WO2013183781A1 - 偏光板の製造方法 - Google Patents

偏光板の製造方法 Download PDF

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Publication number
WO2013183781A1
WO2013183781A1 PCT/JP2013/065900 JP2013065900W WO2013183781A1 WO 2013183781 A1 WO2013183781 A1 WO 2013183781A1 JP 2013065900 W JP2013065900 W JP 2013065900W WO 2013183781 A1 WO2013183781 A1 WO 2013183781A1
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Prior art keywords
film
acrylic resin
resin film
polarizing
acrylic
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PCT/JP2013/065900
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English (en)
French (fr)
Japanese (ja)
Inventor
正寛 市原
林　秀樹
敬之 名田
民載 丁
Original Assignee
住友化学株式会社
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Application filed by 住友化学株式会社 filed Critical 住友化学株式会社
Priority to CN201380029146.2A priority Critical patent/CN104335086B/zh
Priority to KR1020147032003A priority patent/KR102094051B1/ko
Publication of WO2013183781A1 publication Critical patent/WO2013183781A1/ja

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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
    • 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
    • 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
    • B29D11/00634—Production of filters
    • B29D11/00644—Production of filters polarizing

Definitions

  • the present invention relates to a method for producing a polarizing plate by bonding an acrylic resin film as a protective film to a polyvinyl alcohol polarizing film.
  • a polarizing plate is widely used mainly for components of liquid crystal display devices.
  • a polarizing plate usually circulates in a state where a protective film is laminated on at least one surface of a polarizing film made of a polyvinyl alcohol-based resin, and is incorporated into a liquid crystal display device or the like.
  • a triacetyl cellulose film has been used as a protective film for a polyvinyl alcohol polarizing film constituting such a polarizing plate.
  • triacetyl cellulose does not have sufficient heat-and-moisture resistance, and a polarizing plate using a triacetyl cellulose film as a protective film sometimes has reduced performance such as degree of polarization and hue under high-temperature and wet-heat conditions.
  • JP 2007-25008 Patent Document 1
  • a thermoplastic resin layer is formed on both sides of an acrylic resin film having a thickness of 40 ⁇ m or less, and the thermoplastic resin layers on both sides are peeled off before use.
  • a protective film for a polarizing plate JP 2007-41563 A (Patent Document 2) discloses a protective film having a three-layer structure of an acrylic resin film / polyethyleneimine layer / polyvinyl alcohol resin layer on the polyvinyl alcohol resin layer side.
  • JP 2007-52404 A Patent Document 3
  • an adhesive layer / metal salt layer / protective film is provided in this order on one surface of a polyvinyl alcohol polarizing film to form a polarizing plate, and the protective film.
  • Patent Document 4 0.1 to 1.5 parts by weight of a lubricant composed of a metal salt is blended with 100 parts by weight of a resin component mainly composed of an acrylic resin, A protective film is disclosed.
  • Patent Document 5 discloses a liquid crystal display in which an antiglare film made of an acrylic resin film having a hard coat layer is laminated on one surface of a polyvinyl alcohol polarizing film. It is disclosed that the polarizing plate is disposed on the viewing side of the apparatus, and the acrylic resin constituting the antiglare film contains acrylic rubber particles from the viewpoint of impact resistance and film forming property of the film. There is also a statement that it is preferable. Not only the acrylic resin film but also the resin film is generally wound up around a cylindrical core after production and stored in a roll shape.
  • the object of the present invention is to produce a polarizing plate with few defects even when an acrylic resin film in which defects are generated by winding tightening is used and the defects are repaired and bonded to a polarizing film.
  • a method for producing a polarizing plate by laminating an acrylic resin film to a polarizing film made of a polyvinyl alcohol resin on which a dichroic dye is adsorbed and oriented, and the acrylic resin film described above.
  • the glass transition temperature is Tg
  • the heat treatment step of performing heat treatment at a temperature within the range of (Tg ⁇ 30 ° C.) to (Tg + 5 ° C.) and the acrylic resin film subjected to the heat treatment are continued.
  • the manufacturing method of a polarizing plate provided with the bonding process bonded to a polarizing film is provided.
  • the acrylic resin film used in this method is preferably formed from an acrylic resin composition in which rubber elastic particles are blended with an acrylic base resin, and the rubber elastic particles have a number average particle diameter. It is preferable that it is in the range of 10 to 300 nm and is blended in a proportion of 25 to 45% by weight with respect to the acrylic base resin.
  • the heat treatment step is preferably performed in a heating furnace heated to the above temperature.
  • a heat processing process is performed for the time within the range of 5 second or more and 60 second or less.
  • the acrylic resin film is preferably subjected to the heat treatment step and then the bonding step while unwinding from a long and rolled state.
  • the heat treatment step is preferably performed such that the dimensional change rate in the width direction orthogonal to the flow direction of the acrylic resin film before and after the heat treatment is 0.3% or less.
  • the acrylic resin before being bonded to the polarizing film is bonded to the polarizing film after being subjected to heat treatment, even if defects due to tightening have occurred.
  • a board can be manufactured. Therefore, even a roll of an acrylic resin film in which winding tightening has occurred can be used, and the productivity of a polarizing plate using the acrylic resin film as a protective film can be significantly increased.
  • FIG. 1 is a side view schematically showing an arrangement example of apparatuses used for manufacturing a polarizing plate.
