WO2013137388A1 - 光学フィルムロール - Google Patents
光学フィルムロール Download PDFInfo
- Publication number
- WO2013137388A1 WO2013137388A1 PCT/JP2013/057188 JP2013057188W WO2013137388A1 WO 2013137388 A1 WO2013137388 A1 WO 2013137388A1 JP 2013057188 W JP2013057188 W JP 2013057188W WO 2013137388 A1 WO2013137388 A1 WO 2013137388A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- film
- optical film
- liquid crystal
- polarizing film
- roll
- Prior art date
Links
Images
Classifications
-
- 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
- G02B5/3058—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state comprising electrically conductive elements, e.g. wire grids, conductive particles
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
- B29C55/08—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique transverse to the direction of feed
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
- B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
- B29C55/14—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
- B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
- B29C55/16—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial simultaneously
-
- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
-
- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/04—Punching, slitting or perforating
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/20—Filters
- G02B5/22—Absorbing filters
-
- 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
-
- 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
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133509—Filters, e.g. light shielding masks
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
- G02F1/133536—Reflective polarizers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
- B29K2029/04—PVOH, i.e. polyvinyl alcohol
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/0034—Polarising
-
- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/04—Punching, slitting or perforating
- B32B2038/045—Slitting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/416—Reflective
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/42—Polarizing, birefringent, filtering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
- G02F1/133531—Polarisers characterised by the arrangement of polariser or analyser axes
Definitions
- the present invention relates to an optical film roll.
- Patent Document 1 A number of methods (so-called roll-to-panel; RTP) in which a roll-shaped optical film is cut while being sent out in a liquid crystal display panel production line and bonded to a liquid crystal cell have been proposed (for example, Patent Document 1).
- a long optical film that includes a polarizing film having an absorption axis in the longitudinal direction and is cut (slit) into a width corresponding to the short side of the liquid crystal cell is wound into a roll.
- a roll-shaped optical film that includes a film and is slit to a width corresponding to the long side of the liquid crystal cell is cut out to a length corresponding to the short side of the liquid crystal cell, and bonded to the other surface of the liquid crystal cell.
- Patent Document 2 it has been proposed that the problem related to the technique described in Patent Document 1 can be solved by using a polarizing film having an absorption axis in the width direction for one optical film (for example, Patent Document 2).
- a polarizing film having an absorption axis in the width direction for one optical film
- display characteristics of the obtained liquid crystal display panel are insufficient.
- the present invention has been made to solve the above-described conventional problems, and a main object thereof is to provide an optical film roll capable of realizing excellent display characteristics while maintaining manufacturing efficiency. .
- the optical film roll of the present invention has a width corresponding to a pair of opposite sides of the liquid crystal cell, and is cut into a length corresponding to the other pair of opposite sides of the liquid crystal cell.
- a long optical film obtained by slitting in the conveying direction while being conveyed is wound in a roll shape.
- the polarizing film has a thickness of less than 10 ⁇ m.
- the said optical film original fabric has laminated
- an optical film roll set is provided.
- the optical film roll set has a width corresponding to one pair of sides facing the liquid crystal cell, and the other pair of sides facing the liquid crystal cell.
- a long optical film including a polarizing film having an absorption axis in the longitudinal direction was wound into a roll shape.
- a second optical film roll is provided.
- the driving mode of the liquid crystal cell is a VA mode or an IPS mode.
- the manufacturing method of an optical film roll is provided.
- This method of manufacturing an optical film roll has a width corresponding to a pair of opposite sides of the liquid crystal cell, and is cut into a length corresponding to the other pair of opposite sides of the liquid crystal cell.
- a method for producing an optical film roll used for bonding to the surface of a cell, wherein a polarizing film having an absorption axis in the width direction and a reflective polarizing film having a reflection axis in the width direction are laminated in this order to be long A step of producing an optical film original fabric, a step of slitting the optical film original fabric with a width corresponding to a pair of opposing sides of the liquid crystal cell in parallel with the longitudinal direction thereof, and the slit And a step of winding the long optical film obtained in the step into a roll.
- the polarizing film has a thickness of less than 10 ⁇ m.
- the said optical film original fabric has laminated
- the optical film roll of the present invention it is possible to provide a liquid crystal display panel having excellent display characteristics while being excellent in production efficiency.
- FIG. 1 is a schematic perspective view of an optical film roll according to a preferred embodiment of the present invention. It is a partial expanded sectional view of the film of FIG. 1A. It is a partial expanded sectional view of the optical film by another embodiment of the present invention. It is a partial expanded sectional view of the optical film by another embodiment of this invention. It is a graph explaining the calculation method of the Nz coefficient of a polyvinyl alcohol-type resin film. It is the schematic explaining the specific example of the manufacturing method of a polarizing film. It is the schematic explaining the specific example of the manufacturing method of a polarizing film. It is a schematic perspective view of an example of a reflective polarizing film. It is the schematic explaining the evaluation method of orientation nonuniformity.
- Refractive index (nx, ny, nz) “Nx” is the refractive index in the direction in which the in-plane refractive index is maximum (that is, the slow axis direction), “ny” is the refractive index in the direction perpendicular to the slow axis in the plane, and “nz” "Is the refractive index in the thickness direction.
- Re Refractive index
- ny refractive index in the direction perpendicular to the slow axis in the plane
- nz Is the refractive index in the thickness direction.
- FIG. 1A is a schematic perspective view of an optical film roll according to a preferred embodiment of the present invention
- FIG. 1B is a partially enlarged sectional view of the film of FIG. 1A
- FIG. 1C is a partially enlarged sectional view of a film of another embodiment
- FIG. 1D is a partially enlarged sectional view of a film according to still another embodiment.
- the optical film roll 100 is formed by winding a long optical film into a roll shape.
- the optical film 100 has a width corresponding to a pair of opposing sides of the liquid crystal cell to be bonded. More specifically, RTP has a width corresponding to the side of the liquid crystal cell in the direction (width direction) orthogonal to the direction (bonding direction) when continuously pasting to the surface of the liquid crystal cell.
- the optical film 100 includes a polarizing plate 10. In one embodiment, as illustrated in FIG. 1B, the polarizing plate 10 is disposed on the polarizing film 11, the first protective film 21 disposed on one side of the polarizing film 11, and the other side of the polarizing film 10. And a second protective film 22.
- the polarizing plate 10 includes a polarizing film 11 and a first protective film 21 disposed on one side of the polarizing film 11. That is, the second protective film 22 may be omitted. According to this embodiment, there is an advantage that a reduction in thickness can be achieved while imparting appropriate resistance to environmental changes.
- the polarizing plate 10 can be composed of a polarizing film 11. That is, both the first protective film 21 and the second protective film 22 may be omitted.
- the optical film 100 includes an adhesive layer 30 disposed on one side of the polarizing plate 10 and a reflective polarizing film 40 disposed on the other side of the polarizing plate 10. As shown in the figure, practically, a release film 50 is bonded to the surface of the pressure-sensitive adhesive layer 30, and as the outermost layer on the opposite side, surface protection (on the surface of the reflective polarizing film 40 in the illustrated example). A film 60 is disposed. Although not shown, the optical film 100 may include other films (layers).
- the polarizing film 11 has an absorption axis in the width direction X.
- the direction of the absorption axis of the polarizing film 11 may include a direction of ⁇ 5 ° to + 5 ° counterclockwise with respect to the width direction X of the optical film.
- the reflective polarizing film 40 has a reflection axis in the width direction X thereof.
- the direction of the reflection axis of the reflective polarizing film 40 may include a direction of ⁇ 5 ° to + 5 ° counterclockwise with respect to the width direction X of the optical film.
- the polarizing plate includes at least a polarizing film.
- the polarizing plate is configured by arranging a protective film on at least one side of the polarizing film.
- the polarizing film is typically composed of a polyvinyl alcohol resin (hereinafter referred to as “PVA resin”) film containing a dichroic substance.
- PVA resin polyvinyl alcohol resin
- dichroic substance examples include iodine and organic dyes. These may be used alone or in combination of two or more. Preferably, iodine is used.
- any appropriate resin can be used as the PVA resin for forming the PVA resin film.
- Examples thereof include polyvinyl alcohol and ethylene-vinyl alcohol copolymer.
- Polyvinyl alcohol is obtained by saponifying polyvinyl acetate.
- the ethylene-vinyl alcohol copolymer can be obtained by saponifying an ethylene-vinyl acetate copolymer.
- the degree of saponification of the PVA-based resin is usually 85 mol% to 100 mol%, preferably 95.0 mol% to 99.95 mol%, more preferably 99.0 mol% to 99.93 mol%. .
- the degree of saponification can be determined according to JIS K 6726-1994. By using a PVA resin having such a saponification degree, a polarizing film having excellent durability can be obtained. If the degree of saponification is too high, there is a risk of gelation.
- the average degree of polymerization of the PVA resin can be appropriately selected according to the purpose.
- the average degree of polymerization is usually 1000 to 10,000, preferably 1200 to 4500, and more preferably 1500 to 4300.
- the average degree of polymerization can be determined according to JIS K 6726-1994.
- the Nz coefficient of the PVA resin film is preferably 1.10 or more, more preferably 1.20 or more.
- the Nz coefficient of the PVA resin film is preferably 1.50 or less, more preferably 1.40 or less.
- the orientation (uniaxiality) of the PVA-based resin film is low, and for example, the display quality required for a liquid crystal television may not be obtained.
