WO2011049108A1 - 機能性シートおよびそれを用いたレンズ - Google Patents
機能性シートおよびそれを用いたレンズ Download PDFInfo
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- WO2011049108A1 WO2011049108A1 PCT/JP2010/068444 JP2010068444W WO2011049108A1 WO 2011049108 A1 WO2011049108 A1 WO 2011049108A1 JP 2010068444 W JP2010068444 W JP 2010068444W WO 2011049108 A1 WO2011049108 A1 WO 2011049108A1
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- WIPO (PCT)
- Prior art keywords
- layer
- sheet
- functional
- film
- acrylic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/0073—Optical laminates
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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
- B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
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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
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
- C09J129/00—Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Adhesives based on hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Adhesives based on derivatives of such polymers
- C09J129/02—Homopolymers or copolymers of unsaturated alcohols
- C09J129/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
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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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- 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
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
- G02B1/14—Protective coatings, e.g. hard coatings
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/20—Filters
- G02B5/22—Absorbing filters
- G02B5/23—Photochromic filters
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
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- G—PHYSICS
- G02—OPTICS
- 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
- G02B5/3041—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 comprising multiple thin layers, e.g. multilayer stacks
- G02B5/305—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 comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
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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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- G—PHYSICS
- G02—OPTICS
- G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
- G02C7/00—Optical parts
- G02C7/10—Filters, e.g. for facilitating adaptation of the eyes to the dark; Sunglasses
- G02C7/102—Photochromic filters
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- G—PHYSICS
- G02—OPTICS
- G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
- G02C7/00—Optical parts
- G02C7/10—Filters, e.g. for facilitating adaptation of the eyes to the dark; Sunglasses
- G02C7/108—Colouring materials
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- G—PHYSICS
- G02—OPTICS
- G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
- G02C7/00—Optical parts
- G02C7/12—Polarisers
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- G—PHYSICS
- G02—OPTICS
- G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
- G02C2202/00—Generic optical aspects applicable to one or more of the subgroups of G02C7/00
- G02C2202/16—Laminated or compound lenses
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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
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/24983—Hardness
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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]
- Y10T428/31507—Of polycarbonate
Definitions
- the present invention relates to a polarizing or photochromic functional sheet suitably used for sunglasses, goggles, correction lenses, and the like, and a lens using the same.
- Optical articles such as sunglasses with polarizers, goggles, and correction lenses are preferably used for the purpose of relieving glare from reflected light from the water surface, snow surface, road surface, etc. and making it easier to see.
- This is based on the fact that when the absorption axis of the polarizer is used as horizontal, the polarization component that increases monotonously with respect to the reflection angle can be cut off when natural light is incident on the water surface and reflected.
- the vibration component of light in a plane including incident light and normal direction oscillates in a plane perpendicular to the p-polarized light.
- the component is s-polarized light
- the light reflected from the water surface or the like has a local minimum point where the p-polarized light becomes almost zero near 55 ° with respect to the reflection angle, whereas the s-polarized light increases monotonously.
- Sunglasses, goggles, and corrections that are provided with a layer containing dimmable (photochromic) dyes and are colored under external light containing a lot of ultraviolet light and decolorized under artificial light with little ultraviolet light.
- There are transparent optical articles such as lenses.
- a resin film typically a polyvinyl alcohol (PVA) film, which is stretched in one direction and dyed with iodine or a dichroic dye to impart polarization is known.
- PVA polyvinyl alcohol
- a method of imparting light control performance (1) a method of forming a casting film using a polymer solution containing a light control pigment, and (2) a film obtained by melt-extruding a thermoplastic polymer mixed with the light control pigment.
- a functional sheet provided with a protective layer on both sides of the polarizing, dimming or bifunctional layer.
- the transparent plastic material used as the protective layer include thermoplastic resins, and examples thereof include aromatic polycarbonate, polymethyl methacrylate, transparent nylon, and acetyl cellulose.
- Lamination integration of the functional layer and the protective layer is usually performed using a curable resin adhesive, but troubles based on poor adhesion between the functional layer and the protective layer are sometimes seen.
- an aromatic polycarbonate is used as a protective layer, this adhesion failure is often observed as peeling of the aromatic polycarbonate protective layer from the adhesive layer.
- Aromatic polycarbonates have the problem of solvent cracking. For this reason, depending on the solvent used, not only the adhesive layer cannot be formed on the aromatic polycarbonate, but also the residual solvent causes cracks. However, excessive drying treatment for removing the solvent usually deteriorates the adhesive strength. In addition, there is a limit to the formation of an adhesive layer on both surfaces to be bonded for good adhesion.
- a method of using a material in which a protective layer for the adhesive is formed on the adhesive surface of the aromatic polycarbonate can be easily considered.
- a functional sheet having an aromatic polycarbonate as a protective layer plasma treatment or the like is performed as a normal pretreatment for bonding.
- no description that directly refers to forming a protective layer for the adhesive has been found.
- Patent Documents 2 and 3 There is a method using a film formed.
- a method of manufacturing an optical article such as sunglasses, goggles, or a correction lens using the functional sheet described above is usually a lens obtained by molding the functional sheet into a desired curved surface, or molded into a curved surface.
- the lens is made by processing to produce a bent product, mounting it on a mold, and injection molding a transparent plastic material on the back side.
- the lens is subjected to hard coating, antireflection, and other surface treatments, and the optical article is assembled through steps such as balling (outer shape processing), drilling, and screw tightening as appropriate.
- the transparent plastic material layer is subjected to stresses such as scratches, bending, compression, tension, twisting, and uneven deformation due to changes in temperature and humidity during handling. Among them, there is a problem of scratching of the surface layer of the transparent plastic material. If the resistance to scratching is low, a scratched product is likely to occur, leading to a decrease in product yield.
- the present invention has been made in view of the above, and has a functionality having a polarizing or photochromic functional layer that improves the adhesion between the functional layer and the protective layer and improves the resistance of the protective layer to scratches. It is an object to provide a sheet and a lens using the sheet.
- the present invention is as follows. (1) In a functional sheet using a polarizing or dimmable functional layer and a protective layer made of an aromatic polycarbonate resin sheet or film on both sides thereof, at least one of the protective layers on one side of the aromatic polycarbonate resin layer Or it is a co-extrusion sheet or film which has an acrylic resin layer on both surfaces, Comprising: At least one surface of the said functional sheet is an acrylic resin layer, The functional sheet characterized by the above-mentioned.
- the functional sheet according to (1), wherein the polarizing functional layer is produced by dyeing and stretching a polyvinyl alcohol resin film with a dichroic organic dye.
- the dimmable functional layer is produced by a casting method using a non-aromatic polymer solution mixed with a dimmable organic compound.
- the dimmable functional layer is obtained by heat curing a two-component thermosetting urethane resin comprising a polyurethane prepolymer mixed with a dimmable organic compound and a curing agent thereof.
- Functional sheet (5) The functional sheet according to (4), wherein the dimmable functional layer is a co-pressed sheet or film that is a protective layer or a layer that adheres a polarizing functional layer.
- the acrylic resin layer of the coextruded sheet or film has a thickness of 60 ⁇ m, a hard acrylic resin layer exhibiting a pencil hardness of 2H or higher or an alkyl (meth) acrylate having an alkyl group with 2 or more carbon atoms
- the functional sheet according to (1) above which is a soft acrylic resin layer used as a copolymerization component in an amount of 5 mol% or more.