  • the polarizing plate 15 is manufactured by bonding the acrylic resin film 20 (21) to the polarizing film 10 made of a polyvinyl alcohol-based resin in which the dichroic dye is adsorbed and oriented. Then, the acrylic resin film (raw film) 20 is subjected to a heat treatment before being bonded to the polarizing film 10, and the acrylic resin film 21 thus subjected to the heat treatment is bonded to the polarizing film 10.
  • the acrylic resin film 20 fed from the first feed roll 25 passes through the heating furnace 40 and is subjected to heat treatment there.
  • the acrylic resin film 21 thus subjected to the heat treatment is supplied to one surface of the polarizing film 10, and the second resin film 30 that is separately fed from the second feeding roll 35 is the other surface of the polarizing film 10.
  • the polarizing plate 15 thus obtained is wound up on the product roll 60.
  • the acrylic resin film 20 is transported by a plurality of transport rolls 45, 45.
  • the polarizing film 10 what was manufactured in the polarizing film manufacturing process mentioned later is generally sent as it is.
  • the straight arrow means the film traveling direction
  • the curved arrow means the roll rotation direction.
  • the step of passing through the heating furnace 40 corresponds to the heat treatment step
  • the step of bonding by the bonding rolls 50 and 51 corresponds to the bonding step.
  • at least one resin film may be made of an acrylic resin.
  • each of the acrylic resin films is subjected to a heat treatment according to the present invention and then subjected to a bonding process. .
  • a resin film can be bonded to only one surface of the polarizing film 10 to form a polarizing plate.
  • the resin film may be made of an acrylic resin.
  • the polarizing film 10 and the acrylic resin film 20 that are used in the present invention, and the second resin film 30 that is optionally used will be described step by step, and then the manufacturing method of the polarizing plate will be described.
  • the polarizing film 10 is obtained by adsorbing and orienting a dichroic dye on a polyvinyl alcohol-based resin film so as to obtain predetermined polarization characteristics. Typically, iodine or a dichroic organic dye is used as the dichroic dye.
  • the polarizing film includes an iodine polarizing film in which iodine is adsorbed and oriented on a polyvinyl alcohol resin film, and a dye polarizing film in which a dichroic organic dye is adsorbed and oriented on a polyvinyl alcohol resin film.
  • the polyvinyl alcohol resin constituting the polarizing film 10 can be obtained by saponifying a polyvinyl acetate resin.
  • the polyvinyl acetate resin include polyvinyl acetate, which is a homopolymer of vinyl acetate, and a copolymer of vinyl acetate and another monomer copolymerizable therewith.
  • Examples of other monomers copolymerizable with vinyl acetate include unsaturated carboxylic acids, unsaturated sulfonic acids, olefins, and vinyl ethers.
  • the polyvinyl alcohol-based resin may be modified, and for example, polyvinyl formal modified with aldehydes, polyvinyl acetal, polyvinyl butyral, and the like can be used.
  • the polarizing film 10 is usually a humidity adjusting step for adjusting the moisture of the polyvinyl alcohol-based resin film, a step of uniaxially stretching the polyvinyl alcohol-based resin film, and a dichroic dye that is obtained by dyeing a polyvinyl alcohol-based resin film with a dichroic pigment.
  • Uniaxial stretching may be performed before dyeing, may be performed during dyeing, or may be performed during boric acid treatment after dyeing. You may uniaxially stretch in these several steps. Uniaxial stretching may be performed between rolls having different peripheral speeds, or may be performed using a hot roll.
  • atmosphere may be sufficient
  • stretches in the state swollen with the solvent may be sufficient.
  • the draw ratio is usually about 4 to 8 times.
  • the thickness of the polyvinyl alcohol polarizing film obtained by uniaxial stretching and dyeing, and further subjected to boric acid treatment, water washing and drying can be set to about 1 to 50 ⁇ m, for example. ⁇ 35 ⁇ m.
  • the acrylic resin is usually a polymer mainly composed of alkyl methacrylate.
  • a homopolymer of alkyl methacrylate or a copolymer using two or more kinds of alkyl methacrylate may be used, or 50 wt% or more of alkyl methacrylate and 50 wt% of monomers other than alkyl methacrylate. % Or less copolymer.
  • alkyl methacrylate those having 1 to 4 carbon atoms of the alkyl group are usually used, and methyl methacrylate is preferably used.
  • the monomer other than alkyl methacrylate may be a monofunctional monomer having one polymerizable carbon-carbon double bond in the molecule, or two or more polymerizable carbons in the molecule.
  • -A polyfunctional monomer having a carbon double bond may be used, but a monofunctional monomer is particularly preferably used.
  • a monofunctional monomer examples thereof include alkyl acrylates such as methyl acrylate and ethyl acrylate, styrene monomers such as styrene and alkyl styrene, and unsaturated nitriles such as acrylonitrile and methacrylonitrile.
  • alkyl acrylate is used as a copolymerization component, the alkyl group usually has about 1 to 8 carbon atoms.
  • the monomer composition of the acrylic resin is preferably 70% by weight or more, more preferably 80% by weight or more, and still more preferably 90% by weight or more based on the amount of the whole monomer.
  • This acrylic resin preferably does not have a glutarimide derivative, a glutaric anhydride derivative, a lactone ring structure, or the like.
