないが、メチルメタクリレート単位50~99質量%、およびこれと共重合可能な他の単量体単位1~50質量%からなるものが好ましい。
カラム: Shodex KF807L(昭和電工(株)製を2本接続使用した。)
カラム温度:40℃
試料濃度: 0.1質量%
検出器: RI Model 504(GLサイエンス社製)
ポンプ: L6000(日立製作所(株)製)
流量: 1.0ml/min
校正曲線: 標準ポリスチレンSTK standard ポリスチレン(Mw=20,700,000~580迄の6サンプルによる校正曲線を使用した。6サンプルは、ほぼ等間隔に用いることが好ましい。
<重量平均分子量100万以上1000万以下のアクリル樹脂(B)>
本発明のアクリル樹脂(B)は、本発明のアクリル樹脂(A)と同様のモノマー組成を有し重量平均分子量が大きいものである。
<セルロースエステル樹脂(C)>
本発明のセルロースエステル樹脂(C)は、脂肪族のアシル基、芳香族のアシル基のいずれで置換されていても良いが、アセチル基で置換されていることが好ましい。
<光学フィルム>
本発明における延性破壊の起こらない光学フィルムであることが好ましい。ここで延性破壊とは、ある材料が有する強度よりも、大きな応力が作用することで生じるものであり、最終破断までに材料の著しい伸びや絞りを伴う破壊と定義される。その破面には、ディンプルと呼ばれる窪みが無数に形成される特徴がある。
<位相差制御剤(D)>
本発明においては、光学フィルムに位相差制御剤(D)を添加することができる。この位相差制御剤(D)としては、特開2002-296421号公報記載の化合物や種々のエステル系可塑剤を用いることができる。以下において、好ましいエステル系化合物について詳細な説明をする。
本発明において使用されるポリエステルポリオールとしては、炭素数の平均が2~3.5であるグリコールと炭素数の平均が4~5.5である二塩基酸との脱水縮合反応、又は該グリコールと炭素数の平均が4~5.5である無水二塩基酸の付加及び脱水縮合反応による常法により製造されるものであることが好ましい。
かかるポリエステルポリオールに用いられるグリコールとしては、例えばエチレングリコール、ジエチレングリコール、1,2-プロピレングリコール、1,3-プロピレングリコール、2-メチル-1,3-プロパンジオール、1,4-ブチレングリコール、ネオペンチルグリコール、3-メチル-1,5-ペンタンジオール、1,6-ヘキサンジオールなどが挙げられ、これらを単独又は2種以上を併用して用いられ、例えばエチレングリコール、又はエチレングリコールとジエチレングリコールの混合物などが特に好ましく用いられる。
次に本発明に用いられるポリエステルポリオールを構成する二塩基酸としては、例えばコハク酸、グルタル酸、アジピン酸、セバチン酸等を挙げることができる。
本発明に係る位相差制御剤として、下記一般式(I)で表される芳香族末端エステル系可塑剤を用いることができる。
(式中、Bはベンゼンモノカルボン酸残基、Gは炭素数2~12のアルキレングリコール残基又は炭素数6~12のアリールグリコール残基又は炭素数が4~12のオキシアルキレングリコール残基、Aは炭素数4~12のアルキレンジカルボン酸残基又は炭素数6~12のアリールジカルボン酸残基を表し、またnは1以上の整数を表す。)
一般式(I)中、Bで示されるベンゼンモノカルボン酸残基とGで示されるアルキレングリコール残基又はオキシアルキレングリコール残基又はアリールグリコール残基、Aで示されるアルキレンジカルボン酸残基又はアリールジカルボン酸残基とから構成されるものであり、通常のポリエステル系可塑剤と同様の反応により得られる。
「酸価」とは、試料1g中に含まれる酸(分子末端に存在するカルボキシル基)を中和するために必要な水酸化カリウムのミリグラム数をいう。酸価及びヒドロキシル基(水酸基)価はJIS K0070に準拠して測定したものである。
本発明では、位相差制御剤として、さらに多価アルコールエステル系可塑剤を使用することができる。
式中、R1はn価の有機基、nは2以上の正の整数、OH基はアルコール性又はフェノール性ヒドロキシル基(水酸基)を表す。
位相差制御剤としては、フラノース構造及びピラノース構造から選ばれる少なくとも一種の構造が1~12個結合した糖化合物のヒドロキシル基(水酸基)をエステル化した糖エステル化合物を含む光学フィルムであることが好ましい。
位相差制御剤としては、分子内にビスフェノールAを含有しているものも好ましい。ビスフェノールAの両端にエチレンオキサイド、プロピレンオキサイドを付加した化合物などを用いることができる。
<アクリル粒子(E)>
本発明においては、光学フィルムにアクリル粒子(E)を含有させてもよい。
本発明の光学フィルムにおいては、組成物の流動性や柔軟性を向上するために、可塑剤を併用することも可能である。可塑剤としては、フタル酸エステル系、脂肪酸エステル系、トリメリット酸エステル系、リン酸エステル系、ポリエステル系、あるいはエポキシ系等が挙げられる。
光学フィルムの製膜方法の例を説明するが、本発明はこれに限定されるものではない。
本発明の光学フィルムを溶液流延法で製造する場合のドープを形成するのに有用な有機溶媒は、アクリル樹脂(A)、(B)、セルロースエステル樹脂(C)、その他の添加剤を同時に溶解するものであれば制限なく用いることが出来る。