- the Nz coefficient of the PVA resin film is an index of molecular chain orientation of the PVA resin film, and is calculated from the phase difference of the PVA resin film.
- the phase difference (a value) of the PVA-based resin film is measured by changing the measurement wavelength ( ⁇ ) and the phase difference of the polarizing film is measured. As shown in FIG. 2, the phase difference of the polarizing film is plotted with the horizontal axis as the measurement wavelength. Then, an approximate curve is created based on the following equation, and an asymptote (a value) is calculated from the approximate curve.
- the retardation of the polarizing film is measured from the front and oblique directions.
- R a + b / ( ⁇ 2 ⁇ 600 2 )
- R retardation of the polarizing film
- a retardation of the PVA resin film
- b constant.
- the polarizing film preferably exhibits absorption dichroism at any wavelength between 380 nm and 780 nm.
- the degree of polarization at a single transmittance of 40% or 41% of the polarizing film is preferably 99.9% or more, more preferably 99.93% or more, and further preferably 99.95% or more.
- the thickness of the polarizing film can be set to any appropriate value.
- the thickness is preferably 30 ⁇ m or less, more preferably 25 ⁇ m or less, still more preferably 20 ⁇ m or less, and particularly preferably less than 10 ⁇ m.
- the polarizing film has a larger shrinkage force than the protective film, and a stress may be generated at the interface between the polarizing film and the protective film to cause cracks.
- the shrinkage force of the polarizing film depends on the thickness. The thinner the thickness, the smaller the shrinkage force, and a polarizing plate having excellent durability can be obtained.
- the thickness is preferably 0.5 ⁇ m or more, more preferably 1 ⁇ m or more. If the thickness is less than 0.5 ⁇ m, sufficient optical properties may not be obtained.
- the polarizing film is produced by any appropriate method as long as it has an absorption axis in the width direction.
- the polarizing film is typically produced by subjecting a PVA resin film to treatments such as stretching and dyeing as appropriate.
- the PVA-based resin film is typically formed in a long shape.
- the thickness of the PVA resin film is preferably less than 100 ⁇ m.
- the PVA resin film may be, for example, a PVA resin film or a PVA resin layer formed on a thermoplastic resin substrate.
- the PVA resin film is preferably used when a polarizing film having a thickness of 10 ⁇ m or more is produced.
- the thickness of the PVA resin film is preferably 30 ⁇ m to 80 ⁇ m.
- the laminate of the thermoplastic resin substrate and the PVA resin layer is preferably used when a polarizing film having a thickness of less than 10 ⁇ m is produced.
- the thickness of the PVA resin layer is preferably 3 ⁇ m to 20 ⁇ m. Even such a thin thickness can be satisfactorily stretched by using a thermoplastic resin substrate.
- the thickness (before stretching) of the thermoplastic resin base material constituting the laminate is preferably 50 ⁇ m to 250 ⁇ m. If it is less than 50 ⁇ m, there is a risk of breaking during stretching. In addition, the thickness may become too thin after stretching, which may make conveyance difficult. If it exceeds 250 ⁇ m, an excessive load may be applied to the stretching machine. Moreover, there exists a possibility that conveyance may become difficult.
- thermoplastic resin substrate examples include ester resins such as polyethylene terephthalate resin, cycloolefin resins, olefin resins such as polypropylene, polyamide resins, polycarbonate resins, and copolymer resins thereof. Can be mentioned. Among these, cycloolefin resins (for example, norbornene resins) and amorphous polyethylene terephthalate resins are preferable. Specific examples of the amorphous polyethylene terephthalate resin include a copolymer further containing isophthalic acid as a dicarboxylic acid, and a copolymer further containing cyclohexanedimethanol as a glycol.
- ester resins such as polyethylene terephthalate resin, cycloolefin resins, olefin resins such as polypropylene, polyamide resins, polycarbonate resins, and copolymer resins thereof. Can be mentioned. Among these, cycloolefin
- the glass transition temperature (Tg) of the thermoplastic resin substrate is preferably 170 ° C. or lower. By using such a thermoplastic resin base material, it is possible to stretch the laminate at a temperature at which crystallization of the PVA resin does not proceed rapidly, and defects due to the crystallization (for example, the PVA resin layer due to stretching). Which prevents orientation).
- the glass transition temperature (Tg) is a value determined according to JIS K 7121.
- the thermoplastic resin substrate is stretched before forming the PVA-based resin layer.
- the stretching direction can be set in any appropriate direction.
- an extending direction is a conveyance direction (MD) of a thermoplastic resin base material.
- the conveying direction is preferably the long direction of the long thermoplastic resin base material, and includes the direction of ⁇ 5 ° to + 5 ° counterclockwise with respect to the long direction of the thermoplastic resin base material.
- the stretching direction is a direction (TD) orthogonal to the transport direction.
- the direction orthogonal to the transport direction is preferably the width direction of the elongated thermoplastic resin base material, and is in the direction of 85 ° to 95 ° counterclockwise with respect to the long direction of the thermoplastic resin base material.
- orthogonal includes the case of being substantially orthogonal.
- substantially orthogonal includes the case of 90 ° ⁇ 5.0 °, preferably 90 ° ⁇ 3.0 °, more preferably 90 ° ⁇ 1.0 °.
- Arbitrary appropriate methods can be employ
- the stretching of the thermoplastic resin substrate may be performed in one step or in multiple steps. When performed in multiple stages, the stretch ratio of the thermoplastic resin substrate described later is the product of the stretch ratios of the respective stages.
- stretching system in this process is not specifically limited, An air extending
- the stretching temperature of the thermoplastic resin substrate can be set to any appropriate value depending on the forming material of the thermoplastic resin substrate, the stretching method, and the like.
- the stretching temperature is typically not less than the glass transition temperature (Tg) of the thermoplastic resin substrate, preferably not less than Tg + 10 ° C., more preferably not less than Tg + 15 ° C. to Tg + 30 ° C.
- Tg glass transition temperature
- the stretching temperature is set to the glass transition temperature of the thermoplastic resin base material (for example, 60 ° C. to 100 ° C. ° C).
- the draw ratio of the thermoplastic resin substrate is preferably 1.5 times or more, more preferably 1.75 times or more with respect to the original length of the thermoplastic resin substrate. By setting the draw ratio to 1.5 times or more, a laminated body described later can be contracted more uniformly. On the other hand, the draw ratio is preferably 2.5 times or less.
- the surface of the thermoplastic resin substrate may be subjected to surface modification treatment (for example, corona treatment), or an easy adhesion layer may be formed on the thermoplastic resin substrate.
- surface modification treatment for example, corona treatment
- an easy adhesion layer may be formed on the thermoplastic resin substrate.
- a PVA-based resin layer is formed by applying a coating solution containing a PVA-based resin on a thermoplastic resin substrate and drying it.
- the PVA-based resin layer thus obtained is not only used as a laminate (as it is formed on the thermoplastic resin substrate), but is peeled off from the thermoplastic resin substrate and used as a PVA-based resin film. Also good.
- the coating solution is typically a solution obtained by dissolving the PVA resin in a solvent.
- the solvent include water, dimethyl sulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, various glycols, polyhydric alcohols such as trimethylolpropane, and amines such as ethylenediamine and diethylenetriamine. These may be used alone or in combination of two or more. Among these, water is preferable.
- the concentration of the PVA resin in the solution is preferably 3 to 20 parts by weight with respect to 100 parts by weight of the solvent. With such a resin concentration, a uniform coating film in close contact with the thermoplastic resin substrate can be formed.
- Additives may be added to the coating solution.
- the additive include a plasticizer and a surfactant.
- the plasticizer include polyhydric alcohols such as ethylene glycol and glycerin.
- the surfactant include nonionic surfactants. These can be used for the purpose of further improving the uniformity, dyeability and stretchability of the resulting PVA resin layer.
- any appropriate method can be adopted as a coating method of the coating solution. Examples thereof include a roll coating method, a spin coating method, a wire bar coating method, a dip coating method, a die coating method, a curtain coating method, a spray coating method, a knife coating method (comma coating method and the like).
- the drying temperature is preferably not higher than the glass transition temperature (Tg) of the thermoplastic resin substrate, more preferably not higher than Tg-20 ° C.
- Tg glass transition temperature
- the thermoplastic resin base material is prevented from being deformed before the PVA resin layer is formed, and the orientation of the resulting PVA resin layer is prevented from deteriorating. Can do.
- the thermoplastic resin substrate can be deformed well together with the PVA-based resin layer, and the later-described laminate can be satisfactorily contracted and stretched.
- good orientation can be imparted to the PVA-based resin layer, and a polarizing film having excellent optical properties can be obtained.
- “orientation” means the orientation of molecular chains of the PVA resin layer.
- the moisture content of the PVA resin layer is preferably 20% or less, more preferably 15% or less.
- stretching methods include fixed end stretching using a tenter stretching machine, free end stretching using rolls having different peripheral speeds, biaxial stretching using a simultaneous biaxial stretching machine, and sequential biaxial stretching. These may be employed alone or in combination of two or more.
- the transport direction (MD) through the rolls 32, 32, 33, 33 having different peripheral speeds (free end stretching)
- stretching to the direction (TD) orthogonal to a conveyance direction is mentioned.
- the Nz coefficient can be controlled by appropriately selecting stretching conditions such as a stretching method, a stretching ratio, and a stretching temperature.
- the polarizing film is produced by shrinking a PVA-based resin film in the transport direction (MD) and stretching it in a direction (TD) perpendicular to the transport direction.