  • An acrylic resin having a cyclic structure such as a glutarimide derivative, a glutaric anhydride derivative, or a lactone ring structure tends to make it difficult to obtain sufficient mechanical strength and wet heat resistance as an optical film.
  • the monomer consists essentially of alkyl methacrylate, or the alkyl methacrylate accounts for 70% by weight or more, preferably 90% by weight or more of the monomer composition, It is preferably a copolymer of only a monomer selected from alkyl acrylate, a styrene monomer and an unsaturated nitrile.
  • the acrylic resin is an acrylic resin composition in which rubber elastic particles are blended with the above-mentioned acrylic base resin from the viewpoint of film-formability to a film and impact resistance when made into a film. You can also.
  • This rubber elastic body particle is a particle having a layer exhibiting rubber elasticity, and may be a particle composed only of a layer exhibiting rubber elasticity, or a particle having a multilayer structure having another layer together with a layer exhibiting rubber elasticity. There may be.
  • the rubber elastic body include an olefin elastic polymer, a diene elastic polymer, a styrene-diene elastic copolymer, an acrylic elastic polymer, and the like.
  • an acrylic elastic polymer is preferably used from the viewpoints of surface hardness, light resistance, and transparency when used as a protective film for a polarizing plate.
  • the acrylic elastic polymer can be composed of a polymer mainly composed of alkyl acrylate.
  • This may be a homopolymer of alkyl acrylate or a copolymer of 50% by weight or more of alkyl acrylate and 50% by weight or less of other monomers.
  • alkyl acrylate an alkyl acrylate having 4 to 8 carbon atoms is usually used.
  • Examples of copolymerization of monomers other than alkyl acrylate include alkyl methacrylates such as methyl methacrylate and ethyl methacrylate, styrene monomers such as styrene and alkylstyrene, acrylonitrile and methacrylo Monofunctional monomers such as unsaturated nitriles such as nitriles, alkenyl esters of unsaturated carboxylic acids such as allyl (meth) acrylate and methallyl (meth) acrylate, and dibasic acids such as diallyl maleate And polyfunctional monomers such as unsaturated carboxylic acid diesters of glycols such as alkylene glycol di (meth) acrylate.
  • alkyl methacrylates such as methyl methacrylate and ethyl methacrylate
  • styrene monomers such as styrene and alkylstyrene
  • the rubber elastic particles are preferably multi-layered particles having an acrylic elastic polymer layer.
  • the thing of the 3 layer structure which has a polymer layer is mentioned.
  • An example of the monomer composition in the polymer mainly composed of alkyl methacrylate constituting the hard polymer layer formed on the outside or inside of the acrylic elastic body is the methacrylic acid mentioned above as an example of the acrylic resin.
  • Such acrylic rubber elastic particles having a multilayer structure can be produced, for example, by the method described in Japanese Patent Publication No. 55-27576.
  • the number average particle diameter of the rubber elastic layer in the acrylic rubber elastic particles having a multilayer structure is preferably in the range of 10 to 300 nm.
  • the average particle diameter of the rubber elastic layer is preferably 50 nm or more, and preferably 250 nm or less.
  • the average particle diameter of the rubber elastic body layer is measured as follows. That is, such rubber elastic particles are mixed with an acrylic base resin to form a film, and when the cross section is dyed with an aqueous solution of ruthenium oxide, only the rubber elastic layer is colored and observed in a substantially circular shape, The acrylic resin of the mother layer is not dyed. Therefore, from the cross section of the film dyed in this way, a thin piece is prepared using a microtome or the like, and this is observed with an electron microscope. And after extracting 100 dye
  • regulated by this invention turns into a number average particle diameter.
  • the outermost layer is a hard polymer mainly composed of methyl methacrylate and rubber elastic particles in which an acrylic elastic polymer is encapsulated are used, when mixed with an acrylic base resin, The outermost layer of the rubber elastic particles is mixed with the acrylic base resin. Therefore, when the cross section is dyed with ruthenium oxide and observed with an electron microscope, the rubber elastic particles are observed as particles excluding the outermost layer.
  • the acrylic elastic of the inner layer is used.
  • the polymer part is dyed and observed as particles of a single layer structure, the innermost layer is a hard polymer mainly composed of methyl methacrylate, the intermediate layer is an acrylic elastic polymer, and the outermost layer is methacrylic.
  • rubber elastic particles with a three-layer structure which is a hard polymer mainly composed of methyl acid, are used, the innermost particle center portion is not dyed, and only the acrylic elastic polymer portion of the intermediate layer is dyed. It will be observed as particles having a two-layer structure.
  • the particle diameter of the rubber elastic layer thus measured is regarded as the particle diameter of the rubber elastic particles.
  • Such rubber elastic particles are preferably blended in a proportion of 25 to 45% by weight based on the total amount with the transparent acrylic base resin described above. By blending the rubber elastic particles at this ratio, the effect of improving the film-forming property to the film and improving the impact resistance of the obtained film is exhibited.
  • the acrylic resin used in the present invention (including the case of an acrylic resin composition in which a rubber elastic body is blended with an acrylic base resin.
  • the same applies hereinafter) includes an ultraviolet absorber, an infrared absorber, Various additives such as a lubricant, a fluorescent brightening agent, a dispersant, a heat stabilizer, a light stabilizer, an antistatic agent, and an antioxidant may be contained.