- the functional sheet of the present invention is (a) a polarizing or dimmable functional layer, and (b) at least one protective layer is a coextruded sheet or film of an aromatic polycarbonate resin layer and an acrylic resin layer. And (c) a functional layer a and a protective layer b or an adhesive layer for adhering the functional layers a to each other. Also, a lens formed by bending the functional sheet, and a molded lens formed by bending the functional sheet, mounting the functional sheet on a mold, and injection molding a transparent thermoplastic resin.
- the polarizing functional layer of the present invention one produced by dyeing and stretching a polyvinyl alcohol resin film with a dichroic organic dye is usually used.
- the polyvinyl alcohols include polyvinyl alcohol (PVA), a PVA acetate ester structure that remains in a trace amount, and PVA derivatives or analogs such as polyvinyl formal, polyvinyl acetal, saponified ethylene-vinyl acetate copolymer, and the like. In particular, PVA is preferred. While this film is stretched in one direction, it is impregnated or adsorbed with a dichroic organic dye, fixed as appropriate, and dried to obtain a polarizing film.
- the weight average molecular weight of the PVA film is from 50,000 to 350,000, preferably from 150,000 to 300,000.
- the thickness of the raw material PVA film is usually about 100 to 300 ⁇ m, and the PVA polarizing film obtained by stretching and dyeing it is usually 10 to 50 ⁇ m.
- the stretching ratio of the PVA film is 2 to 8 times and is appropriately selected according to the purpose, but is preferably 3 to 5 times from the viewpoint of strength after stretching.
- the light control (photochromic) layer of the present invention may be used as (1) a pre-manufactured light control film, or (2) a light control adhesive layer containing a light control organic compound. It may be used as
- the dimming film of (1) is a non-aromatic resin film in which a dimming organic compound is uniformly dispersed, and is a known method such as a casting method, a melt extrusion method, or a thermal diffusion method. Can be manufactured.
- the base resin include cellulose-based cellulose such as acetyl cellulose, ethylene-vinyl acetate copolymer suspension, etc. When heat resistance is required for the base film such as thermal diffusion, polyurethane, diallyl carbonate, etc.
- thermosetting urethane resin comprising a polyurethane prepolymer and its curing agent is preferred.
- the photochromic compound include known spiropyran-based compounds, spirooxazine-based compounds, naphthopyran-based compounds, and the like, which are used alone or in a mixture of two or more.
- a coextruded sheet or film composed of an aromatic polycarbonate resin layer and an acrylic resin layer is used as the protective layer on at least one side.
- Sheets or films having an aromatic polycarbonate resin layer and an acrylic resin layer are not only co-extruded, but also known methods such as extrusion lamination, film or sheet fusion using heat or ultrasonic waves, and coating methods. It can be manufactured, each with advantages and disadvantages.
- the extrusion laminating method in particular, the production of a stable thin acrylic resin film having a high surface height requires a high level of technology.
- the mutual adhesive strength of the film tends to be inferior similarly to the fusion of films and sheets using heat and ultrasonic waves.
- the coating method can use a high molecular weight resin that cannot be extruded as a solution if there is a solvent, and it is also common to use a curable resin, and it has an extremely wide range of applications. It is.
- the aromatic polycarbonate resin is inferior in solvent crack resistance, fine control of the components of the solvent and curable monomer that can be used and the amount ratio thereof, and the usage method is indispensable.
- the high retardation value is inferior in crack resistance compared to the low retardation value, there is a problem that finer control is indispensable.
- a co-extruded sheet or film is used in which molten resin is joined and bonded in an extrusion die due to the adhesion between layers and the adhesive interface structure.
- the coextruded sheet or film of the present invention has two or three layers.
- the physical properties of the acrylic resin layer are usually selected for the purpose of either the improvement of surface hardness or the improvement of chemical resistance for the two layers, and for the three layers, both of these in addition to the above. Choose what you have.
- an acrylic resin with a high surface hardness is selected on one side.
- a flexible and chemical-resistant layer is selected as a surface with improved resistance to organic solvents, increasing interfacial adhesion. Suppress the occurrence of problems such as peeling.
- the adhesion side (inner surface) with the functional layer is preferably a layer that enhances the adhesion and suppresses the occurrence of problems such as peeling, like the bent lens.
- the thickness of the protective layer is 50 ⁇ m to 2 mm, preferably 100 ⁇ m to 1 mm.
- the thickness of the acrylic resin layer is less than 50% of the total thickness and is 10 ⁇ m or more, and is usually selected from the range of 10 ⁇ m to 500 ⁇ m, preferably 20 to 100 ⁇ m.
- the retardation value of the coextruded sheet or film is selected to be 100 nm or less or 3000 nm or more.
- the photoelastic modulus is increased by copolymerizing a monomer having an aromatic ring oriented in a direction perpendicular to the main chain (for example, fluorene group-substituted bisphenol, styrene-grafted bisphenol A polycarbonate).
- a monomer having an aromatic ring oriented in a direction perpendicular to the main chain for example, fluorene group-substituted bisphenol, styrene-grafted bisphenol A polycarbonate.
- the thing using the copolymer polycarbonate resin manufactured using what was made small is preferable.
- a retardation value of 3000 nm or more and 20000 nm or less, preferably 4000 nm or more, particularly 5000 nm or more is selected.
- what has a high retardation value has a big distortion (residual stress) based on molecular orientation, and also has the fault that it is generally inferior to a crack resistance compared with a thing with small residual stress.
- a conventional sheet or film of an aromatic polycarbonate resin having a high retardation value of 3000 nm or more is used to control the stretching amount in the step of peeling and cooling the aromatic polycarbonate resin having a temperature higher than the glass transition temperature from the roll. It is manufactured by the method.
- a high-retardation sheet is not industrially produced. Attempts were made to apply the method of the aromatic polycarbonate resin as described above to the case of a co-extruded sheet or film with improved surface hardness. As the amount of stretching increased, the film was broken and could not be produced. .
- a high-retardation sheet can be produced by stretching a co-extruded sheet or film with a batch-type stretching machine under heating. From this, it is considered that the cause of film breakage is that the acrylic resin layer on the surface cracks and breaks. Therefore, keeping the acrylic resin layer side of the co-pressed sheet or film peeled from the roll and stretched below the glass transition temperature of the aromatic polycarbonate resin and above the glass transition temperature of the acrylic resin, etc. If it can prevent that a defect (crack etc.) arises in acrylic resin layer by this, it is estimated that manufacture of a thing with a large stretched quantity (thing with a high retardation value) is possible.
- aromatic polycarbonate resin of the present invention examples include bishydroxy (halogeno) phenyl such as 2,2-bis (4-hydroxyphenyl) propane and 2,2-bis (4-hydroxy-3,5-dibromophenyl) propane.
- a polymer produced by a well-known method from a monomer such as a bisphenol compound typified by alkane or a fluorene group substituted on the alkane moiety is used.
- the molecular weight may be within a normal range, and is preferably 17,000 to 40,000 in terms of viscosity average molecular weight from the viewpoint of formability and mechanical strength, and more preferably 20 from the viewpoint of production by extrusion. , 30,000 to 30,000.