- the transport direction is preferably the long direction of the long PVA resin film, and includes the direction of ⁇ 5 ° to + 5 ° counterclockwise with respect to the long direction of the PVA resin film. obtain.
- the direction orthogonal to the transport direction is preferably the width direction of the long PVA resin film, and includes the direction of 85 ° to 95 ° counterclockwise with respect to the long direction of the PVA resin film. obtain.
- thermoplastic resin base material When a laminate is composed of a thermoplastic base material obtained by subjecting MD to a stretching process in advance, the thermoplastic resin base material can be returned to the state before stretching by stretching to TD, heat, etc. Can be uniformly shrunk to MD. In this way, even when the shrinkage rate is high, it is possible to obtain a polarizing film having excellent in-plane uniformity by suppressing problems such as alignment unevenness and reduced thickness uniformity. Moreover, the uniaxiality of TD can be improved and the outstanding optical characteristic can be acquired by shrink
- the thermoplastic resin base material When the laminate is composed of a thermoplastic resin base material that has been subjected to fixed-end stretching on TD in advance, the thermoplastic resin base material generates a force that shrinks to MD due to heat during stretching to TD, etc. It is possible to suppress deterioration of uniformity due to necking between clips, which becomes a problem when the laminated body is stretched at the fixed end TD (not causing MD shrinkage). In particular, even when a thin PVA-based resin film is stretched at a high magnification, it is possible to obtain a polarizing film having excellent in-plane uniformity by suppressing problems such as uneven orientation and reduced thickness uniformity. . Moreover, the uniaxiality of TD can be improved and the outstanding optical characteristic can be acquired by shrink
- Shrinkage may be performed simultaneously with stretching or may be performed at another timing. Also, the order is not limited, and it may be contracted in one step or may be contracted in multiple steps.
- the PVA-based resin film is contracted to MD while being stretched to TD.
- the PVA resin film is preferably contracted to MD and then stretched to TD.
- a method of shrinking the laminate separately from stretching a method of heating (thermally shrinking) the laminate is preferable. The heating temperature is preferably equal to or higher than the glass transition temperature (Tg) of the thermoplastic resin substrate.
- the Nz coefficient can be satisfactorily satisfied by adjusting the shrinkage rate of the PVA resin film.
- the MD shrinkage of the PVA-based resin film is preferably 40% or less, more preferably 35% or less, and particularly preferably 20% or less. Excellent durability can be achieved. Note that the contraction of MD may be omitted as long as the Nz coefficient can be satisfactorily satisfied.
- the lower limit of MD shrinkage may be 0% in one embodiment and 5% in another embodiment.
- the shrinkage of MD is preferably greater than 25%, more preferably greater than 30% and less than 50%.
- the stretching of the PVA resin film may be performed in one stage or in multiple stages. When performed in multiple stages, the stretch ratio of the PVA-based resin film described later is the product of the stretch ratios of the respective stages.
- the stretching method in this step is not particularly limited, and may be an air stretching (dry stretching) method or an underwater stretching (wet stretching) method.
- the stretching temperature can be set to any appropriate value depending on the stretching method, the stretching target, and the like.
- the stretching temperature in the case of stretching a laminate of a thermoplastic resin substrate and a PVA resin layer by an air stretching method is set to any appropriate value depending on the material for forming the thermoplastic resin substrate. be able to.
- the stretching temperature is typically at least the glass transition temperature (Tg) of the thermoplastic resin substrate, preferably the glass transition temperature (Tg) of the thermoplastic resin substrate + 10 ° C. or more, more preferably Tg + 15 ° C. or more. .
- the stretching temperature is preferably 170 ° C. or lower.
- the stretching temperature is typically 70 ° C to 130 ° C, preferably 80 ° C to 120 ° C.
- the stretching temperature is preferably 85 ° C. or lower, more preferably 30 ° C. to 65 ° C. If the temperature exceeds 85 ° C., there is a risk that iodine adsorbed on the PVA-based resin may be eluted, or that the PVA-based resin may be eluted, and the optical characteristics of the obtained polarizing film may be deteriorated.
- a thermoplastic resin substrate that can be stretched even at the above temperature is selected.
- amorphous polyethylene terephthalate resin, olefin resin (for example, polymethylpentene) or the like is used as the forming material.
- the PVA resin film When employing an underwater stretching method, it is preferable to stretch the PVA resin film in a boric acid aqueous solution.
- a boric acid aqueous solution By using a boric acid aqueous solution, the PVA resin film can be provided with rigidity that can withstand the tension applied during stretching and water resistance that does not dissolve in water.
- boric acid can generate a tetrahydroxyborate anion in an aqueous solution and can be cross-linked with a PVA resin by hydrogen bonding, and can impart rigidity and water resistance.
- the aqueous boric acid solution is obtained by dissolving boric acid and / or borate in water as a solvent.
- the boric acid concentration is usually 1 to 10 parts by weight per 100 parts by weight of water.
- the immersion time of the PVA resin film in the stretching bath is preferably about 15 seconds to 5 minutes.
- the TD stretch ratio is preferably 4.0 times or more with respect to the original length of the PVA resin film. By contracting to MD, stretching at such a high magnification is possible, and a polarizing film having excellent optical characteristics can be obtained. On the other hand, the TD stretch ratio is preferably 6.0 times or less, and more preferably 5.5 times or less.
- FIG. 1 A specific example of the shrinking / stretching process is shown in FIG.
- the PVA resin film 11 ′ is contracted in the transport direction (MD) using a simultaneous biaxial stretching machine while the PVA resin film 11 ′ is transported in the longitudinal direction, and orthogonal to the transport direction. Stretch in the direction (TD).
- the PVA resin film 11 ′ held by the left and right clips 31, 31 at the tenter inlet is TD-stretched while being conveyed at a predetermined speed.
- the shrinkage of the PVA-based resin film is controlled, for example, by gradually decelerating the moving speed of the clip in the transport direction and shortening the distance between the clips.
- the shrinkage rate can be controlled by adjusting the distance L1 between the clips in the transport direction of the tenter inlet and the distance L2 between the clips in the transport direction of the tenter outlet (the moving speed of the clips in the transport direction). Specifically, a desired shrinkage rate can be achieved by setting the speed of the tenter outlet of the clip to the speed of the tenter inlet ⁇ (1 ⁇ shrinkage rate). In FIG. 3, the broken line indicates the rail of the clip 31.
- the PVA resin film when contracted and stretched using a simultaneous biaxial stretching machine, the PVA resin film is preferably contracted and then stretched. Specifically, TD stretching is performed after the distance between clips in the transport direction is shortened. According to such an embodiment, a force is applied uniformly by the PVA-based resin film during stretching, and the clip gripping portion can be prevented from being selectively stretched. Specifically, it is possible to prevent the portion that is not gripped by the clip from being bent inward at the edge of the PVA-based resin film. As a result, uniformity can be improved.
- A-2-3 Other treatments
- the treatment for producing the polarizing film include a dyeing treatment, an insolubilization treatment, a crosslinking treatment, a washing treatment, and a drying treatment in addition to the stretching treatment. These processes can be performed at any appropriate timing.
- the dyeing process is typically a process of dyeing a PVA resin film with the dichroic substance.
- the dichroic substance is adsorbed on the PVA resin film.
- the adsorption method include a method of immersing a PVA resin film in a dye solution containing a dichroic substance, a method of applying a dye solution to the PVA resin film, a method of spraying the dye solution on the PVA resin film, and the like. Is mentioned.
- the PVA-based resin film is immersed in a staining solution containing a dichroic substance. It is because a dichroic substance can adsorb
- the staining solution is preferably an iodine aqueous solution.
- the amount of iodine is preferably 0.04 to 5.0 parts by weight per 100 parts by weight of water.
- an iodide salt is added to the aqueous iodine solution.
- Examples of the iodide salt include potassium iodide, lithium iodide, sodium iodide, zinc iodide, aluminum iodide, lead iodide, copper iodide, barium iodide, calcium iodide, tin iodide, and iodide.
- Examples include titanium. Among these, potassium iodide and sodium iodide are preferable.
- the blending amount of the iodide salt is preferably 0.3 to 15 parts by weight with respect to 100 parts by weight of water.
- the liquid temperature during staining of the staining liquid is preferably 20 ° C. to 40 ° C.
- the immersion time is preferably 5 seconds to 300 seconds. Under such conditions, the dichroic substance can be sufficiently adsorbed on the PVA resin film.
- the insolubilization treatment and the crosslinking treatment are typically performed by immersing a PVA resin film in an aqueous boric acid solution.
- the cleaning treatment is typically performed by immersing a PVA resin film in an aqueous potassium iodide solution.
- the drying temperature in the drying treatment is preferably 30 ° C. to 100 ° C.
- protective film examples of the material for forming the protective film include (meth) acrylic resins, cellulose resins such as diacetyl cellulose and triacetyl cellulose, cycloolefin resins, olefin resins such as polypropylene, and polyethylene terephthalate resins. Examples thereof include ester resins, polyamide resins, polycarbonate resins, and copolymer resins thereof. In addition, you may use the said thermoplastic resin base material as a protective film as it is.
- the thickness of the protective film is preferably 20 ⁇ m to 100 ⁇ m.
- the protective film may be laminated on the polarizing film via an adhesive layer (specifically, an adhesive layer or an adhesive layer), or may be laminated in close contact with the polarizing film (without an adhesive layer). Also good.
- the adhesive layer is formed of any appropriate adhesive. Examples of the adhesive include a polyvinyl alcohol-based adhesive.