  • the ultraviolet absorber is a compound that absorbs ultraviolet rays having a wavelength of 400 nm or less. The effect which improves the durability of the polarizing plate by which this protective film was bonded to the polarizing film is acquired because the acrylic resin film used as a protective film of a polyvinyl-alcohol-type polarizing film contains a ultraviolet absorber.
  • the ultraviolet absorber known ones such as a benzophenone ultraviolet absorber, a benzotriazole ultraviolet absorber, and an acrylonitrile ultraviolet absorber can be used.
  • the ultraviolet absorber include 2,2′-methylenebis [4- (1,1,3,3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol], 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) -5-chlorobenzotriazole, 2,4-di-tert-butyl-6- (5-chlorobenzotriazol-2-yl) phenol 2,2'-dihydroxy-4,4'-dimethoxybenzophenone, 2,2 ', 4,4'-tetrahydroxybenzophenone, and the like.
  • 2,2′-methylenebis [4- (1,1,3,3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol] is one of preferable ultraviolet absorbers.
  • the blending amount of the ultraviolet absorber can be selected in such a range that the transmittance of the obtained resin film at a wavelength of 370 nm or less is preferably 10% or less, more preferably 5% or less, and further preferably 2% or less.
  • the ultraviolet absorber is premixed in an acrylic resin and pelletized, and this is formed into a film by melt extrusion or the like. Any method can be used.
  • An infrared absorber is a compound that absorbs infrared rays having a wavelength of 800 nm or more.
  • infrared absorbers are preferably selected so that they can absorb the entire infrared ray (light having a wavelength in the range of about 800 nm to 1100 nm), and two or more types may be used in combination.
  • the compounding quantity of an infrared absorber can be suitably adjusted, for example so that the light transmittance in wavelength 800nm or more of the resin film obtained may be 10% or less.
  • the acrylic resin for forming the acrylic resin film preferably has a glass transition temperature Tg in the range of 80 to 110 ° C.
  • the polarizing plate obtained by bonding the film formed from the polarizing film to the polarizing film has a large shrinkage in the heat resistance test, and sufficient heat resistance cannot be obtained. There is.
  • the glass transition temperature is higher than 110 ° C., a defect generated by tightening may not be sufficiently repaired even if a heat treatment described later is performed.
  • the film formed from this resin has high surface hardness.
  • JIS K 5600-5-4 1999 “Paint General Test Method—Part 5: Mechanical Properties of Coating Film— It is preferable that the pencil hardness measured with a load of 500 g according to “Section 4: Scratch hardness (pencil method)” is H or higher. Further, this film preferably has a flexural modulus of 1,500 MPa or less measured in accordance with JIS K 7171: 2008 "Plastics-Determination of bending properties" from the viewpoint of flexibility. The flexural modulus is more preferably 1,300 MPa or less, and still more preferably 1,200 MPa or less.
  • the flexural modulus varies depending on the type of acrylic resin, the presence / absence of rubber elastic particles, and the type and amount of rubber elastic particles when blended. In general, the flexural modulus is smaller when a copolymer of alkyl methacrylate and alkyl acrylate is used than when an alkyl homopolymer is used. In general, the flexural modulus decreases as the content of the rubber elastic particles increases. On the other hand, the elastic modulus particles generally have a smaller bending elastic modulus than the acrylic elastic polymer particles having the three-layer structure described above rather than the acrylic elastic polymer particles having the two-layer structure described above. The bending elastic modulus becomes even smaller when the acrylic elastic polymer particles having a layer structure are used.
  • the type of acrylic resin, and further the type and / or amount of the rubber elastic particles may be adjusted within the predetermined range so that the flexural modulus is 1,500 MPa or less.
  • the acrylic resin film may have a multilayer structure in which a layer formed from an acrylic resin is a single layer.
  • the composition of the layer that can exist other than the acrylic resin layer is not particularly limited.
  • stacked In that case, you may mutually differ content in each layer of rubber elastic-body particle
  • a configuration in which layers containing no ultraviolet absorber and no infrared absorber are stacked with a layer containing an ultraviolet absorber and / or an infrared absorber interposed therebetween may be employed.
  • the acrylic resin described above into a film, the acrylic resin film used in the present invention can be manufactured. Since this acrylic resin film is used as a protective film for a polyvinyl alcohol polarizing film, the thickness can be arbitrarily selected from the range of about 5 to 200 ⁇ m.
  • the thickness is preferably 10 ⁇ m or more, preferably 150 ⁇ m or less, more preferably 100 ⁇ m or less.
  • the metal roll is preferably a mirror roll, whereby a resin film having excellent surface smoothness can be obtained.
  • the acrylic resin film is produced in a multilayer structure, the multilayer film may be formed by co-extrusion so that the acrylic resin layer has one layer or two or more layers. [Functions that can be arbitrarily added to the acrylic resin film]
  • the acrylic resin film can be subjected to a hard coat treatment from the viewpoint of preventing surface scratches in the assembly process of the liquid crystal module.
  • surface treatment such as antistatic treatment can be performed.
  • the antistatic function in the polarizing plate can be imparted by applying a surface treatment to the acrylic resin film, and other parts of the polarizing plate to which the acrylic resin film is bonded, such as an adhesive layer. It can also be granted.