- the acrylic resin that can be used in the present invention is a homopolymer of various (meth) acrylic esters represented by polymethyl methacrylate (PMMA) or polymethacrylate (PMA), or methyl methacrylate (MMA) or methyl acrylate ( MA) and a copolymer of one or more other monomers, and a mixture of a plurality of these resins may be used.
- MMA or hard acrylic resin of 2H or more, mainly composed of MA, is suitably used for the surface layer for scratch resistance.
- a soft acrylic resin copolymerized with an alkyl (meth) acrylate having an alkyl group having 2 or more carbon atoms, usually 5 mol% or more, preferably 10 mol% or more, has a surface hardness or Although the degree of improvement in crack resistance is inferior, it is flexible and excellent in adhesiveness, and is suitably used as the surface of a pretreatment layer for coating such as an inner layer surface or a hard coat.
- MMA and other monomers copolymerizable with MA include alkyl (meth) acrylates having an alkyl group with 2 to 18 carbon atoms, ⁇ , ⁇ -unsaturated acids such as acrylic acid and methacrylic acid, maleic Unsaturated divalent carboxylic acids such as acid, fumaric acid and itaconic acid and their alkyl esters, aromatic vinyl compounds such as styrene, ⁇ -methylstyrene and nucleus-substituted styrene, vinyl cyanide such as acrylonitrile and methacrylonitrile Compound, maleic anhydride, maleimide, N-substituted maleimide and the like.
- various derivatives such as a mixture of these copolymers and a hydrogenated product, may be sufficient.
- an aliphatic compound is preferable, and an alkyl (meth) acrylate having an alkyl group having 2 to 18 carbon atoms is preferable.
- an alkyl (meth) acrylate having an alkyl group having 2 to 18 carbon atoms is preferable.
- what hydrogenated the benzene ring of the acrylic resin which copolymerized styrene etc. is also used.
- examples of such (meth) acrylic resins include Acrypet (trademark, manufactured by Mitsubishi Rayon), Delpet (trademark, manufactured by Asahi Kasei Chemicals), and Parapet (trademark, manufactured by Kuraray).
- the adhesive layer is used for adhesion between the protective layer and the functional layer, and for mutual adhesion when a polarizing film layer and a dimmable (photochromic) film are used as the functional layer.
- the adhesive used include acrylic resin materials, urethane resin materials, polyester resin materials, melamine resin materials, epoxy resin materials, and silicone materials.
- a two-component thermosetting urethane resin composed of a polyurethane prepolymer that is a urethane resin material and a curing agent is preferable from the viewpoint of adhesiveness with an aromatic polycarbonate and adhesiveness with a polarizing layer and a light control layer.
- the functional sheet of this invention is manufactured using the above.
- a coextruded sheet or film comprising an aromatic polycarbonate resin layer and an acrylic resin layer used as a protective layer of the present invention is obtained in a long roll and is used in that form.
- the polarizing functional layer is also obtained by using a long roll, and when a dimming film manufactured in advance as the dimming functional layer is used, it is obtained and used by a long roll.
- the sheet or film unrolled from the roll is appropriately subjected to a predetermined surface treatment, applied with the adhesive solution of the present invention, and dried to form a substantially solvent-free adhesive layer.
- These are manufactured by stacking and pressure-bonding them, winding them up, or stacking and bonding them, and then cutting them to a predetermined size and proceeding with the curing reaction.
- a light controllable functional layer when a light controllable functional layer is formed with an adhesive composition, it can be manufactured in the same manner as described above except that a thick adhesive layer is usually formed.
- dimming that is, when a polarizing film is not used, it is essential to form a dimming functional layer on the surface of the coextruded sheet or film of the present invention.
- a component of the agent composition a material that does not harm the aromatic polycarbonate is selected, or a layer that imparts solvent resistance, for example, a coextruded sheet or film having the soft acrylic resin layer described above, on the acrylic resin layer side Is used as a solvent resistant layer.
- an adhesive composition layer is formed on one side of the polarizing film, a coextruded sheet or film is adhered, and a solvent-free dimming adhesive composition layer is formed on the opposite side of the polarizing film.
- adopting a high retardation product as a protective sheet or film since there exists a tendency to be inferior to crack resistance compared with a low retardation product, careful attention is required.
- the stretching direction of each sheet or film and the stretching direction of the polarizing film are used as parallel or perpendicular to each other.
- the functional sheet surface on the injection molding side is filled with a molten resin, defects such as scratches that are not foreign matter disappear, and normal injection molding is performed.
- those having an aromatic polycarbonate as a surface layer are preferred.
- the side filled with the injection resin only needs to have a sufficient thickness to protect the functional layer.
- the contact surface with the mold which is usually a convex surface, is usually a molded lens, and then various functional layers are formed on the surface to form a lens. Accordingly, those having a surface layer suitable for such a surface treatment step are suitable.
- a material having a flexible acrylic copolymer layer is used as the mold side.
- the thickness of the functional sheet used is 0.3 mm or more in total on both sides, preferably 0.4 to 0.9 mm.
- a co-pressed sheet having a high retardation when selecting a functional sheet having a polarizing layer and selecting a co-pressed sheet using a normal aromatic polycarbonate, it is preferable to select a co-pressed sheet having a high retardation.
- the most common ordinary aromatic polycarbonate resin that is, a polycarbonate resin having 2,2-bis (4-hydroxyphenyl) propane as a main monomer has a large photoelastic constant. For this reason, when using a polycarbonate resin having this large photoelastic constant, if a special operation that maintains low retardation is not used, stress due to fixing to the frame, temperature change, etc., stress generated by bending, etc.
- interference fringes are observed due to the birefringence generated by this stress.
- new interference fringes are not observed due to such stress. This is because the change due to the value of the stress birefringence is negligible in the case of a sufficiently large retardation, and the direction does not change substantially.
- FIG. 1 is a schematic sectional view showing a coextruded sheet used as a protective layer of the present invention.
- the thickness of each layer is appropriately changed, but the layer configuration of the coextruded sheet is the four types described.
- Reference numeral 2 denotes a hard acrylic resin layer, which is mainly intended to improve surface hardness.
- Reference numeral 3 denotes a soft acrylic resin layer, which is mainly intended to improve solvent resistance and interlayer adhesion.
- FIG. 2 is a schematic cross-sectional view showing the functional sheet of the present invention corresponding to the embodiment.
- 2A and 2B correspond to Examples 1 and 2, respectively, and have a hard acrylic resin layer 2 of number 2 on both sides, and a soft acrylic resin layer of number 3 on the inner layer side in b. . 2, c, d, and e correspond to Examples 3, 4, and 5, respectively, the surface on one side is an aromatic polycarbonate resin layer of No. 1, and in d, the soft acrylic resin layer of No. 3 on the inner layer side It has.
- the functional sheet of the present invention has a hard or soft acrylic resin layer of number 2 or 3 on at least one side.
- the soft acrylic resin layer is also superior in scratch resistance than the aromatic polycarbonate resin layer 1.
- the surface having the soft acrylic resin layer of No. 3 can be improved in adhesion.
- the aromatic polycarbonate resin layer of No. 1 on the one-side surface is integrated with the aromatic polycarbonate resin layer of No. 7 by injection molding to have a molded product having no
- FIG. 3 is a schematic sectional view showing a bent lens (Example 6) using the functional sheet of the present invention corresponding to Examples 1 and 2.