- the pressure-sensitive adhesive layer is formed of any appropriate pressure-sensitive adhesive. Typically, an acrylic adhesive is used.
- the thickness of the pressure-sensitive adhesive layer is preferably 7 ⁇ m to 25 ⁇ m.
- FIG. 5 is a schematic perspective view of an example of a reflective polarizing film.
- the reflective polarizing film is a multilayer laminate in which layers A having birefringence and layers B having substantially no birefringence are alternately laminated.
- the refractive index nx in the x-axis direction of the A layer is larger than the refractive index ny in the y-axis direction, and the refractive index nx in the x-axis direction and the refractive index ny in the y-axis direction of the B layer are substantially equal.
- the difference in refractive index between the A layer and the B layer is large in the x-axis direction and is substantially zero in the y-axis direction.
- the x-axis direction becomes the reflection axis
- the y-axis direction becomes the transmission axis.
- the refractive index difference in the x-axis direction between the A layer and the B layer is preferably 0.2 to 0.3.
- the x-axis direction corresponds to the stretching direction of the reflective polarizing film in the manufacturing method described later.
- the A layer is preferably made of a material that exhibits birefringence by stretching.
- Typical examples of such materials include naphthalene dicarboxylic acid polyester (for example, polyethylene naphthalate), polycarbonate, and acrylic resin (for example, polymethyl methacrylate). Polyethylene naphthalate is preferred.
- the B layer is preferably made of a material that does not substantially exhibit birefringence even when stretched.
- a typical example of such a material is a copolyester of naphthalenedicarboxylic acid and terephthalic acid.
- the reflective polarizing film transmits light having a first polarization direction (for example, p-wave) at the interface between the A layer and the B layer, and has a second polarization direction orthogonal to the first polarization direction. (For example, s wave) is reflected.
- the reflected light is partially transmitted as light having the first polarization direction and partially reflected as light having the second polarization direction at the interface between the A layer and the B layer.
- the light utilization efficiency can be increased by repeating such reflection and transmission many times inside the reflective polarizing film.
- the reflective polarizing film includes a reflective layer R as the outermost layer opposite to the polarizing film 11 as shown in FIG.
- a reflective layer R as the outermost layer opposite to the polarizing film 11 as shown in FIG.
- the total thickness of the reflective polarizing film can be appropriately set according to the purpose, the total number of layers included in the reflective polarizing film, and the like.
- the total thickness of the reflective polarizing film is preferably 20 ⁇ m to 600 ⁇ m.
- the reflective polarizing film for example, those described in JP-T-9-507308 can be used.
- a commercially available product may be used as it is, or a commercially available product may be used after secondary processing (for example, stretching).
- a commercial item 3M company brand name DBEF and 3M company brand name APF are mentioned, for example.
- the reflective polarizing film can be typically produced by combining coextrusion and transverse stretching. Coextrusion can be performed in any suitable manner. For example, a feed block method or a multi-manifold method may be used. For example, the material constituting the A layer and the material constituting the B layer are extruded in a feed block, and then multilayered using a multiplier. Such a multi-layer apparatus is known to those skilled in the art. Next, the obtained long multilayer laminate is typically stretched in a direction (TD) orthogonal to the transport direction. The material constituting the A layer (for example, polyethylene naphthalate) increases the refractive index only in the stretching direction due to the transverse stretching, and as a result, develops birefringence.
- TD direction orthogonal to the transport direction.
- the material constituting the A layer for example, polyethylene naphthalate
- the refractive index of the material constituting the B layer does not increase in any direction even by the transverse stretching.
- a reflective polarizing film having a reflection axis in the stretching direction (TD) and a transmission axis in the transport direction (MD) can be obtained (TD corresponds to the x-axis direction in FIG. 2 and MD is in the y-axis direction).
- stretching operation can be performed using arbitrary appropriate apparatuses.
- the optical film of the present invention can be obtained by laminating the reflective polarizing film and the polarizing film by any appropriate method. As described above, since the polarizing film has an absorption axis in TD, the polarizing film and the reflective polarizing film can be bonded together by roll-to-roll.
- the thickness of the polarizing film is thin (for example, less than 10 ⁇ m)
- sufficient rigidity is imparted to the optical film by combining with the reflective polarizing film, and the cutting performance (particularly, slit processing accuracy) can be improved.
- the axial direction can be favorably adjusted. As a result, a liquid crystal display panel having more excellent display characteristics can be provided.
- a polarizing film having an absorption axis in the width direction and a reflective polarizing film having a reflection axis in the width direction are laminated in advance (preferably, a roll). It is preferable to produce an optical film roll by slitting an elongated optical film original (integrated by a toe roll system). If the polarizing film is thin, the rigidity is low, and there is a possibility that the slit processing accuracy of the polarizing film (polarizing plate) alone cannot be sufficiently secured.
- the slit processing accuracy cannot be ensured, there is a possibility that the axial accuracy with the reflective polarizing film is lowered and the slit width accuracy is lowered.
- the absorption axis of the polarizing film and the reflective axis of the reflective polarizing film can be superimposed with high accuracy (the degree of polarization of the polarizing film can be sufficiently compensated by the reflective polarizing film).
- the reflective polarizing film imparts sufficient rigidity to the original optical film, and fluttering and meandering during slit processing can be suppressed to improve slit processing accuracy.
- the release film is typically composed of a plastic film and a release imparting layer provided on one side of the plastic film.
- a polyester film is preferably used as the plastic film.
- the thickness of the release film is preferably 25 to 50 ⁇ m.
- the surface protective film can function as a protective film for the polarizing plate.
- the surface protective film is typically a plastic film or a laminate of plastic films. Examples of the material of the plastic film include polyester and polypropylene.
- the thickness of the surface protective film is preferably 25 ⁇ m to 75 ⁇ m.
- Examples of the other film (layer) include a retardation plate.
- Arbitrary appropriate adhesives or adhesives are typically used for lamination
- the width of a long optical film wound into a roll as an optical film roll is preferably set corresponding to the size of the liquid crystal cell to be bonded.
- the long optical film has a width corresponding to a pair of opposing sides of the liquid crystal cell.
- the long optical film is preferably manufactured by slitting a wide and long optical film original sheet (roll original film before slitting). More preferably, a plurality of long optical films having the same width or different widths are simultaneously manufactured by slitting a wide and long optical film original (roll raw roll before slit).
- the slit processing includes a method of rewinding the optical film original and a method of rewinding without rewinding, both of which can be adopted.
- the slit processing is performed while rewinding the optical film original.
- the slit processing accuracy is further improved.
- you may slit before the winding in the production line of an optical film original fabric.
- the method for producing the optical film roll includes a release film, a pressure-sensitive adhesive layer, a polarizing plate including a polarizing film having an absorption axis in the width direction, and a reflection polarization having a reflection axis in the width direction.
- parallel includes the case of being substantially parallel.
- substantially parallel includes the case of 0 ° ⁇ 5.0 °, preferably 0 ° ⁇ 3.0 °, more preferably 0 ° ⁇ 1.0 °.
- FIG. 7A is a schematic perspective view for explaining an example of a production process of a long optical film original.
- an elongated optical film original fabric 100 ′ is composed of a polarizing plate with an adhesive layer 91 (a laminate of the polarizing plate 10, the adhesive layer 30, and the release film 50) and a reflection with a surface protective film. It can be obtained by laminating the polarizing film 92 (laminated body of the reflective polarizing film 40 and the surface protective film 60) by roll-to-roll. Lamination is performed such that the polarizing plate 10 and the reflective polarizing film 40 face each other via any appropriate pressure-sensitive adhesive or adhesive (not shown).
- a surface protective film is disposed on the surface where the protective film of the polarizing film is not provided in the polarizing plate with an adhesive layer. Then, lamination is performed while peeling the surface protective film (not shown).
- FIG. 7B is a schematic view showing an example of an apparatus for producing an optical film roll of the present invention.
- This manufacturing apparatus includes a roll R0 rewinding mechanism 80 of an optical film original fabric (roll original roll before slit) 100 ', a cutting mechanism 70 of the optical film original fabric 100', and a long shape obtained by slit processing. And a winding device 63 for winding rolls R1, R2 of the optical film 100. In the production line for long sheet-shaped products, the rewinding mechanism 80 is not necessary when slitting.
- the rewinding mechanism 80 is for rewinding the optical film original 100 'from the roll R0 by the tension generated by the nip roller 57, and includes a nip roller 57 and a roll support portion that rotates and supports the roll R0.
- the roll support portion may be provided with a braking mechanism, a drive mechanism, a tension control mechanism, and the like.
- the cutting mechanism 70 includes a cutting blade 51 provided in the conveyance path of the optical film original fabric 100 ′.
- the cutting blade include a gang blade and a gobel blade.
- the cutting method include a gang method and a share cut method.
- a rotatable circular cutting blade is arranged at a predetermined interval in the direction of the slit, and the slit is continuously performed while passing the optical film original 100 ′ between the cutting blade and the support roll. Is possible.
- FIG. 7C is a schematic perspective view illustrating details of the slit processing. In FIG. 7C, the cutting device 70 provided with the gang blade is shown. As shown in FIG.
- a plurality of optical films (optical film rolls) 100 can be obtained from the optical film original fabric 100 ′.
- the number of optical films obtained from the original optical film can be appropriately set according to the purpose.
- the width of each optical film may be the same or different as long as it corresponds to the size of the liquid crystal cell to be bonded.
- the cutting device provided with the laser apparatus instead of the cutting blade.