  • Other examples of surface treatment for the acrylic resin film include antireflection treatment and antifouling treatment.
  • an antiglare treatment can be performed from the viewpoints of improving visibility, preventing reflection of external light, and reducing moire due to interference between the prism sheet and the color filter.
  • the resin film 30 can be bonded.
  • the second resin film 30 may be composed of an acrylic resin or may be composed of other resins. Examples of resins other than acrylic resins that can be the second resin film 30 include cellulose ester resins typically represented by triacetyl cellulose, polyolefin resins typically represented by norbornene resins and polypropylene resins. is there.
  • the second resin film 30 may be provided with a phase difference. The phase difference can be imparted by uniaxially or biaxially stretching the resin film.
  • This heat treatment is performed at a temperature in the range of (Tg ⁇ 30 ° C.) to (Tg + 5 ° C.), where Tg is the glass transition temperature of the acrylic resin film 20.
  • Tg is the glass transition temperature of the acrylic resin film 20.
  • the temperature of the heat treatment is preferably Tg or less.
  • this heat treatment is preferably performed by passing the acrylic resin film 20 through a heating furnace 40 heated to the above temperature.
  • the heat treatment time is preferably in the range of 5 seconds to 60 seconds. If the heat treatment time is less than 5 seconds, there is a possibility that defects due to tightening occurring in the acrylic resin film 20 cannot be sufficiently repaired.
  • the acrylic resin film 20 is stretched, and the width of the film may be narrowed. Since this heat treatment is for repairing defects caused by tightening occurring in the acrylic resin film 20, it is preferably performed immediately before being bonded to the polarizing film 10. Further, from the same viewpoint, the acrylic resin film 20 is long and wound in a roll shape, specifically, while being unwound from the state wound on the first feeding roll 25 as shown above, It is preferable that the heat treatment is performed, and subsequently subjected to bonding to the polarizing film 10. When a long resin film is thus targeted, the dimensional change rate in the width direction of the film is 0.3% between the acrylic resin film 20 before the heat treatment and the acrylic resin film 21 after the heat treatment.
  • the acrylic resin film 21 is bonded to the polarizing film 10 on the surface opposite to the antiglare treatment layer.
  • the bonding of the acrylic resin film 21 and the second resin film 30 that have been heat-treated is bonded as illustrated. It is preferable to carry out simultaneously by the combined rolls 50 and 51.
  • the bonding surfaces of the acrylic resin film 21 and the second resin film 30 to the polarizing film 10 are subjected to physical or physicochemical easy adhesion treatment such as corona discharge treatment. It is preferable to keep it.
  • the corona discharge treatment is a treatment for activating the resin film disposed between the electrodes by discharging by applying a high voltage between the electrodes.
  • the effect of corona discharge treatment varies depending on the type of electrode, electrode interval, voltage, humidity, type of resin film used, etc., but for example, the electrode interval is set to 1 to 5 mm and the moving speed is set to about 3 to 20 m / min. It is preferable to do this.
  • an adhesive is used for bonding the polarizing film 10 and the acrylic resin film 21 and bonding the polarizing film 10 and the second resin film 30.
  • a polarizing film is bonded to the treated surface via an adhesive.
  • an adhesive having epoxy resin, urethane resin, cyanoacrylate resin, acrylamide resin, or the like as an adhesive component can be used.
  • One of the adhesives preferably used is a solventless adhesive. Solventless adhesives do not contain a significant amount of solvent, and are curable components (monomers or oligomers) that are reactively cured by heating or irradiation with active energy rays (for example, ultraviolet rays, visible light, electron beams, X-rays, etc.).
  • the adhesive layer is formed by curing of the curable component, and typically comprises a curable component that is reactively cured by heating or irradiation with active energy rays, and a polymerization initiator.
  • a curable component that is reactively cured by heating or irradiation with active energy rays, and a polymerization initiator.
  • the solventless adhesives those that are cured by cationic polymerization are preferable from the viewpoint of reactivity.
  • the solventless epoxy adhesive having an epoxy compound as a curable component includes the polarizing film 10, an acrylic type, and the like. Since it is excellent in adhesiveness with the other resin film used as the resin film 21 and the 2nd resin film 30, it is used preferably.
  • the epoxy compound which is a curable component contained in the solventless epoxy adhesive, is preferably cured by cationic polymerization, and particularly contains no aromatic ring in the molecule from the viewpoint of weather resistance, refractive index, and the like. It is more preferable to use an epoxy compound. Examples of such epoxy compounds that do not contain an aromatic ring in the molecule include hydrides of aromatic epoxy compounds, alicyclic epoxy compounds, and aliphatic epoxy compounds. In addition, the epoxy compound that is a curable component usually has two or more epoxy groups in the molecule. First, the hydride of an aromatic epoxy compound will be described.
  • the hydride of an aromatic epoxy compound is a nuclear water obtained by selectively subjecting an aromatic polyhydroxy compound, which is a raw material of an aromatic epoxy compound, to an aromatic ring in the presence of a catalyst and under pressure.
  • the additive polyhydroxy compound can be obtained by a method of glycidyl etherification.