- FIG. 2 are bent using a and b in FIG. 2 and have a hard acrylic resin layer 2 of No. 2 on both sides and improved scratch resistance.
- FIG. 4 is a schematic sectional view showing a molded lens (Example 7) using the functional sheet of the present invention corresponding to Examples 3, 4, and 5.
- FIG. 5 is a schematic sectional view showing a functional sheet of a conventional example.
- the lens produced above is used as it is, or further, various functional layers such as an antireflection layer, a hard coat layer, an antifouling layer and an antifogging layer are appropriately formed. And lenses with other designs, and are suitably used for sunglasses, goggles, or correcting eyeglass lenses.
- the functional sheet of the present invention is used as it is with improved scratch resistance as it is, or appropriately formed various functional layers such as an antireflection layer, a hard coat layer, an antifouling layer and an antifogging layer. It can be used for polarizing plates, photochromic plates, polarizing / photochromic plates, and the like.
- Co-pressed sheet 1 (see FIG. 1a): A PC / PMMA co-extruded sheet (PMMA: methyl methacrylate, manufactured by Mitsubishi Gas Chemical Co., Ltd.) was stretched under heating at a temperature of 160 ° C. with a batch type stretching machine, and the thickness was 0.7 mm (the thickness of the PMMA layer was 100 ⁇ m). The retardation value was about 5500 nm. This sheet has an inclined structure at the boundary between PC and PMMA, and the reflection of light at the boundary is relatively small.
- Co-pressing sheet 2 (see FIG. 1a): A PC / PMMA co-extruded sheet (PMMA: methyl methacrylate, manufactured by Mitsubishi Gas Chemical Co., Ltd.) was stretched under heating at a temperature of 160 ° C. with a batch type stretching machine, and the thickness was 0.7 mm (the thickness of the PMMA layer was 100 ⁇ m). The retardation value was about 5500 nm. This sheet has an inclined structure at the boundary between PC and PMMA, and
- a PMMA / PC / C-PMMA coextruded sheet (C-PMMA: methyl methacrylate, methyl acrylate and butyl acrylate copolymer, manufactured by Mitsubishi Gas Chemical Co., Ltd.) was uniaxially stretched in the same manner as described above, and the thickness was 0.7 mm.
- the retardation value was about 5500 nm (PMMA layer thickness 100 ⁇ m, C-PMMA thickness 30 ⁇ m).
- This sheet also has an inclined structure at the boundary as described above.
- Co-pressing sheet 3 (see FIG. 1a): A PC / PMMA two-layer coextrusion sheet (thickness of PMMA layer: 60 ⁇ m, manufactured by Mitsubishi Gas Chemical Co., Ltd.) having a thickness of 0.3 mm was prepared. This sheet has an inclined structure at the boundary as described above.
- Co-pressing sheet 4 (see FIG. 1a): A PC / PMMA two-layer coextruded sheet (Mitsubishi Gas Chemical Co., Ltd.) was uniaxially stretched in the same manner as described above, and a thickness of 0.3 mm and a retardation value of about 5500 nm (PMMA: methyl methacrylate, methyl acrylate copolymer, The thickness was about 50 ⁇ m. This sheet has an inclined structure at the boundary as described above.
- Co-pressing sheet 5 (see FIG. 1c): A C-PMMA / PC / C-PMMA three-layer co-extruded sheet (Mitsubishi Gas Chemical Co., Ltd.) was uniaxially stretched in the same manner as described above to obtain a thickness of 0.3 mm and a retardation value of about 5500 nm (of the C-PMMA layer). The thickness was about 30 ⁇ m). This sheet also has an inclined structure at the boundary as described above. Co-pressing sheet 6 (see FIG.
- a PC / C-PMMA coextruded sheet (Mitsubishi Gas Chemical Co., Ltd.) was uniaxially stretched in the same manner as described above to obtain a thickness of 0.3 mm and a retardation value of about 5500 nm (C-PMMA layer thickness of about 30 ⁇ m). .
- This sheet also has an inclined structure at the boundary as described above.
- a PVA film (trade name VF-PS # 7500, manufactured by Kuraray Co., Ltd.) was immersed in water at 35 ° C. to remove glycerin contained in the film.
- Sumilite Red 4B-P (C.I. 28160) 0.35 g / L
- Chrysophenine (C.I. 24895) 0.18 g / L
- Sumilite Spula Blue G (C.I. 34200) 1.33 g / L
- This dyed film was immersed in a 35 ° C. aqueous solution containing 2.5 g / L nickel acetate and 6.0 g / L boric acid for 3 minutes. The film was dried for 3 minutes at room temperature with the tension kept, and then heat treated at 110 ° C. for 3 minutes to obtain a polarizing film.
- Photochromic adhesive solution 20 g of a curing agent is added to 100 g of a polyurethane prepolymer, and 4- [4- [6- (4-morpholinyl) -3-phenyl-3H-naphth (2,1-b) pyran-3-yl] phenyl is used as a photochromic compound.
- -Morphine trade name: Reversesol Flame, manufactured by James Robinson Ltd. 0.82 g (1% based on the total weight of the solvent after volatilization and curing) was added and stirred at room temperature for 1 hour to produce a photochromic adhesive A solution was prepared.
- Adhesive composition An adhesive composition was prepared using 5 parts by weight of a curing agent and 60 parts by weight of ethyl acetate as a solvent with respect to 50 parts by weight of a polyurethane prepolymer.
- Example 1 see FIG. 2a
- the adhesive composition is applied to one side of the polarizing film obtained above using a coater and dried at 110 ° C. for 5 minutes, and then the PC side of the two-layer co-pressed sheet 1 having a thickness of 0.7 mm is attached. Lamination was performed using a laminator. Next, after the adhesive layer was formed in the same manner on the polarizing film surface of the obtained laminate, the PC side of the second co-pressed sheet 1 was laminated. Next, it is dried at room temperature for 1 day or more and further at 70 ° C. for 1 day, and a PMMA * PC / adhesive layer / polarizing film / adhesive layer / PC * PMMA polarizing sheet with a thickness of 1.5 mm on both surfaces. Got. When the pencil hardness test JIS-K-5600-5-4 of the obtained polarizing sheet was carried out, it was confirmed that the pencil hardness was 3H. Comparative Example 1 (see FIG. 5)
- the above adhesive composition was applied to the C-PMMA side of the three-layer co-pressed sheet 2 having a thickness of 0.7 mm using a coater, dried at 110 ° C. for 5 minutes, and the polarizing film obtained above was then used as a laminator. Were laminated. On the surface of this polarizing film, the coated surface on the C-PMMA side of the co-pressed sheet 2 coated with the adhesive composition and dried as described above was laminated. Next, it was dried at room temperature for 1 day or more, and further at 70 ° C. for 1 day, and PMMA * PC * C-PMMA / adhesive layer / polarizing film / adhesive layer / C- A polarizing sheet of PMMA * PC * PMMA was obtained.
- Example 3 (see FIG. 2c)
- Example 4 instead of the co-pressed sheet 1 used in Example 1, a 0.3 mm thick co-pressed sheet 4 (2) was used for the protective sheet on one side, and a high retardation PC film with a thickness of 0.3 mm was used for the protective sheet on the opposite side.
- a polarizing sheet of PMMA * PC / adhesive layer / polarizing film / adhesive layer / PC having a thickness of 0.6 mm was obtained in the same manner as in Example 1 except that.