- the cutting mechanism 70 includes, for example, a cutting table provided on the back side of the original optical film and a laser device provided above the original optical film. The laser irradiation position is fixed, and the cutting proceeds by continuous conveyance of the optical film.
- the optical film roll of the present invention is cut into a length corresponding to another set of opposite sides of the liquid crystal cell, and is continuously bonded to the surface of the liquid crystal cell.
- “the length (width) corresponding to one pair (another pair) of opposite sides of the liquid crystal cell” refers to the case where the optical film is aligned and bonded to the liquid crystal cell. It refers to a length (width) that can ensure an appropriate manufacturing margin (specifically, an exposed portion where the optical film is not bonded) at the peripheral edge of the liquid crystal cell.
- the length (width) corresponding to one set (another set) of opposite sides of the liquid crystal cell is the exposure of both ends of the opposite set (another set) of the liquid crystal cell in the side direction.
- the cutting may include a form (so-called half cut) in which at least a polarizing film (polarizing plate) and a reflective polarizing film are cut to form a cut line.
- a form so-called half cut
- the surface protective film 60, the reflective polarizing film 40, the polarizing plate 10, and the pressure-sensitive adhesive layer 30 are cut while leaving the release film 50.
- the long optical film is in a state in which a plurality of the score lines are formed at intervals corresponding to the other pair of sides of the liquid crystal cell. May be.
- the cutting direction of the optical film is typically the direction of the absorption axis of the polarizing film (the width direction of the optical film) and the direction orthogonal to the absorption axis of the polarizing film (the longitudinal direction of the optical film).
- the cutting in the direction perpendicular to the absorption axis of the polarizing film is typically performed by continuously cutting the optical film so as to have a predetermined width while transporting the optical film in the longitudinal direction, and winding it into a roll after the cutting. Is called.
- cutting in a direction perpendicular to the absorption axis of the polarizing film may be referred to as “slit processing”.
- the optical film of the present invention (hereinafter referred to as “first optical film”) is bonded to one side of the liquid crystal cell, and a second optical film different from the first optical film is attached to the liquid crystal cell.
- a liquid crystal display panel is manufactured by bonding to the other side.
- the second optical film is long and has a width corresponding to a pair of opposing sides of the liquid crystal cell.
- the second optical film is cut to a length corresponding to another set of sides facing the liquid crystal cell, and is continuously bonded to the surface of the liquid crystal cell.
- the second optical film includes a polarizing film having an absorption axis in the longitudinal direction.
- the direction of the absorption axis of the polarizing film may include a direction of ⁇ 5 ° to + 5 ° counterclockwise with respect to the longitudinal direction of the second optical film.
- the absorption axes of the upper and lower polarizing films of the liquid crystal display panel obtained by this embodiment are orthogonal to each other.
- the optical film roll set of the present invention includes the optical film roll of the present invention (first optical film roll) and the second optical film roll in which the second optical film is wound into a roll shape.
- any appropriate mode is adopted as the driving mode of the liquid crystal cell.
- the VA mode or the IPS mode is preferable.
- thermoplastic resin base material As a thermoplastic resin base material, a long cycloolefin resin film (trade name “ARTON” manufactured by JSR Corporation) having a thickness of 200 ⁇ m and a Tg of 123 ° C. was used.
- thermoplastic resin base material a long cycloolefin resin film (trade name “ARTON” manufactured by JSR Corporation) having a thickness of 200 ⁇ m and a Tg of 123 ° C. was used.
- coating solution Polyvinyl alcohol (PVA) resin having a polymerization degree of 1800 and a saponification degree of 98 to 99% (trade name “GOHSENOL (registered trademark) NH-18” manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) is dissolved in water to a concentration of 7% by weight. An aqueous polyvinyl alcohol solution was prepared.
- the coating solution was applied to one side of a stretched thermoplastic resin substrate by a die coater (die coating method) and then dried at 100 ° C. for 180 seconds to form a 9 ⁇ m thick PVA resin layer. In this way, a laminate was produced.
- ⁇ Crosslinking treatment> The layered product after dyeing was immersed in an aqueous boric acid solution at 60 ° C. (boric acid concentration: 5% by weight, potassium iodide concentration: 5% by weight) for 60 seconds.
- a protective film (thickness: 40 ⁇ m, manufactured by Fuji Film Co., Ltd., trade name “TD40UL”) was bonded to the polarizing film side of the laminate through a polyvinyl alcohol adhesive. Next, the thermoplastic resin substrate was peeled from the polarizing film to obtain a polarizing plate.
- a 60 ⁇ m-thick surface protective film with a pressure-sensitive adhesive layer (manufactured by Mitsubishi Polyester Co., Ltd., trade name “PPF-100T”) is bonded to the polarizing film side of the polarizing plate, and then the thickness is applied to the protective film side of the polarizing plate.
- a 23 ⁇ m acrylic pressure-sensitive adhesive layer was formed, and a 38 ⁇ m-thick release film (manufactured by Mitsubishi Polyester Film Co., Ltd., trade name “MRF-ELB4”) was bonded to the surface.
- MRF-ELB4 38 ⁇ m-thick release film
- a reflective polarizing plate (manufactured by 3M, trade name “DBEF”) in which a reflective polarizing film having a thickness of 107 ⁇ m and a surface protective film with an adhesive layer having a thickness of 60 ⁇ m were laminated was prepared.
- a 12 ⁇ m thick acrylic adhesive is formed on the reflective polarizing film side of this reflective polarizing plate, and a 38 ⁇ m thick release film (trade name “MRF-ELB4” manufactured by Mitsubishi Polyester Film Co., Ltd.) is bonded to the surface. It was.
- MRF-ELB4 manufactured by Mitsubishi Polyester Film Co., Ltd.
- Example 1 In the same manner as in Example 1, a polarizing plate with an adhesive layer and a reflective polarizing film with an adhesive layer were obtained. The obtained polarizing plate with the pressure-sensitive adhesive layer and the reflective polarizing film with the pressure-sensitive adhesive layer were each slitted to a width of 511 mm in the same manner as in Example 1.
- Comparative Example 2 In the same manner as in Comparative Example 1, a slit-processed polarizing plate with an adhesive layer and a reflective polarizing film with an adhesive layer were obtained. On the back side of the liquid crystal cell, a polarizing plate with a pressure-sensitive adhesive layer that has been slit is bonded by RTP while peeling the release film, and after the surface protective film is peeled off from the bonded polarizing plate with the pressure-sensitive adhesive layer, A liquid crystal display panel was produced in the same manner as in Example 1 except that the reflective polarizing film with the adhesive layer that had been slit was bonded to the polarizing plate with the adhesive layer by RTP while peeling the release film. The contrast ratio was measured. The results are shown in Table 1.
- Example 2 In the same manner as in Example 1, a laminate having a polarizing film with a thickness of 3 ⁇ m on a thermoplastic resin substrate was produced. On the other hand, the same reflective polarizing plate as in Example 1 was prepared. A reflective polarizing plate was bonded to the polarizing film side of the laminate having the polarizing film by a roll-to-roll through a polyvinyl alcohol adhesive.
- thermoplastic resin substrate is peeled from the obtained laminate, an acrylic pressure-sensitive adhesive having a thickness of 23 ⁇ m is formed on the surface of the polarizing film from which the thermoplastic resin substrate has been peeled, and a release film having a thickness of 38 ⁇ m
- the product was “MRF-ELB4” manufactured by Mitsubishi Polyester Film Co., Ltd.).
- a long optical film original film was obtained in which a polarizing film having an absorption axis in the width direction and a reflective polarizing film having a reflection axis in the width direction were laminated.
- the following procedure was performed in the same manner as in Example 1 to produce an optical film (optical film roll) and a liquid crystal display panel. The contrast ratio of the obtained liquid crystal display panel was measured. The results are shown in Table 1.
- the total thickness (including the release film) of the original optical film during slit processing was 231 ⁇ m.
- Example 3 An acrylic pressure-sensitive adhesive layer having a thickness of 23 ⁇ m is formed on the polarizing film side of the laminate having a polarizing film on the thermoplastic resin substrate obtained in Example 2, and a release film having a thickness of 38 ⁇ m (Mitsubishi polyester film) (Trade name “MRF-ELB4”) manufactured by Co., Ltd. This laminate was slit in the same manner as in Example 1. On the other hand, the reflective polarizing film with an adhesive layer was slitted in the same manner as in Example 1.
- Comparative Example 4 In the same manner as in Comparative Example 3, a laminate having a slit-processed polarizing film and a reflective polarizing film with an adhesive layer were obtained. On the back side of the liquid crystal cell, after laminating the laminate having the slit processed polarizing film by RTP while peeling the release film, after peeling the thermoplastic resin base material from the stuck polarizing plate with the adhesive layer, Subsequently, the liquid crystal display was performed in the same manner as in Example 1 except that the slit-processed reflective polarizing film with the adhesive layer was bonded to the bonded polarizing plate with the adhesive layer by RTP while peeling the release film. A panel was prepared and the contrast ratio was measured. The results are shown in Table 1.
- the optical film of the present invention is applied to a liquid crystal display panel such as a liquid crystal television, a liquid crystal display, a mobile phone, a personal digital assistant, a digital camera, a video camera, a portable game machine, a car navigation system, a copy machine, a printer, a fax machine, a clock, and a microwave oven.
- a liquid crystal display panel such as a liquid crystal television, a liquid crystal display, a mobile phone, a personal digital assistant, a digital camera, a video camera, a portable game machine, a car navigation system, a copy machine, a printer, a fax machine, a clock, and a microwave oven.