アクリル樹脂(A)、(B)、セルロースエステル樹脂(C)に対する良溶媒を主とする有機溶に、溶解釜中で該アクリル樹脂(A)、(B)、セルロースエステル樹脂(C)、場合によってアクリル粒子(E)、その他の添加剤を攪拌しながら溶解しドープを形成する工程、或いは該アクリル樹脂(A)、(B)、セルロースエステル樹脂(C)溶液に、場合によってアクリル粒子(E)溶液、その他の添加剤溶液を混合して主溶解液であるドープを形成する工程である。
ドープを送液ポンプ(例えば、加圧型定量ギヤポンプ)を通して加圧ダイ30に送液し、無限に移送する無端の金属ベルト31、例えばステンレスベルト、或いは回転する金属ドラム等の金属支持体上の流延位置に、加圧ダイスリットからドープを流延する工程である。
ウェブ(流延用支持体上にドープを流延し、形成されたドープ膜をウェブと呼ぶ)を流延用支持体上で加熱し、溶媒を蒸発させる工程である。
金属支持体上で溶媒が蒸発したウェブを、剥離位置で剥離する工程である。剥離されたウェブは次工程に送られる。
なお、残留溶媒量を測定する際の加熱処理とは、115℃で1時間の加熱処理を行うことを表す。
剥離後、ウェブを乾燥装置内に複数配置したロールに交互に通して搬送する乾燥装置35、及び/またはクリップでウェブの両端をクリップして搬送するテンター延伸装置34を用いて、ウェブを乾燥する。
・幅手方向に延伸-幅手方向に延伸-流延方向に延伸-流延方向に延伸
また、同時2軸延伸には、一方向に延伸し、もう一方を張力を緩和して収縮させる場合も含まれる。同時2軸延伸の好ましい延伸倍率は幅手方向、長手方向ともに×1.01倍~×1.5倍の範囲でとることができる。
ウェブ中の残留溶媒量が2質量%以下となってから光学フィルムとして巻き取り機37により巻き取る工程であり、残留溶媒量を0.4質量%以下にすることにより寸法安定性の良好なフィルムを得ることが出来る。
<偏光板>
本発明に用いられる偏光板は一般的な方法で作製することが出来る。本発明の光学フィルムの裏面側に粘着層を設け、沃素溶液中に浸漬延伸して作製した偏光子の少なくとも一方の面に、貼り合わせることが好ましい。
タクリレート等の嫌気性粘着剤、シアノアクリレート系の瞬間粘着剤、アクリレートとペルオキシド系の2液型瞬間粘着剤等が挙げられる。
<液晶表示装置>
本発明の光学フィルムを貼合した偏光板を液晶表示装置に組み込むことによって、種々の視認性に優れた液晶表示装置を作製することが出来る。本発明に係る偏光板は、前記粘着層等を介して液晶セルに貼合する。
以下のアクリル樹脂(A)A1~A6、アクリル樹脂(B)B1~B7を、公知の方法によって作製し、また市販の樹脂を入手した。
A1:(PMMA) Mw300000
A2:(PMMA) Mw70000
A3:(PMMA) Mw85000
A4:(PMMA) Mw100000
A5:ポリ(MMA-St)質量比90:10 Mw280000
A6:ポリ(MMA-CHMI-St)質量比90:5:5 Mw90000
A7:メタブレンP-700(PMMA)Mw50万
A8:カネエースPA10:ポリ(MMA-BA)質量比70:30 Mw80万
B1:(PMMA) Mw100万
B2:(PMMA) Mw115万
B3:メタブレンP-551A:ポリ(MMA-MA)質量比85:15 Mw150万B4:メタブレンP-530A:ポリ(MMA-BA)質量比85:15 Mw310万B5:カネエースPA40:ポリ(MMA-BA)質量比70:30 Mw600万
B6:カネエースPA60:ポリ(MMA-BA)質量比70:30 Mw900万
B7:ポリ(MMA-BA-St)質量比80:15:5 Mw310万
MMA:メチルメタクリレート
St:スチレン
CHMI:シクロヘキシルマレイミド
MA:メチルアクリレート
BA:ブチルアクリレート
セルロースエステル樹脂(C)は、表1に記載のものを使用した。
(ドープ液組成)
アクリル樹脂 A1 65質量部
アクリル樹脂 B4 5質量部
セルローエステル樹脂C1 30質量部
メチレンクロライド 300質量部
エタノール 40質量部
上記組成物を、加熱しながら十分に溶解し、ドープ液を作製した。
上記作製したドープ液を、ベルト流延装置を用い、温度22℃、2m幅でステンレスバンド支持体に均一に流延した。ステンレスバンド支持体で、残留溶剤量が100%になるまで溶媒を蒸発させ、剥離張力162N/mでステンレスバンド支持体上から剥離した。
得られた光学フィルム試料について以下の評価を実施した。
テンシロン試験機(ORIENTEC社製、RTC-1225A)を用いて、以下のような評価を行った。
脆性を下記の延性破壊試験によって評価した。
○・・・10回のうち1回折れる
△・・・10回のうち2回折れる
×・・・10回のうち3回以上折れる
(液晶表示装置としての特性評価)
〈偏光板の作製〉
本発明の光学フィルムを偏光板保護フィルムとした偏光板を以下のようにして作製した。
(画面ムラ)
上記作製した偏光板を使用して、本発明の光学フィルムの表示特性評価を行った。
(画面ムラ)
◎:明室、暗室ともにムラが全く観察されない。
○:明室では全く観察されないが、暗室で若干ムラが観察される。
△:明室では気にならないが、暗室でムラが観察される。
×:明室でもムラが観察される。
実施例1において、位相差制御剤(D)、アクリル粒子(E)として表4に記載の化合物を添加した他は同様にして同膜厚の試料を作製し、同様の評価を行った。結果を表4に示す。
D1:芳香族末端エステル系可塑剤例示化合物(14)
D2:糖エステル化合物例示化合物(3)
D3:多価アルコールエステル例示化合物(16)