  • aromatic epoxy compound examples include bisphenol type epoxy compounds such as diglycidyl ether of bisphenol A, diglycidyl ether of bisphenol F, and diglycidyl ether of bisphenol S; phenol novolac epoxy resin, cresol novolac epoxy resin, and Examples include novolak-type epoxy resins such as hydroxybenzaldehyde phenol novolak epoxy resins; glycidyl ethers of tetrahydroxydiphenylmethane, glycidyl ethers of tetrahydroxybenzophenone, and polyfunctional epoxy resins such as epoxidized polyvinylphenol.
  • bisphenol type epoxy compounds such as diglycidyl ether of bisphenol A, diglycidyl ether of bisphenol F, and diglycidyl ether of bisphenol S
  • phenol novolac epoxy resin cresol novolac epoxy resin
  • novolak-type epoxy resins such as hydroxybenzaldehyde phenol novolak epoxy resins
  • An alicyclic epoxy compound means an epoxy compound having one or more epoxy groups bonded to an alicyclic ring, and “having one or more epoxy groups bonded to an alicyclic ring” is expressed by the following formula: Means having the structure shown. M in the formula is an integer of 2 to 5.
  • the alicyclic epoxy compound is a compound having at least one structure represented by the above formula and having a total of two or more epoxy groups in the molecule including the structure. More specifically, (CH in the above formula 2 ) m A compound in which one or a plurality of hydrogen atoms in the group is bonded to another chemical structure can be an alicyclic epoxy compound. (CH 2 ) m One or a plurality of hydrogen atoms therein may be appropriately substituted with a linear alkyl group such as a methyl group or an ethyl group.
  • suitable alicyclic epoxy compounds are listed below. Here, the compound names are given first, and then the chemical formulas corresponding to each are shown, and the same reference numerals are given to the compound names and the chemical formulas corresponding thereto.
  • A 3,4-epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate
  • B 3,4-epoxy-6-methylcyclohexylmethyl 3,4-epoxy-6-methylcyclohexanecarboxylate
  • C ethylene bis (3,4-epoxycyclohexanecarboxylate)
  • D Bis (3,4-epoxycyclohexylmethyl) adipate
  • E bis (3,4-epoxy-6-methylcyclohexylmethyl) adipate
  • F Diethylene glycol bis (3,4-epoxycyclohexyl methyl ether)
  • G ethylene glycol bis (3,4-epoxycyclohexyl methyl ether
  • H 2,3,14,15-diepoxy-7,11,18,21-tetraoxatrispiro- [5.2.2.5.2.2] henicosane (this compound is also a 3,4-epoxy Cyclohexa
  • the aliphatic epoxy compound may be an aliphatic polyhydric alcohol or a polyglycidyl ether of an alkylene oxide adduct thereof. More specifically, 1,4-butanediol diglycidyl ether, 1,6-hexanediol diglycidyl ether, glycerin triglycidyl ether, trimethylolpropane triglycidyl ether, polyethylene glycol diglycidyl ether, propylene Polyether polyol obtained by adding one or more alkylene oxides (ethylene oxide or propylene oxide) to diglycidyl ether of glycol, aliphatic polyhydric alcohol such as ethylene glycol or propylene glycol, and glycerin And polyglycidyl ether.
  • 1,4-butanediol diglycidyl ether 1,6-hexanediol diglycidyl ether
  • the epoxy compound demonstrated above may be used individually by 1 type, and may be used in combination of 2 or more type.
  • the epoxy equivalent of the epoxy compound contained in the solventless epoxy adhesive is usually in the range of 30 to 3,000 g / equivalent, preferably 50 to 1,500 g / equivalent. If the epoxy equivalent is less than 30 g / equivalent, the flexibility of the polarizing plate after the adhesive layer is cured may be reduced, or the adhesive strength may be reduced. On the other hand, if the epoxy equivalent exceeds 3,000 g / equivalent, the compatibility with other components contained in the epoxy adhesive may be lowered.
  • the solventless epoxy adhesive usually contains a cationic polymerization initiator in order to cause the epoxy compound to undergo cationic polymerization.
  • the cationic polymerization initiator generates a cationic species or a Lewis acid by irradiation with active energy rays such as visible light, ultraviolet rays, X-rays, electron beams, or heating, and initiates an epoxy group polymerization reaction. Any of these types of cationic polymerization initiators may be used, but it is preferable from the viewpoint of workability that the potential is imparted.
  • a cationic polymerization initiator that generates a cationic species or a Lewis acid upon irradiation with active energy rays such as visible light, ultraviolet rays, X-rays, and electron beams and initiates a polymerization reaction of an epoxy group is a photocationic polymerization initiator. Also called.
  • the photocationic polymerization initiator When the photocationic polymerization initiator is used, it becomes possible to cure the adhesive component at room temperature, so the need to consider the heat resistance of the polarizing film or the distortion due to expansion is reduced. It can be formed on a polarizing film with good adhesion.
  • a cationic photopolymerization initiator when a cationic photopolymerization initiator is used, it acts catalytically by light, so that it is excellent in storage stability and workability even when mixed with an epoxy adhesive.
  • the photocationic polymerization initiator include aromatic diazonium salts; onium salts such as aromatic iodonium salts and aromatic sulfonium salts; iron-arene complexes. These cationic photopolymerization initiators may be used alone or in combination of two or more.
  • aromatic sulfonium salts are particularly preferable because they have ultraviolet absorption characteristics even in a wavelength region of 300 nm or more, and thus can provide a cured product having excellent curability and good mechanical strength and adhesive strength.