- the pencil hardness test was performed in the same manner as in Example 1, the pencil hardness was 3H on the PMMA side and the pencil hardness B on the PC side.
- Example 4 see FIG. 2d
- the adhesive composition was applied on the C-PMMA surface of the three-layer co-pressed sheet 5 having a thickness of 0.3 mm using a coater, dried at 110 ° C. for 5 minutes, and then the polarizing film obtained above was used. Lamination was performed using a laminator. On the surface of the polarizing film, the coating surface on the C-PMMA side of the two-layer co-pressed sheet 6 having a thickness of 0.3 mm, which was similarly coated with the adhesive composition on the C-PMMA surface and dried, was laminated. . Next, it was dried at room temperature for 1 day or more and further at 70 ° C.
- the photochromic adhesive solution obtained above was applied to the co-pressed sheet 3 using a coater and dried at 70 ° C. for 10 minutes, and then a normal PC film was laminated using a laminator.
- the PMMA * PC / light control layer / PC light control sheet was obtained by drying and curing at room temperature for one day or more and further at 70 ° C. for one day.
- the pencil hardness test was performed in the same manner as in Example 1, the pencil hardness was 3H on the PMMA side and the pencil hardness B on the PC side.
- Example 6 see FIG. 3
- a polarizing sheet having a thickness of 1.5 mm in Examples 1 and 2 the sheet was punched into a capsule shape in which the rectangular direction was cut in a stretching direction of 80 mm and a width in the vertical direction of 55 mm.
- a concave spherical bending mold (curvature radius 66.81 mm, base curve 7.932) with vacuum suction and silicon rubber sheet coating, a cut piece was placed on a female silicon rubber sheet set at a surface temperature of 145 ° C. Vacuum suction was started, and then spherical bending was performed by applying pressure with a male mold coated with a silicon rubber sheet.
- the base curve referred to here is the curvature of the front surface of the lens, which is a value obtained by dividing 530 by the radius of curvature in millimeters.
- a bent lens having good punching into a desired shape and bending workability and hardly causing surface scratches was obtained.
- Example 7 (see FIG. 4)
- the polarizing sheet having a thickness of 0.6 mm in Examples 3 and 4 and the light control sheet having a thickness of 0.6 mm in Example 5 are each a perfect circle having a diameter of 79.5 mm and a width in the direction perpendicular to the stretching direction is 55 mm. Punched into a cut shape. Next, using a mold with the same surface shape so that it matches the spherical surface (curvature radius 66.81 mm, base curve 7.932) of the mold used for injection molding, the PMMA or C-PMMA side is the convex surface side. Bending was performed. The bent product was inserted into an injection mold, and an aromatic polycarbonate resin was injection molded at 300 ° C.
- the obtained molded lens is usually used after further hard coating treatment. Even when untreated, the convex side is less likely to be scratched, so that it is easy to handle, and the scratch resistance after the hard coat treatment is further improved.
- the functional sheet of the present invention and a lens using the functional sheet exhibit stable interlayer adhesion, are excellent in scratch resistance, and are excellent in applicability to post-treatment such as a hard coat. It can be suitably used for correcting eyeglass lenses.
Abstract
Description
また、調光性能を付与する方法としては、(1)調光色素を含むポリマー溶液を用いてキャスティングフィルムとする方法、(2)調光色素を混合した熱可塑性ポリマーを溶融押し出ししてフィルムとする方法、(3)調光色素を混合した塗膜形成用の組成物を調製し用いる方法、(4)調光色素を混合した接着剤組成物を調製し用いる方法、および(5)フィルムや基材に調光色素を熱拡散などさせて調光性の拡散層を形成したものとする方法などが知られている(例えば、特許文献1)。