- a liquid crystal display panel such as a liquid crystal television, a liquid crystal display, a mobile phone, a personal digital assistant, a digital camera, a video camera, a portable game machine, a car navigation system, a copy machine, a printer, a fax machine, a clock, and a microwave oven.
Landscapes
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Nonlinear Science (AREA)
- Mathematical Physics (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Polarising Elements (AREA)
- Liquid Crystal (AREA)
- Laminated Bodies (AREA)
Abstract
Description
好ましい実施形態においては、上記偏光膜の厚みが10μm未満である。
好ましい実施形態においては、上記光学フィルム原反が、剥離フィルムと、粘着剤層と、上記偏光膜と、上記反射偏光フィルムとがこの順で積層されている。
本発明の別の局面によれば、光学フィルムロールセットが提供される。この光学フィルムロールセットは、上記光学フィルムロールである第1の光学フィルムロールと、上記液晶セルの対向する一組の辺に対応する幅を有し、該液晶セルの対向するもう一組の辺に対応する長さに切断し、連続的に液晶セルの表面に貼り合わせるのに用いられ、長尺方向に吸収軸を有する偏光膜を含む長尺状の光学フィルムがロール状に巻回された第2の光学フィルムロールを備える。
好ましい実施形態においては、上記液晶セルの駆動モードが、VAモードまたはIPSモードである。
本発明のさらに別の局面によれば、光学フィルムロールの製造方法が提供される。この光学フィルムロールの製造方法は、液晶セルの対向する一組の辺に対応する幅を有し、該液晶セルの対向するもう一組の辺に対応する長さに切断し、連続的に液晶セルの表面に貼り合わせるのに用いられる光学フィルムロールの製造方法であって、幅方向に吸収軸を有する偏光膜と、幅方向に反射軸を有する反射偏光フィルムとをこの順に積層して長尺状の光学フィルム原反を作製する工程と、該光学フィルム原反を、その長尺方向と平行に、該液晶セルの対向する一組の辺に対応する幅でスリット加工する工程と、該スリット工程で得られた長尺状の光学フィルムをロール状に巻回する工程とを含む。
好ましい実施形態においては、上記偏光膜の厚みが10μm未満である。
好ましい実施形態においては、上記光学フィルム原反が、剥離フィルムと、粘着剤層と、上記偏光膜と、上記反射偏光フィルムとがこの順で積層されている。
本明細書における用語および記号の定義は下記の通りである。
(1)屈折率(nx、ny、nz)
「nx」は面内の屈折率が最大になる方向(すなわち、遅相軸方向)の屈折率であり、「ny」は面内で遅相軸と直交する方向の屈折率であり、「nz」は厚み方向の屈折率である。
(2)正面位相差(Re)
正面位相差(Re)は、膜(層)の厚みをd(nm)としたとき、Re=(nx-ny)×dによって求められる。
(3)厚み方向の位相差(Rth)
厚み方向の位相差(Rth)は、膜(層)の厚みをd(nm)としたとき、Rth={(nx+ny)/2-nz}×dによって求められる。
(4)Nz係数
Nz係数は、Nz=(nx-nz)/(nx-ny)によって求められる。
偏光板は、少なくとも偏光膜を含む。好ましくは、偏光板は、偏光膜の少なくとも片側に保護フィルムが配置されて構成されている。
上記偏光膜は、代表的には、二色性物質を含むポリビニルアルコール系樹脂(以下、「PVA系樹脂」と称する)膜から構成される。
R=a+b/(λ2-6002)
ここで、R:偏光膜の位相差、a:PVA系樹脂膜の位相差、b:定数である。
上記偏光膜は、その幅方向に吸収軸を有する限り、任意の適切な方法により製造される。偏光膜は、代表的には、PVA系樹脂膜に、適宜、延伸、染色等の処理を施すことにより製造される。
上記PVA系樹脂膜は、代表的には、長尺状に形成される。PVA系樹脂膜の厚みは、好ましくは100μm未満である。PVA系樹脂膜は、例えば、PVA系樹脂フィルムであってもよいし、熱可塑性樹脂基材上に形成されたPVA系樹脂層であってもよい。PVA系樹脂フィルムは、厚み10μm以上の偏光膜を製造する場合に好ましく用いられる。PVA系樹脂フィルムの厚みは、好ましくは30μm~80μmである。熱可塑性樹脂基材とPVA系樹脂層との積層体は、厚み10μm未満の偏光膜を製造する場合に好ましく用いられる。PVA系樹脂層の厚みは、好ましくは3μm~20μmである。このような薄い厚みでも、熱可塑性樹脂基材を用いることで良好に延伸することができる。
延伸方法としては、例えば、テンター延伸機を用いた固定端延伸、周速の異なるロールを用いた自由端延伸、同時二軸延伸機を用いた二軸延伸、逐次二軸延伸が挙げられる。これらは、単独で、または、二種以上組み合わせて採用し得る。具体的には、図4に示すように、PVA系樹脂膜11’を周速の異なるロール32,32,33,33間に通して搬送方向(MD)に延伸(自由端延伸)する場合、例えば、搬送方向に直交する方向(TD)への延伸と組み合わせる形態が挙げられる。なお、上記Nz係数は、例えば、延伸方法、延伸倍率、延伸温度等の延伸条件を適宜選択することにより制御することができる。以下、好ましい実施形態について具体的に説明する。
偏光膜を製造するための処理としては、延伸処理以外に、例えば、染色処理、不溶化処理、架橋処理、洗浄処理、乾燥処理等が挙げられる。これらの処理は、任意の適切なタイミングで施し得る。
上記保護フィルムの形成材料としては、例えば、(メタ)アクリル系樹脂、ジアセチルセルロース、トリアセチルセルロース等のセルロース系樹脂、シクロオレフィン系樹脂、ポリプロピレン等のオレフィン系樹脂、ポリエチレンテレフタレート系樹脂等のエステル系樹脂、ポリアミド系樹脂、ポリカーボネート系樹脂、これらの共重体樹脂等が挙げられる。なお、上記熱可塑性樹脂基材を、そのまま保護フィルムとして用いてもよい。
上記粘着剤層は、任意の適切な粘着剤により形成される。代表的には、アクリル系粘着剤が用いられる。粘着剤層の厚みは、好ましくは7μm~25μmである。
光学フィルムロールとしてロール状に巻回された長尺状の光学フィルムの幅は、好ましくは、貼り合わせる液晶セルのサイズに対応して設定される。具体的には、長尺状の光学フィルムは、液晶セルの対向する一組の辺に対応する幅を有する。長尺状の光学フィルムは、好ましくは、広幅で長尺状の光学フィルム原反(スリット前ロール原反)を、スリット加工することにより製造される。より好ましくは、広幅で長尺状の光学フィルム原反(スリット前ロール原反)をスリット加工することにより、同じ幅または異なる幅の長尺状の光学フィルムが同時に複数製造される。
本発明の光学フィルムロールは、液晶セルの対向するもう一組の辺に対応する長さに切断され、連続的に液晶セルの表面に貼り合わされる。本明細書において「液晶セルの対向する一組(もう一組)の辺に対応する長さ(幅)」とは、光学フィルムを液晶セルに対して位置合わせして貼り合わせた場合に、当該液晶セルの周縁部に適切な製造上のマージン(具体的には、光学フィルムが貼り合わされていない露出部分)を確保できる長さ(幅)をいう。具体的には、「液晶セルの対向する一組(もう一組)の辺に対応する長さ(幅)」は、液晶セルの対向する一組(もう一組)の辺方向両端部の露出部分を除いた長さ(幅)をいう。
(1)偏光膜の厚み
ダイヤルゲージ(PEACOCK社製、製品名「DG-205 type pds-2」)を用いて、後述の染色処理後に、PVA系樹脂層もしくはPVA系樹脂フィルムの厚みを測定した。
(2)液晶表示パネルのコントラスト比
実施例および比較例で得られた液晶表示パネルについて、当該実施例および比較例で用いた液晶テレビに搭載されていたバックライトを用いて、液晶表示パネルの中央部のコントラスト比を(株)トプコンテクノハウス SR-UL1Rにより測定した。
<粘着剤層付偏光板の作製>
(熱可塑性樹脂基材)
熱可塑性樹脂基材として、長尺状で厚み200μm、Tg123℃のシクロオレフィン系樹脂フィルム(JSR社製、商品名「ARTON」)を用いた。
(塗布液の調製)
重合度1800、ケン化度98~99%のポリビニルアルコール(PVA)樹脂(日本合成化学工業社製、商品名「ゴーセノール(登録商標)NH-18」)を水に溶解させて、濃度7重量%のポリビニルアルコール水溶液を調製した。
(PVA系樹脂層の形成)
延伸処理を施した熱可塑性樹脂基材の片面に、上記塗布液をダイコーター(ダイコート法)により塗布した後、100℃で180秒間乾燥して、厚み9μmのPVA系樹脂層を形成した。このようにして、積層体を作製した。
得られた積層体を、図3に示すように、同時二軸延伸機を用いて、140℃で、MDに40%収縮させると同時に、TDに5.0倍に乾式延伸した。
次いで、積層体を、25℃のヨウ素水溶液(ヨウ素濃度:0.5重量%、ヨウ化カリウム濃度:10重量%)に30秒間浸漬させた。
染色後の積層体を、60℃のホウ酸水溶液(ホウ酸濃度:5重量%、ヨウ化カリウム濃度:5重量%)に60秒間浸漬させた。
架橋処理後、積層体を、25℃のヨウ化カリウム水溶液(ヨウ化カリウム濃度:5重量%)に5秒間浸漬させた。
このようにして、熱可塑性樹脂基材上に、厚み3μmの偏光膜を作製した。
厚み107μmの反射偏光フィルムと厚み60μmの粘着剤層付表面保護フィルムが積層された反射型偏光板(3M社製、商品名「DBEF」)を用意した。この反射型偏光板の反射偏光フィルム側に厚み12μmのアクリル系粘着剤を形成し、その表面に厚み38μmの剥離フィルム(三菱ポリエステルフィルム(株)製、商品名「MRF-ELB4」)を貼り合わせた。このようにして、粘着剤層付反射偏光フィルムを作製した。
上記の粘着剤層付偏光板と上記の粘着剤層付反射偏光フィルムとを、粘着剤層付偏光板の表面保護フィルムおよび粘着剤層付反射偏光フィルムの剥離フィルムをそれぞれ剥離しながら、ロールトゥロールにより貼り合わせ、幅方向に吸収軸を有する偏光膜と幅方向に反射軸を有する反射偏光フィルムとが積層された長尺状の光学フィルム原反を得た。なお、得られた光学フィルム原反は、巻回して原反ロールとした。