D4:下記トリアジン化合物
3、6、12、15 濾過器
4、13 ストックタンク
5、14 送液ポンプ
8、16 導管
10 紫外線吸収剤仕込釜
20 合流管
21 混合機
30 ダイ
31 金属支持体
32 ウェブ
33 剥離位置
34 テンター装置
35 ロール乾燥装置
41 粒子仕込釜
42 ストックタンク
43 ポンプ
44 濾過器
Claims (3)
- 重量平均分子量Mw7万以上100万未満のアクリル樹脂(A)、重量平均分子量100万以上1000万以下のアクリル樹脂(B)およびセルロースエステル樹脂(C)を含有することを特徴とする光学フィルム。
- 前記光学フィルムが位相差制御剤(D)を含有することを特徴とする請求項1記載の光学フィルム。
- 前記光学フィルムがアクリル粒子(E)を含有することを特徴とする請求項1または2記載の光学フィルム。
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JP2011536079A JP5652401B2 (ja) | 2009-10-13 | 2010-09-07 | 光学フィルム |
KR1020127009237A KR101390618B1 (ko) | 2009-10-13 | 2010-09-07 | 광학 필름 |
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WO2011045991A1 true WO2011045991A1 (ja) | 2011-04-21 |
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PCT/JP2010/065291 WO2011045991A1 (ja) | 2009-10-13 | 2010-09-07 | 光学フィルム |
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JP (1) | JP5652401B2 (ja) |
KR (1) | KR101390618B1 (ja) |
WO (1) | WO2011045991A1 (ja) |
Cited By (11)
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JP2012237818A (ja) * | 2011-05-10 | 2012-12-06 | Fujifilm Corp | 光学フィルムとその製造方法、偏光板および液晶表示装置 |
JP2013100405A (ja) * | 2011-11-08 | 2013-05-23 | Dai Ichi Kogyo Seiyaku Co Ltd | 樹脂改質剤 |
US9292843B1 (en) | 2009-10-20 | 2016-03-22 | Dynamics Inc. | Advanced payment options for powered cards and devices |
JPWO2015064732A1 (ja) * | 2013-11-01 | 2017-03-09 | 富士フイルム株式会社 | 偏光板保護フィルム、ドープ組成物、偏光板保護フィルムの製造方法、偏光板ならびに液晶表示装置 |
US20170174802A1 (en) * | 2014-02-03 | 2017-06-22 | Kuraray Co., Ltd. | Copolymer and molded article |
WO2017184714A1 (en) * | 2016-04-20 | 2017-10-26 | Rohm And Haas Company | Method for improving the melt strength of an oriented polyvinyl chloride composition |
WO2017184711A1 (en) * | 2016-04-20 | 2017-10-26 | Rohm And Haas Company | Oriented thermoplastic polymer composition comprising polyvinyl chloride formulation and an acrylic copolymer as process aid |
JP2019509389A (ja) * | 2016-03-25 | 2019-04-04 | アルケマ フランス | 高溶融強さアクリル配合物 |
CN110832364A (zh) * | 2017-06-28 | 2020-02-21 | Dic株式会社 | 光学材料用树脂组合物和光学薄膜 |
JP2021060542A (ja) * | 2019-10-09 | 2021-04-15 | コニカミノルタ株式会社 | 光学フィルム、その製造方法及び偏光板 |
JP2021517929A (ja) * | 2018-09-05 | 2021-07-29 | エルジー・ケム・リミテッド | 熱可塑性樹脂組成物 |
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KR102156198B1 (ko) * | 2018-11-19 | 2020-09-16 | 효성화학 주식회사 | 셀룰로오스 에스테르 다층 위상차 필름 |