この保護層として用いる透明なプラスチック材料としては、熱可塑性樹脂があげられ、芳香族ポリカーボネート、ポリメチルメタアクリレート、透明ナイロン、アセチルセルロースなどが例示される。
この中で、耐衝撃性の点からは、芳香族ポリカーボネートが、また、ポリメチルメタクリレート、透明ナイロン、脂環を主鎖に持つ炭化水素系の樹脂、アセチルセルロースなど、耐クラック性、ファション性、その他の種々の要求から用いられている。
特に、芳香族ポリカーボネートを保護層とする場合、この接着不良は、芳香族ポリカーボネート製の保護層の接着剤層からの剥離として観察される場合が多い。
芳香族ポリカーボネートには、溶剤クラックの発生の問題がある。このため用いる溶剤によっては、芳香族ポリカーボネート上に接着剤層を形成できないのみでなく、残存溶剤もクラック発生の原因となる。しかし、溶剤除去のための過剰の乾燥処理などは、通常、接着力を劣化させる。また、良好な接着のための被接着面両面への接着層の形成などにも制限があった。
しかし、接着剤に対する保護層を形成することに直接言及した記載は見出していない。
他の目的、例えば、機能性シートを用いた熱硬化性レンズの製造方法においては、機能性シートの表面に硬化性樹脂モノマー液に耐性を持つ塗膜、例えば、硬化性のアクリル系樹脂などの膜を形成したものを用いる方法がある(特許文献2、3)。
その際、透明なプラスチック材料の層には取り扱い中の擦傷、曲げ、圧縮、引っ張り、ねじれ、温度や湿度の変化による不均一な変形などの応力が加わる。それらの中で透明なプラスチック材料の表面層の擦傷性の問題がある。この擦傷性に対する耐性が低いと擦り傷のついた製品が発生しやすく、製品歩留まりの低下に繋がる。
また、特許文献5には、(メタ)アクリル系樹脂を保護層とする場合には機械的強度などが不足する場合があるとし、保護層である(メタ)アクリル系樹脂の外表面(機能性シートとしての)にポリカーボネート系樹脂層を有するものを用いるとの記載がある。
本発明は、上記に鑑みてなされたものであり、機能層と保護層との接着性を改善し、保護層の擦り傷への耐性を向上させた偏光性或いはフォトクロミック性の機能層を有する機能性シートおよびそれを用いたレンズを提供することを課題とする。
(1)偏光性或いは調光性の機能層とその両面に芳香族ポリカーボネート樹脂シート或いはフィルムからなる保護層を用いてなる機能性シートにおいて、少なくとも片面の前記保護層が芳香族ポリカーボネート樹脂層の片面或いは両面にアクリル系樹脂層を有する共押出しシート或いはフィルムであって、前記機能性シートの少なくとも片面がアクリル系樹脂層であることを特徴とする機能性シート。
(3)前記調光性の機能層が、調光性有機化合物を混合した非芳香族系のポリマー溶液を用いてキャスティング法にて製造されたものである前記(1)記載の機能性シート。
(4)前記調光性の機能層が、調光性有機化合物を混合したポリウレタンプレポリマーとその硬化剤からなる2液型の熱硬化性ウレタン樹脂を加熱硬化したものである前記(1)記載の機能性シート。
(5)前記調光性の機能層が、保護層である共押しシート或いはフィルムまたは偏光性の機能層を接着する層である前記(4)記載の機能性シート。
(7)前記共押出しシート或いはフィルムのリタデーションが3000nm以上である前記(1)記載の機能性シート。
(9)前記(1)記載の機能性シートであって、片面がアクリル系樹脂層、反対面が芳香族ポリカーボネート樹脂層である機能性シートをアクリル系樹脂層が凸面側となるように外形加工し加熱加圧下に曲げ加工した後、凸面側を金型面側として金型に装着し、凹面側に芳香族ポリカーボネート樹脂を射出成形してなる成形レンズ。
(10)前記(8)または(9)記載のレンズを用いてなるサングラスまたはゴーグル。
本発明の機能性シートは、(a)偏光性或いは調光性の機能層、(b)少なくとも片面の保護層が芳香族ポリカーボネート樹脂層とアクリル系樹脂層との共押出しシート或いはフィルムである保護層、および適宜、(c)機能層aと保護層b、または機能層a相互を接着するための接着層とからなる。
また、この機能性シートを曲げ加工してなるレンズ、並びに、機能性シートを曲げ加工し金型に装着し、透明熱可塑性樹脂を射出成形してなる成形レンズである。
本発明の偏光性の機能層は、ポリビニルアルコール系樹脂のフィルムを二色性の有機染料で染色および延伸して製造されたものを通常用いる。
このポリビニルアルコール類としては、ポリビニルアルコール(PVA)、PVAの酢酸エステル構造を微量残したもの及びPVA誘導体または類縁体であるポリビニルホルマール、ポリビニルアセタール、エチレン-酢酸ビニル共重合体ケン化物等が例示され、特にPVAが好ましい。このフィルムを一方向に延伸させつつ、2色性の有機染料を含浸もしくは吸着させ、適宜、固定し、乾燥して偏光のフィルムとする。
PVAフィルムの重量平均分子量は、50,000~350,000、好ましくは、分子量150,000~300,000である。原料PVAフィルムの厚みは、通常100~300μm程度であり、これを延伸・染色してなるPVA偏光フィルムは、通常10~50μmである。
PVAフィルムの延伸倍率は2~8倍であり、目的に応じて適宜選択されるが、延伸後の強度の点から3~5倍が好ましい。
本発明の調光(フォトクロミック)層は、(1)予め製造された調光性のフィルムとして用いても良いし、また、(2)調光性有機化合物を配合した調光性の接着剤層として用いても良い。
前記(1)の調光性のフィルムは、非芳香族系の樹脂フィルムに調光性有機化合物が均一分散したものであり、キャスティング法、溶融押出し法、さらに、熱拡散法などの公知の方法にて製造できる。基材の樹脂としては、アセチルセルロースなどのセルロース系、エチレン-酢酸ビニル共重合体懸化物などが挙げられ、熱拡散などの基材フィルムに耐熱性が要求される場合にはポリウレタンやジアリルカーボネートなどを用いた硬化物フィルムが挙げられる。
本発明では、ポリウレタンプレポリマーとその硬化剤からなる2液型の熱硬化性ウレタン樹脂が好ましい。
フォトクロミック化合物としては、公知のスピロピラン系、スピロオキサジン系、ナフトピラン系などの化合物が挙げられ、1種または2種以上混合物で用いる。
本発明では、少なくとも片面の保護層として、芳香族ポリカーボネート樹脂層とアクリル系樹脂層とからなる共押出しシート或いはフィルムを用いる。芳香族ポリカーボネート樹脂層とアクリル系樹脂層とを持つシート或いはフィルムは、共押出しのほかに、押出しラミネート、熱や超音波を用いたフィルムやシート同士の融着法、コーティング法など公知の方法で製造が可能であり、各々利点と欠点を持つものである。
コーティング法は、溶剤があれば、押し出しなどの出来ない高分子量の樹脂を溶液として用いることが可能であり、また、硬化性のものの使用も一般的であり、極めて広い応用範囲を持つ優れた製法である。しかし、芳香族ポリカーボネート樹脂は、耐溶剤クラック性に劣るため、用いることの出来る溶剤や硬化性モノマーの成分とその量比、更に使用方法などの細かい制御が必要不可欠である。さらに、高リタデーション値のものは、低いものに比べて耐クラック性に劣るためより細かい制御が必要不可欠であるとの問題があった。
本発明の共押出しシート或いはフィルムは、2層または3層である。アクリル系樹脂層の物性は、その目的から通常は、2層では表面硬度の改良かまたは耐薬品性の改良かの何れかを主目的として選択し、3層では、上記の他にこの両者をもつものを選択する。
共押出しシート或いはフィルムの場合、アクリル系樹脂層の厚みは、全厚みの50%未満で10μm以上であり、通常、10μm~500μm、好ましくは20~100μmの範囲から選択する。
リタデーション値が100nm以下の場合、主鎖に対して垂直方向に向いた芳香環をもつモノマーを共重合(例えば、フルオレン基置換のビスフェノール、スチレングラフトビスフェノールAポリカーボネートなど)することにより、光弾性率を小さくしたものを用いて製造した共重合ポリカーボネート樹脂を用いたものが好ましい。
通常の芳香族ポリカーボネート樹脂(2,2-ビス(4-ヒドロキシフェニル)プロパンを用いたもの)の場合、リタデーションの値が3000nm以上20000nm以下、好ましくは4000nm以上、特に5000nm以上のものを選択する。なお、高いリタデーション値をもつものとは、分子配向に基づく大きな歪(残留応力)をもつことであり、一般的に残留応力の小さいものに比較して耐クラック性に劣るという欠点も有する。