上記で得られた光学フィルム原反ロールを巻き戻し、長尺状の光学フィルム原反を30m/minで搬送しながら、図7Cに示すようにして511mmの幅(後述する液晶セルの短辺に対応する幅)に切断刃でスリット加工し、長尺状の光学フィルムを得た。なお、スリット加工時の光学フィルム原反の総厚み(剥離フィルムも含む)は283μmであった。
40インチ液晶テレビ(SHARP社製、商品名:LC40Z5)から取り出した液晶セルの視認側に偏光板(日東電工(株)製、VEGQ1724NTB)を、背面側に上記で得られた光学フィルムを、それぞれ剥離フィルムを剥離しながらロールトゥパネル(RTP)により貼り合わせて液晶表示パネルを作製し、そのコントラスト比を測定した。結果を表1に示す。
実施例1と同様にして、粘着剤層付偏光板および粘着剤層付反射偏光フィルムを得た。得られた粘着剤層付偏光板および粘着剤層付反射偏光フィルムを、それぞれ、実施例1と同様にして511mmの幅にスリット加工した。それぞれスリット加工された粘着剤層付偏光板と粘着剤層付反射偏光フィルムとを、粘着剤層付偏光板の表面保護フィルムおよび粘着剤層付反射偏光フィルムの剥離フィルムをそれぞれ剥離しながら、ロールトゥロールにより貼り合わせ、幅方向に吸収軸を有する偏光膜と幅方向に反射軸を有する反射偏光フィルムとが積層された長尺状の光学フィルムを得た。得られた光学フィルムを用いたこと以外は実施例1と同様にして液晶表示パネルを作製し、そのコントラスト比を測定した。結果を表1に示す。
比較例1と同様にして、スリット加工された粘着剤層付偏光板および粘着剤層付反射偏光フィルムを得た。液晶セルの背面側に、スリット加工された粘着剤層付偏光板を、剥離フィルムを剥離しながらRTPにより貼り合わせ、貼り合わされた粘着剤層付偏光板から表面保護フィルムを剥離した後、続けて、当該粘着剤層付偏光板に、スリット加工された粘着剤層付反射偏光フィルムを、剥離フィルムを剥離しながらRTPにより貼り合わせたこと以外は実施例1と同様にして液晶表示パネルを作製し、そのコントラスト比を測定した。結果を表1に示す。
実施例1と同様にして、熱可塑性樹脂基材上に厚み3μmの偏光膜を有する積層体を作製した。一方、実施例1と同様の反射型偏光板を用意した。偏光膜を有する積層体の偏光膜側に、ポリビニルアルコール系接着剤を介して反射型偏光板を、ロールトゥロールにより貼り合わせた。次いで、得られた積層体から熱可塑性樹脂基材を剥離し、当該熱可塑性樹脂基材を剥離した偏光膜表面に厚み23μmのアクリル系粘着剤を形成し、その表面に厚み38μmの剥離フィルム(三菱ポリエステルフィルム(株)製、商品名「MRF-ELB4」)を貼り合わせた。このようにして、幅方向に吸収軸を有する偏光膜と幅方向に反射軸を有する反射偏光フィルムとが積層された長尺状の光学フィルム原反を得た。以下の手順は実施例1と同様にして、光学フィルム(光学フィルムロール)および液晶表示パネルを作製した。得られた液晶表示パネルのコントラスト比を測定した。結果を表1に示す。なお、スリット加工時の光学フィルム原反の総厚み(剥離フィルムも含む)は231μmであった。
実施例2で得られた熱可塑性樹脂基材上に偏光膜を有する積層体の偏光膜側に、厚み23μmのアクリル系粘着剤層を形成し、その表面に厚み38μmの剥離フィルム(三菱ポリエステルフィルム(株)製、商品名「MRF-ELB4」)を貼り合わせた。この積層体を実施例1と同様にしてスリット加工した。一方、粘着剤層付反射偏光フィルムを実施例1と同様にしてスリット加工した。スリット加工した偏光膜を有する積層体とスリット加工した粘着剤層付反射偏光フィルムとを、偏光膜を有する積層体の熱可塑性樹脂基材および粘着剤層付反射偏光フィルムの剥離フィルムを剥離しながらロールトゥロールにより貼り合わせ、幅方向に吸収軸を有する偏光膜と幅方向に反射軸を有する反射偏光フィルムとが積層された長尺状の光学フィルムを得た。得られた光学フィルムを用いたこと以外は実施例1と同様にして液晶表示パネルを作製し、そのコントラスト比を測定した。結果を表1に示す。
比較例3と同様にして、スリット加工された偏光膜を有する積層体および粘着剤層付反射偏光フィルムを得た。液晶セルの背面側に、スリット加工された偏光膜を有する積層体を、剥離フィルムを剥離しながらRTPにより貼り合わせ、貼り合わされた粘着剤層付偏光板から熱可塑性樹脂基材を剥離した後、続けて、貼り合わされた粘着剤層付偏光板に、スリット加工された粘着剤層付反射偏光フィルムを、剥離フィルムを剥離しながらRTPにより貼り合わせたこと以外は実施例1と同様にして液晶表示パネルを作製し、そのコントラスト比を測定した。結果を表1に示す。
表1から明らかなように、本発明の実施例によれば、積層後に液晶セルのサイズに対応したスリット加工を行うことにより、軸ズレを抑制し、コントラストの高い液晶表示パネルを得ることができる。さらに、本発明の光学フィルムはロールトゥロールにより得ることができ、かつ、本発明の光学フィルムを用いれば、ローウトゥパネル(RTP)により液晶表示パネルを得ることができるので、非常に優れた製造効率を実現することができる。
11 偏光膜
21 第1の保護フィルム
22 第2の保護フィルム
30 粘着剤層
40 反射偏光フィルム
50 剥離フィルム
60 表面保護フィルム
100 光学フィルムロール(光学フィルム)
Claims (8)
- 液晶セルの対向する一組の辺に対応する幅を有し、該液晶セルの対向するもう一組の辺に対応する長さに切断し、連続的に液晶セルの表面に貼り合わせるのに用いられる光学フィルムロールであって、
幅方向に吸収軸を有する偏光膜と、幅方向に反射軸を有する反射偏光フィルムとが積層された長尺状の光学フィルム原反を、その長尺方向に搬送しながら搬送方向にスリット加工することで得られた長尺状の光学フィルムがロール状に巻回されている、
光学フィルムロール。 - 前記偏光膜の厚みが10μm未満である、請求項1に記載の光学フィルムロール。
- 前記光学フィルム原反が、剥離フィルムと、粘着剤層と、前記偏光膜と、前記反射偏光フィルムとがこの順で積層されている、請求項1または2に記載の光学フィルムロール。
- 請求項1から3のいずれかに記載の光学フィルムロールである第1の光学フィルムロールと、
前記液晶セルの対向する一組の辺に対応する幅を有し、該液晶セルの対向するもう一組の辺に対応する長さに切断し、連続的に液晶セルの表面に貼り合わせるのに用いられ、長尺方向に吸収軸を有する偏光膜を含む長尺状の光学フィルムがロール状に巻回された第2の光学フィルムロールと
を備える、光学フィルムロールセット。 - 前記液晶セルの駆動モードが、VAモードまたはIPSモードである、請求項4に記載の光学フィルムロールセット。
- 液晶セルの対向する一組の辺に対応する幅を有し、該液晶セルの対向するもう一組の辺に対応する長さに切断し、連続的に液晶セルの表面に貼り合わせるのに用いられる光学フィルムロールの製造方法であって、
幅方向に吸収軸を有する偏光膜と、幅方向に反射軸を有する反射偏光フィルムとをこの順に積層して長尺状の光学フィルム原反を作製する工程と、
該光学フィルム原反を、その長尺方向と平行に、該液晶セルの対向する一組の辺に対応する幅でスリット加工する工程と、
該スリット工程で得られた長尺状の光学フィルムをロール状に巻回する工程と
を含む、光学フィルムロールの製造方法。 - 前記偏光膜の厚みが10μm未満である、請求項6に記載の光学フィルムロールの製造方法。
- 前記光学フィルム原反が、剥離フィルムと、粘着剤層と、前記偏光膜と、前記反射偏光フィルムとがこの順で積層されている、請求項6または7に記載の光学フィルムロールの製造方法。
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1020147024963A KR20140131949A (ko) | 2012-03-14 | 2013-03-14 | 광학 필름 롤 |
US14/373,788 US9977167B2 (en) | 2012-03-14 | 2013-03-14 | Optical film roll |
CN201380013704.6A CN104169755B (zh) | 2012-03-14 | 2013-03-14 | 光学膜卷筒套组及光学膜卷筒套组的制造方法 |
KR1020167024382A KR102008563B1 (ko) | 2012-03-14 | 2013-03-14 | 광학 필름 롤 |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2012057934 | 2012-03-14 | ||
JP2012-057934 | 2012-03-14 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2013137388A1 true WO2013137388A1 (ja) | 2013-09-19 |
Family
ID=49161291
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/JP2013/057188 WO2013137388A1 (ja) | 2012-03-14 | 2013-03-14 | 光学フィルムロール |
Country Status (6)
Country | Link |
---|---|
US (1) | US9977167B2 (ja) |
JP (1) | JP6245817B2 (ja) |
KR (2) | KR102008563B1 (ja) |
CN (1) | CN104169755B (ja) |
TW (1) | TWI629543B (ja) |
WO (1) | WO2013137388A1 (ja) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105319636A (zh) * | 2014-07-29 | 2016-02-10 | 住友化学株式会社 | 偏振片、带有粘合剂的偏振片和液晶显示装置 |
Families Citing this family (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP6172980B2 (ja) | 2012-03-14 | 2017-08-02 | 日東電工株式会社 | 液晶表示パネルの製造方法 |
JP6112921B2 (ja) * | 2012-03-14 | 2017-04-12 | 日東電工株式会社 | 液晶表示パネルの製造方法 |
CN103953892B (zh) * | 2014-04-22 | 2015-07-29 | 苏州环明电子科技有限公司 | 一种新型侧边反射片的加工工艺 |
JP6577174B2 (ja) * | 2014-09-19 | 2019-09-18 | 日東電工株式会社 | 偏光板 |
JP6692599B2 (ja) * | 2014-09-19 | 2020-05-13 | 日東電工株式会社 | 粘着剤層付き偏光板 |