  • photocationic polymerization initiators can be easily obtained as commercial products, for example, “Kayarad PCI-220” sold by Nippon Kayaku Co., Ltd., and “ “Kayarad PCI-620”, “UVI-6990” sold by Union Carbide, “Adekaoptomer SP-150” and “Adekaoptomer SP-170” sold by ADEKA Corporation, Nippon Soda ( "CI-5102", “CIT-1370", “CIT-1682”, “CIP-1866S”, “CIP-2048S” and “CIP-2064S” sold by Midori Chemical Co., Ltd.
  • the compounding amount of the cationic photopolymerization initiator is usually 0.5 to 20 parts by weight, preferably 1 part by weight or more, and preferably 15 parts by weight or less with respect to 100 parts by weight of the epoxy compound as the curable component.
  • the solventless epoxy adhesive can contain a photosensitizer as necessary in addition to the photocationic polymerization initiator.
  • a photosensitizer By using a photosensitizer, the reactivity is improved and the mechanical strength and adhesive strength of the cured product can be improved.
  • the photosensitizer include carbonyl compounds, organic sulfur compounds, persulfides, redox compounds, azo and diazo compounds, halogen compounds, and photoreductive dyes.
  • the amount is about 0.1 to 20 parts by weight with respect to 100 parts by weight of the epoxy compound.
  • thermal cationic polymerization initiator that generates a cationic species or a Lewis acid by heating and initiates a polymerization reaction of an epoxy group
  • a thermal cationic polymerization initiator that generates a cationic species or a Lewis acid by heating and initiates a polymerization reaction of an epoxy group
  • thermal cationic polymerization initiators can also be easily obtained as commercial products.
  • “ADEKA OPTON CP77” and “ADEKA OPTON CP66” sold by ADEKA Co., Ltd.
  • thermal cationic polymerization initiators may be used alone or in combination of two or more.
  • a photocationic polymerization initiator and a thermal cationic polymerization initiator can be used in combination.
  • the solventless epoxy adhesive may further contain a compound that promotes cationic polymerization, such as oxetanes and polyols.
  • the adhesive between the polarizing film 10 and the resin film 21 or 30 is performed by applying the adhesive to the adhesive surface of the resin film and / or the polarizing film and bonding them together. It can be carried out.
  • the method of applying the solventless epoxy adhesive to the resin film and / or the polarizing film For example, various coatings such as a doctor blade, a wire bar, a die coater, a comma coater, and a gravure coater. A scheme is available.
  • each coating method has an optimum viscosity range, the viscosity may be adjusted using a small amount of solvent.
  • the solvent used for this is not particularly limited as long as it can dissolve the epoxy adhesive well without deteriorating the optical performance of the polarizing film.
  • hydrocarbons typified by toluene, typified by ethyl acetate, and the like.
  • Organic solvents such as esters can be used.
  • the ultraviolet light source include a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, a black light lamp, and a metal halide lamp.
  • the irradiation intensity and irradiation amount of active energy rays such as ultraviolet rays are appropriately selected so as to sufficiently activate the cationic polymerization initiator and not adversely affect the cured adhesive layer, polarizing film, and optical film.
  • active energy rays such as ultraviolet rays
  • it can be heated by a generally known method, and the temperature and time at that time can sufficiently activate the cationic polymerization initiator, and the cured adhesive layer or It is appropriately selected so as not to adversely affect the polarizing film and the optical film.
  • the thickness of the adhesive layer made of the cured epoxy adhesive obtained as described above can be generally in the range of about 0.1 to 50 ⁇ m, preferably 1 ⁇ m or more. More preferably, it is in the range of 1 to 20 ⁇ m, more preferably 2 to 10 ⁇ m.
  • a water-based adhesive that is, an adhesive component in water. What melt
  • water-based adhesives include those containing water-soluble crosslinkable epoxy resins or hydrophilic urethane resins as adhesive components.
  • a water-soluble crosslinkable epoxy resin for example, a polyalkylene polyamine such as diethylenetriamine or triethylenetetramine and a polyamide polyamine obtained by a reaction of a dicarboxylic acid such as adipic acid are reacted with epichlorohydrin. Mention may be made of the polyamide epoxy resin obtained.
  • Commercially available products of such polyamide epoxy resins include “Smileys Resin 650” and “Smileys Resin 675” sold by Sumika Chemtex Co., Ltd. under the trade name.
  • polyvinyl alcohol-based resins include partially saponified polyvinyl alcohol and fully saponified polyvinyl alcohol as well as modified, such as carboxyl group-modified polyvinyl alcohol, acetoacetyl group-modified polyvinyl alcohol, methylol group-modified polyvinyl alcohol, and amino group-modified polyvinyl alcohol. It may be a polyvinyl alcohol resin.
  • carboxyl group-modified polyvinyl alcohol a saponified product of a copolymer of vinyl acetate and unsaturated carboxylic acid or a salt thereof, that is, carboxyl group-modified polyvinyl alcohol is preferably used.
  • carboxyl group is a concept including —COOH and a salt thereof.
  • suitable commercially available carboxyl group-modified polyvinyl alcohols are “Kuraraypoval KL-506”, “Kuraraypoval KL-318” and “Kuraray” sold by Kuraray Co., Ltd. under the trade names.