本発明で用いる表面硬度を改良した共押出しシート或いはフィルムの場合、高リタデーションのものは工業的には生産されていない。
前記した芳香族ポリカーボネート樹脂の方法をそのまま表面硬度を改良した共押出しシート或いはフィルムの場合に適用することを試みたところ、延伸量を大きくしていくとフィルム切れが発生し製造できないものであった。
分子量は、通常の範囲で良く、賦型性や機械的強度の観点から、好ましくは粘度平均分子量で17,000~40,000であり、押し出しにて製造するとの観点からは、より好ましくは20,000~30,000である。
MMAやMAを主体とした通常2H以上の硬質アクリル系樹脂は、耐擦り傷性の用途として表面層に好適に用いられる。これに対して、アルキル基の炭素数が2以上のアルキル(メタ)アクリレートを共重合したもの、通常、5モル%以上、好ましくは10モル%以上共重合した軟質アクリル系樹脂は、表面硬度や耐クラック性の改善の程度は劣るが柔軟で接着性などに優れたものであり、内層面用やハードコートなどのコーティング用の前処理層表面として好適に用いられる。
本発明では、保護層と機能層との接着、機能層として偏光フィルム層と調光性(フォトクロミック)フィルムとを用いる場合の相互接着に接着剤層を用いる。
使用される接着剤としては、アクリル樹脂系材料、ウレタン樹脂系材料、ポリエステル樹脂系材料、メラミン樹脂系材料、エポキシ樹脂系材料、シリコーン系材料等が挙げられる。特に芳香族ポリカーボネートとの接着性、及び、偏光層や調光層との接着性から、ウレタン樹脂系材料であるポリウレタンプレポリマーと硬化剤からなる2液型の熱硬化性ウレタン樹脂が好ましい。
以上を用いて本発明の機能性シートを製造する。
通常、本発明の保護層として用いる芳香族ポリカーボネート樹脂層とアクリル系樹脂層とからなる共押出しシート或いはフィルムは、長尺のロールで入手されるのでその形態で用いられる。また、偏光性の機能層も長尺のロールで、さらに、調光性の機能層として予め製造された調光性のフィルムを用いる場合も長尺のロールで入手し、用いる。これらの場合、ロールから巻きだしたシート或いはフィルムに適宜、所定の表面処理を施し、本発明の接着剤の溶液を塗布し、乾燥して実質的に無溶剤の接着剤層を形成した後、これらを重ね加圧接着し、巻き取るか、重ねて接着した後、所定寸法に切断したものを、保存して硬化反応を進めることにより製造される。
まず、調光性のみの場合、すなわち、偏光フィルムを用いないときには、本発明の共押出しシート或いはフィルムの表面に調光性の機能層を形成することが必須となるので、調光性の接着剤組成物の成分として、芳香族ポリカーボネートに害のないものを選択するか、または、溶剤耐性を付与する層、例えば、前記した軟質アクリル樹脂層をもつ共押出しシート或いはフィルムのアクリル系樹脂層側を溶剤耐性層として用いることによる。
なお、偏光フィルムを用い、保護シート或いはフィルムとして高リタデーション品を採用する場合には、低リタデーション品に比較して耐クラック性に劣る傾向があるので、細心の注意が必要である。また、高リタデーション品を用いる場合、シート或いはフィルムの各々の延伸方向および偏光フィルムの延伸方向を互いに平行或いは垂直として用いる。
上記で製造した、偏光、調光、または偏光・調光である機能性シートを用いて、アクリル系樹脂層が凸面表面となるように外形加工し加熱加圧下に曲げ加工してレンズとするか、または、同様にして外形加工し曲げ加工した後、凸面側を金型に装着し、凹面側に透明な熱可塑性樹脂を射出成形して成形レンズとする。
射出成形せずに曲げたままでレンズとして用いる場合には、それ自体で強度をもつことが必須であり、また、両面が製品の表面となる。ゆえに、保護層に用いるシートは厚手のものとし、両表面がアクリル系樹脂となる構成として製造した機能性シートを選択する。厚みは、両面の合計で0.8mm以上、好ましくは1~3mmである。また、通常の芳香族ポリカーボネートを用いた共押しシートの場合、高リタデーションのものが好ましい。
また、通常、凸面である金型との接触面は、通常、成形レンズとされた後、その表面に各種機能性層を形成してレンズとされる。これらから、このような表面処理工程に好適な表面層を持ったものが好適であり、たとえば、柔軟性のあるアクリル系共重合体層を持つものを金型側として用いる。
用いる機能性シートの厚みは、両面の合計で0.3mm以上、好ましくは0.4~0.9mmである。
最も一般的な、通常の芳香族ポリカーボネート樹脂、すなわち、2,2-ビス(4-ヒドロキシフェニル)プロパンを主なモノマーとするポリカーボネート樹脂は、大きな光弾性定数を有する。
このため、この大きな光弾性定数を有するポリカーボネート樹脂を用いた場合、低リタデーションを保つような特別の操作を用いない場合、枠への固定、温度変化などによる応力や曲げ加工その他にて発生した応力が残り、偏光層をもつ機能性シートでは、この応力により発生した複屈折によって干渉縞が観察されるようになる。
これに対して、十分に大きなリタデーションのものを用いたもの場合、このような応力によって、新たに干渉縞が観察されるようにはならない。これは、十分に大きなリタデーションのものでは、応力複屈折の値による変化は無視できるもので、その方向が実質的に変化しないことを用いたものである。
まず、図1は本発明の保護層として用いる共押出しシートを示す概略断面図である。それぞれの層の厚みなどは、適宜、変更されるものであるが、共押出しシートの層構成としては、記載の4種となる。番号2が硬質アクリル系樹脂層であり、表面硬度の向上を主目的とするものである。番号3が軟質アクリル系樹脂層であり、耐溶剤性や層間接着力の向上を主目的とするものである。
本発明の機能性シートは、少なくとも片面に番号2或いは3の硬質或いは軟質アクリル系樹脂層をもつ。軟質アクリル系樹脂層においても、芳香族ポリカーボネート樹脂層1よりも耐擦り傷性に優れたものである。また、番号3の軟質アクリル系樹脂層をもつ面は、接着性の改良されたものとできるものである。なお、片側表面は番号1の芳香族ポリカーボネート樹脂層は、番号7の射出成形による芳香族ポリカーボネート樹脂層と一体化し界面を持たない成形品とするためである。
図4は、実施例3、4、5に相当する本発明の機能性シートを用いた成形レンズ(実施例7)を示す概略断面図である。
図5は、従来例の機能性シートを示す概略断面図である。
なお、本発明の機能性シートは、そのままで耐擦り傷性の改良されたものとして、または、適宜、反射防止層、ハードコート層、防汚層、防曇層等の各種機能性層を形成して、偏光板、フォトクロミック板、偏光・フォトクロミック板などに用いることができる。
[保護層]
共押シート1(図1a参照):
PC/PMMA共押出しシート(PMMA:メチルメタクリレート、三菱ガス化学株式会社製)をバッチ式の延伸機で温度160℃の加熱下に延伸して、厚み0.7mm(PMMA層の厚さ100μm)、リタデーション値約5500nmとした。
このシートはPCとPMMAとの境界に傾斜構造が生じており、境界での光の反射は比較的少ない。
共押シート2(図1b参照):
PMMA/PC/C-PMMA共押出しシート(C-PMMA:メチルメタクリレート、メチルアクリレートおよびブチルアクリレート共重合体、三菱ガス化学株式会社製)を前記と同様にして1軸延伸して、厚み0.7mm、リタデーション値約5500nm(PMMA層の厚さ100μm、C-PMMAの厚さ約30μm)とした。
このシートも前記と同様に境界に傾斜構造が生じているものである。
厚さ0.3mmのPC/PMMAの2層共押出しシート(PMMA層の厚さ60μm、三菱ガス化学株式会社製)を準備した。このシートは前記と同様に境界に傾斜構造が生じているものである。
共押シート4(図1a参照):
PC/PMMAの2層共押出しシート(三菱ガス化学株式会社製)を前記と同様にして1軸延伸して、厚み0.3mm、リタデーション値約5500nm(PMMA:メチルメタクリレート、メチルアクリレート共重合体、厚さ約50μm)とした。
このシートは前記と同様に境界に傾斜構造が生じているものである。
C-PMMA/PC/C-PMMAの3層共押出しシート(三菱ガス化学株式会社製)を前記と同様にして1軸延伸して、厚み0.3mm、リタデーション値約5500nm(C-PMMA層の厚さ約30μm)とした。
このシートも前記と同様に境界に傾斜構造が生じているものである。
共押シート6(図1d参照):
PC/C-PMMA共押出しシート(三菱ガス化学株式会社製)を前記と同様にして1軸延伸して、厚み0.3mm、リタデーション値約5500nm(C-PMMA層の厚さ約30μm)とした。