TWI686629B (zh) * | 2014-09-30 | 2020-03-01 | 日商住友化學股份有限公司 | 偏光板及其製造方法 |
JP5885813B1 (ja) * | 2014-12-03 | 2016-03-16 | 日東電工株式会社 | 光学的表示装置の製造方法及び製造装置 |
JP5885812B1 (ja) * | 2014-12-03 | 2016-03-16 | 日東電工株式会社 | 光学的表示装置の製造方法及び製造装置 |
KR102170168B1 (ko) * | 2016-03-30 | 2020-10-26 | 스미또모 가가꾸 가부시키가이샤 | 연신 필름의 제조 방법 및 연신 필름의 제조 장치 |
CN107529343B (zh) | 2016-04-15 | 2019-12-10 | 住友化学株式会社 | 多孔质间隔件条带及其制造方法、卷绕体及锂离子电池 |
JP7018711B2 (ja) * | 2017-02-28 | 2022-02-14 | 住友化学株式会社 | 偏光板の製造方法 |
WO2020110816A1 (ja) * | 2018-11-28 | 2020-06-04 | 富士フイルム株式会社 | 光学積層フィルムロールの製造方法、および、光学積層フィルムロール |
JP7544059B2 (ja) | 2019-09-05 | 2024-09-03 | 日本ゼオン株式会社 | 偏光フィルムの製造方法、及び製造装置 |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2009113123A (ja) * | 2007-11-01 | 2009-05-28 | Nitto Denko Corp | 積層光学フィルムの切断方法 |
JP2009282140A (ja) * | 2008-05-20 | 2009-12-03 | Nitto Denko Corp | 画像表示パネル及びその製造方法 |
WO2010092926A1 (ja) * | 2009-02-13 | 2010-08-19 | 日東電工株式会社 | 積層光学体、光学フィルム、および該光学フィルムを用いた液晶表示装置、ならびに積層光学体の製造方法 |
US20120055608A1 (en) * | 2010-09-03 | 2012-03-08 | Nitto Denko Corporation | Method of producing roll of laminate strip with polarizing film |
WO2012176614A1 (ja) * | 2011-06-20 | 2012-12-27 | コニカミノルタアドバンストレイヤー株式会社 | 長尺状偏光板及び液晶表示装置 |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2004264727A (ja) | 2003-03-04 | 2004-09-24 | Sumitomo Chem Co Ltd | 感圧接着剤付き積層偏光フィルム及びその製造方法 |
US20070264447A1 (en) * | 2004-08-30 | 2007-11-15 | Teijin Dupont Films Japan Limited | Optical Film Laminated Body |
JP4855493B2 (ja) * | 2008-04-14 | 2012-01-18 | 日東電工株式会社 | 光学表示装置製造システム及び光学表示装置製造方法 |
JP4406043B2 (ja) | 2008-04-16 | 2010-01-27 | 日東電工株式会社 | ロール原反セット、及びロール原反の製造方法 |
JP5917834B2 (ja) * | 2010-06-28 | 2016-05-18 | 日東電工株式会社 | 光学フィルム用粘着剤層、粘着型光学フィルムおよび画像表示装置 |
-
2013
- 2013-03-13 JP JP2013049994A patent/JP6245817B2/ja active Active
- 2013-03-14 US US14/373,788 patent/US9977167B2/en not_active Expired - Fee Related
- 2013-03-14 KR KR1020167024382A patent/KR102008563B1/ko active IP Right Grant
- 2013-03-14 KR KR1020147024963A patent/KR20140131949A/ko active Application Filing
- 2013-03-14 WO PCT/JP2013/057188 patent/WO2013137388A1/ja active Application Filing
- 2013-03-14 TW TW102109095A patent/TWI629543B/zh active
- 2013-03-14 CN CN201380013704.6A patent/CN104169755B/zh active Active
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2009113123A (ja) * | 2007-11-01 | 2009-05-28 | Nitto Denko Corp | 積層光学フィルムの切断方法 |
JP2009282140A (ja) * | 2008-05-20 | 2009-12-03 | Nitto Denko Corp | 画像表示パネル及びその製造方法 |
WO2010092926A1 (ja) * | 2009-02-13 | 2010-08-19 | 日東電工株式会社 | 積層光学体、光学フィルム、および該光学フィルムを用いた液晶表示装置、ならびに積層光学体の製造方法 |
US20120055608A1 (en) * | 2010-09-03 | 2012-03-08 | Nitto Denko Corporation | Method of producing roll of laminate strip with polarizing film |
WO2012176614A1 (ja) * | 2011-06-20 | 2012-12-27 | コニカミノルタアドバンストレイヤー株式会社 | 長尺状偏光板及び液晶表示装置 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105319636A (zh) * | 2014-07-29 | 2016-02-10 | 住友化学株式会社 | 偏振片、带有粘合剂的偏振片和液晶显示装置 |
CN105319636B (zh) * | 2014-07-29 | 2020-11-17 | 住友化学株式会社 | 偏振片、带有粘合剂的偏振片和液晶显示装置 |
Also Published As
Publication number | Publication date |
---|---|
TWI629543B (zh) | 2018-07-11 |
JP6245817B2 (ja) | 2017-12-13 |
CN104169755A (zh) | 2014-11-26 |
KR20160108594A (ko) | 2016-09-19 |
KR20140131949A (ko) | 2014-11-14 |
US9977167B2 (en) | 2018-05-22 |
JP2013218316A (ja) | 2013-10-24 |
TW201344302A (zh) | 2013-11-01 |
CN104169755B (zh) | 2020-05-08 |
KR102008563B1 (ko) | 2019-08-07 |
US20150002792A1 (en) | 2015-01-01 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
JP6245817B2 (ja) | 光学フィルムロール | |
JP6176827B2 (ja) | 光学フィルムロール | |
JP6112921B2 (ja) | 液晶表示パネルの製造方法 | |
JP6172980B2 (ja) | 液晶表示パネルの製造方法 | |
JP6409142B1 (ja) | 偏光膜、偏光板、および偏光膜の製造方法 | |
KR20200054185A (ko) | 편광판, 편광판 롤 및 편광막의 제조 방법 | |
JP2019194660A (ja) | 偏光膜、偏光板、偏光板ロール、および偏光膜の製造方法 | |
TW202346905A (zh) | 透鏡部、積層體、顯示體、顯示體之製造方法及顯示方法 | |
JP2019197204A (ja) | 偏光板および偏光板ロール | |
KR20200054182A (ko) | 편광판, 편광판 롤 및 편광막의 제조 방법 | |
KR20200054183A (ko) | 편광판, 편광판 롤 및 편광막의 제조 방법 | |
JP2019197205A (ja) | 偏光板および偏光板ロール | |
JP2019197206A (ja) | 偏光板および偏光板ロール | |
KR20200054184A (ko) | 편광판, 편광판 롤 및 편광막의 제조 방법 |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 13761338 Country of ref document: EP Kind code of ref document: A1 |
|
WWE | Wipo information: entry into national phase |
Ref document number: 14373788 Country of ref document: US |
|
ENP | Entry into the national phase |
Ref document number: 20147024963 Country of ref document: KR Kind code of ref document: A |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
122 | Ep: pct application non-entry in european phase |
Ref document number: 13761338 Country of ref document: EP Kind code of ref document: A1 |