KR102134148B1 (ko) * | 2018-11-19 | 2020-07-16 | 효성화학 주식회사 | +c 플레이트 광학 특성을 갖는 셀룰로오스 에스테르 필름 |
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- 2010-09-07 KR KR1020127009237A patent/KR101390618B1/ko not_active IP Right Cessation
- 2010-09-07 JP JP2011536079A patent/JP5652401B2/ja active Active
- 2010-09-07 WO PCT/JP2010/065291 patent/WO2011045991A1/ja active Application Filing
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US9292843B1 (en) | 2009-10-20 | 2016-03-22 | Dynamics Inc. | Advanced payment options for powered cards and devices |
JP2012237818A (ja) * | 2011-05-10 | 2012-12-06 | Fujifilm Corp | 光学フィルムとその製造方法、偏光板および液晶表示装置 |
JP2013100405A (ja) * | 2011-11-08 | 2013-05-23 | Dai Ichi Kogyo Seiyaku Co Ltd | 樹脂改質剤 |
JPWO2015064732A1 (ja) * | 2013-11-01 | 2017-03-09 | 富士フイルム株式会社 | 偏光板保護フィルム、ドープ組成物、偏光板保護フィルムの製造方法、偏光板ならびに液晶表示装置 |
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US20170174802A1 (en) * | 2014-02-03 | 2017-06-22 | Kuraray Co., Ltd. | Copolymer and molded article |
JP2019509389A (ja) * | 2016-03-25 | 2019-04-04 | アルケマ フランス | 高溶融強さアクリル配合物 |
WO2017184711A1 (en) * | 2016-04-20 | 2017-10-26 | Rohm And Haas Company | Oriented thermoplastic polymer composition comprising polyvinyl chloride formulation and an acrylic copolymer as process aid |
WO2017184714A1 (en) * | 2016-04-20 | 2017-10-26 | Rohm And Haas Company | Method for improving the melt strength of an oriented polyvinyl chloride composition |
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AU2017252618B2 (en) * | 2016-04-20 | 2021-03-18 | Rohm And Haas Company | Method for improving the melt strength of an oriented Polyvinyl Chloride composition |
CN110832364A (zh) * | 2017-06-28 | 2020-02-21 | Dic株式会社 | 光学材料用树脂组合物和光学薄膜 |
JP2021517929A (ja) * | 2018-09-05 | 2021-07-29 | エルジー・ケム・リミテッド | 熱可塑性樹脂組成物 |
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JP7118462B2 (ja) | 2018-09-05 | 2022-08-16 | エルジー・ケム・リミテッド | 熱可塑性樹脂組成物 |
JP2021060542A (ja) * | 2019-10-09 | 2021-04-15 | コニカミノルタ株式会社 | 光学フィルム、その製造方法及び偏光板 |
JP7342593B2 (ja) | 2019-10-09 | 2023-09-12 | コニカミノルタ株式会社 | 光学フィルム、その製造方法及び偏光板 |
Also Published As
Publication number | Publication date |
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KR20120073274A (ko) | 2012-07-04 |
JP5652401B2 (ja) | 2015-01-14 |
JPWO2011045991A1 (ja) | 2013-03-04 |
KR101390618B1 (ko) | 2014-04-29 |
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