このシートも前記と同様に境界に傾斜構造が生じているものである。
PVAフィルム(クラレ株式会社製、商品名VF-PS#7500)を35℃の水に浸漬させてフィルムに含まれるグリセリンを除去した。次いでスミライトレッド4B-P(C.I.28160)0.35g/L、クリソフェニン(C.I.24895)0.18g/L、スミライトスプラブルーG(C.I.34200)1.33g/L及び無水硫酸ナトリウム5g/Lを含む35℃の水溶液に3分間浸漬させ、この染色時とその後で一方向に4倍延伸させた。この染色フィルムを酢酸ニッケル2.5g/Lおよびホウ酸6.0g/Lを含む35℃の水溶液に3分間浸漬させた。そのフィルムを緊張状態が保持された状態のまま室温下で3分間乾燥した後、110℃で3分間加熱処理し、偏光フィルムを得た。
ポリウレタンプレポリマー100gに、硬化剤20gを加え、フォトクロミック化合物として4-[4-〔6-(4-モルフォニル)-3-フェニル-3H-ナフト(2,1-b)ピラン-3-イル〕フェニル]-モルフィン(商品名:ReversacolFlame、James RobinsonLTD社製)を0.82g(溶媒の揮散と硬化後の全重量に対して1%)添加し、室温下で1時間攪拌してフォトクロミック性の接着剤溶液を調製した。
ポリウレタンプレポリマー50重量部に対し、硬化剤5重量部、溶媒として酢酸エチル60重量部を使用して接着剤組成物を調製した。
実施例1(図2a参照)
得られた偏光シートの鉛筆硬度試験JIS-K-5600-5-4を実施したところ、鉛筆硬度3Hであることが確認された。
比較例1(図5参照)
実施例1と同様に鉛筆硬度試験行ったところ、鉛筆硬度がBであった。
実施例2(図2b参照)
実施例1と同様に鉛筆硬度試験行ったところ、鉛筆硬度3Hであることが確認された。
なお、この接着剤組成物をPC面に塗布し乾燥した場合には、微細クラックの発生が観察されることが多いが、本実施例の場合には微細なクラックの発生は見られなかった。
実施例3(図2c参照)
実施例1と同様に鉛筆硬度試験行ったところ、PMMA側の鉛筆硬度3H、PC側の鉛筆硬度Bであった。
実施例4(図2d参照)
実施例1と同様に鉛筆硬度試験行ったところ、C-PMMA側の鉛筆硬度H、PC側の鉛筆硬度Bであった。
なお、この接着剤組成物をPC面に塗布し乾燥した場合には、微細クラックの発生が観察されることが多いが、本実施例の場合にも実施例2と同様に微細なクラックの発生は見られなかった。
実施例5(図2e参照)
実施例1と同様に鉛筆硬度試験行ったところ、PMMA側の鉛筆硬度3H、PC側の鉛筆硬度Bであった。
実施例6(図3参照)
これを真空吸引付きでシリコンゴムシート被覆を備えた凹球面曲げ型(曲率半径66.81mm、ベースカーブ7.932)を用い、表面温度145℃に設定した雌型のシリコンゴムシート上にカット片を載せ、真空吸引を開始し、次にシリコンゴムシート被覆した雄型にて加圧することにより球面曲げ加工を行った。なお、ここで言うベースカーブとは、レンズ前面の曲率であり、530をミリメータ単位の曲率半径で除した値のことである。
所望形状への打ち抜き、曲げ加工性共に良好であり、表面の擦り傷の生じ難い曲げレンズが得られた。
実施例7(図4参照)
次に、射出成形に用いる金型の球面状の表面(曲率半径66.81mm、ベースカーブ7.932)に合うように、同じ表面形状を持つ金型を用いて、PMMA或いはC-PMMA側を凸面側として曲げ加工を行った。
この曲げ品を射出成形用の金型内にインサートし、凹面側に300℃で芳香族ポリカーボネート樹脂を射出成形することにより芳香族ポリカーボネート偏光及び調光レンズを作製した。
得られた成形レンズは、通常、さらにハードコート処理などして用いられる。
未処理においても凸面側が擦り傷の生じ難いものであることから、取り扱い容易となり、さらに、ハードコート処理後の耐擦り傷もより向上したものが得られた。
2 硬質アクリル系樹脂層
3 軟質アクリル系樹脂層
4 接着層
5 偏光フィルム層
6 調光層
7 射出成形による芳香族ポリカーボネート樹脂層
Claims (10)
- 偏光性或いは調光性の機能層とその両面に芳香族ポリカーボネート樹脂シート或いはフィルムからなる保護層を用いてなる機能性シートにおいて、少なくとも片面の前記保護層が芳香族ポリカーボネート樹脂層の片面或いは両面にアクリル系樹脂層を有する共押出しシート或いはフィルムであって、前記機能性シートの少なくとも片面がアクリル系樹脂層であることを特徴とする機能性シート。
- 前記偏光性の機能層が、ポリビニルアルコール系樹脂のフィルムを二色性の有機染料で染色および延伸して製造されたものである請求項1記載の機能性シート。
- 前記調光性の機能層が、調光性有機化合物を混合した非芳香族系のポリマー溶液を用いてキャスティング法にて製造されたものである請求項1記載の機能性シート。
- 前記調光性の機能層が、調光性有機化合物を混合したポリウレタンプレポリマーとその硬化剤からなる2液型の熱硬化性ウレタン樹脂を加熱硬化したものである請求項1記載の機能性シート。
- 前記調光性の機能層が、保護層である共押しシート或いはフィルムまたは偏光性の機能層を接着する層である請求項4記載の機能性シート。
- 前記共押出しシート或いはフィルムのアクリル系樹脂層が、厚さ60μmのときに2H以上の鉛筆硬度を示す硬質アクリル系樹脂層またはアルキル基の炭素数が2以上のアルキル(メタ)アクリレートを共重合成分として5モル%以上用いた軟質アクリル系樹脂層である請求項1記載の機能性シート。
- 前記共押出しシート或いはフィルムのリタデーションが3000nm以上である請求項1記載の機能性シート。
- 請求項1記載の機能性シートであって、両面がアクリル系樹脂層である機能性シートを外形加工し加熱加圧下に曲げ加工してなるレンズ。
- 請求項1記載の機能性シートであって、片面がアクリル系樹脂層、反対面が芳香族ポリカーボネート樹脂層である機能性シートをアクリル系樹脂層が凸面側となるように外形加工し加熱加圧下に曲げ加工した後、凸面側を金型面側として金型に装着し、凹面側に芳香族ポリカーボネート樹脂を射出成形してなる成形レンズ。
- 請求項8または9記載のレンズを用いてなるサングラスまたはゴーグル。
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- 2010-10-20 KR KR20127012888A patent/KR20120085817A/ko not_active Application Discontinuation
- 2010-10-20 US US13/502,415 patent/US20120206689A1/en not_active Abandoned
- 2010-10-20 CN CN201080047501.5A patent/CN102576112B/zh not_active Expired - Fee Related
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Also Published As
Publication number | Publication date |
---|---|
US10534199B2 (en) | 2020-01-14 |
KR20170116236A (ko) | 2017-10-18 |
EP2492723A4 (en) | 2017-05-31 |
EP2492723A1 (en) | 2012-08-29 |
EP2492723B1 (en) | 2019-09-25 |
US20120206689A1 (en) | 2012-08-16 |
TWI532595B (zh) | 2016-05-11 |
US20150160479A1 (en) | 2015-06-11 |
KR20120085817A (ko) | 2012-08-01 |
CN102576112B (zh) | 2014-12-31 |
JPWO2011049108A1 (ja) | 2013-03-14 |
TW201121787A (en) | 2011-07-01 |
ES2755023T3 (es) | 2020-04-21 |
KR102114534B1 (ko) | 2020-05-22 |
CN102576112A (zh) | 2012-07-11 |
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