  • the adhesive containing a water-soluble crosslinkable epoxy resin can be prepared as an aqueous adhesive solution by dissolving the above epoxy resin and other water-soluble resin such as a polyvinyl alcohol resin added as necessary in water.
  • the water-soluble crosslinkable epoxy resin preferably has a concentration in the range of about 0.2 to 2 parts by weight with respect to 100 parts by weight of water.
  • the amount is preferably about 1 to 10 parts by weight, more preferably about 1 to 5 parts by weight, with respect to 100 parts by weight of water.
  • suitable urethane resins include ionomer-type urethane resins, particularly polyester-based ionomer-type urethane resins.
  • the ionomer type is obtained by introducing a small amount of an ionic component (that is, a hydrophilic component) into a urethane resin constituting the skeleton.
  • the polyester ionomer type urethane resin is a urethane resin having a polyester skeleton, into which a small amount of an ionic component (hydrophilic component) is introduced.
  • Such an ionomer-type urethane resin is suitable as a water-based adhesive because it is emulsified directly in water without using an emulsifier to form an emulsion.
  • polyester ionomer-type urethane resins examples include “Hydran AP-20” and “Hydran APX-101H” sold by DIC Corporation, both of which are in the form of emulsions. Available.
  • an ionomer-type urethane resin is used as an adhesive component, it is preferable to further blend an isocyanate-based crosslinking agent.
  • the isocyanate-based crosslinking agent is a compound having at least two isocyanato groups (—NCO) in the molecule.
  • Examples thereof include 2,4-tolylene diisocyanate, phenylene diisocyanate, 4,4′-diphenylmethane diisocyanate, 1,
  • polyisocyanate monomers such as 6-hexamethylene diisocyanate and isophorone diisocyanate
  • Modified with polyisocyanate such as trifunctional isocyanurate with an isocyanurate ring formed at the part and burette formed by hydration and decarboxylation of three diisocyanate molecules at each isocyanato group.
  • isocyanate crosslinking agents examples include those sold by DIC Corporation under the trade name “Hydran Assist C-1.”
  • concentration of the urethane resin is about 10 to 70% by weight, further 20% by weight or more, and 50% by weight or less from the viewpoint of viscosity and adhesiveness.
  • those dissolved or dispersed in water are preferred.
  • the isocyanate crosslinking agent is blended, the blending amount is appropriately selected so that the isocyanate crosslinking agent is about 5 to 100 parts by weight with respect to 100 parts by weight of the urethane resin.
  • the polarizing film 10 and the acrylic resin film 21 and / or the second resin film 30 subjected to the heat treatment are bonded to the polarizing film 10 and the adhesive film. It can apply by apply
  • a water-based adhesive is applied to the polarizing film 10 and / or the films 21 and 30 bonded thereto, for example, a coating method such as a doctor blade, a wire bar, a die coater, a comma coater, or a gravure coater. And the like, and
  • Drying can be performed at a temperature of about 60 to 100 ° C., for example. In order to further improve the adhesiveness, it is preferable to cure for about 1 to 10 days after drying at a temperature slightly higher than room temperature, for example, a temperature of about 30 to 50 ° C.
  • the acrylic resin film 21 is bonded to one surface of the polarizing film 10 and the second resin film bonded to the other surface of the polarizing film 10 is composed of an acrylic resin film, and other than the acrylic resin
  • the same adhesive may be used for adhesion of the film bonded to both surfaces of the polarizing film 10, or different adhesives may be used. However, in order to simplify the manufacturing process and reduce the number of constituent members of the polarizing plate, it is preferable to use the same adhesive as long as an appropriate adhesive force is obtained.
  • Example 1 (Acrylic resin and acrylic rubber elastic particles) A copolymer having a weight ratio of methyl methacrylate / methyl acrylate of 96/4 was used as an acrylic base resin.
  • the innermost layer is a hard polymer polymerized with methyl methacrylate using a small amount of allyl methacrylate, and the intermediate layer is polymerized with butyl acrylate as the main component, and further using styrene and a small amount of allyl methacrylate.
  • the outermost layer is a rubber elastic body particle having a three-layer structure made of a hard polymer obtained by polymerizing methyl methacrylate with a small amount of ethyl acrylate, and is an intermediate body elastic body Those having an average particle size of 240 nm were used as acrylic rubber elastic particles.
  • (Preparation of acrylic resin film) While pellets in which the above acrylic resin and the above acrylic rubber elastic particles are blended in a weight ratio of the former / the latter 70/30 are melt-kneaded with a twin screw extruder, 0.05 parts of a certain stearic acid was added and mixed, and it was set as the pellet of the acrylic resin composition.
  • Example 2 A polarizing plate was produced, cut and inspected in the same manner as in Example 1 except that the tension at the time of heat treatment was changed from 500 N to 300 N. At this time, the dimensional shrinkage in the width direction after the acrylic resin film exited the heating furnace was 0.2%. As a result of the inspection, defects due to the acrylic resin film were observed on nine polarizing plates.
  • Example 3 In the same manner as in Example 1, except that the temperature of the heating furnace for performing the heat treatment was changed from 85 ° C. to 95 ° C. (Tg-11 ° C.) and the tension applied to the film at that time was changed from 500 N to 300 N. Plates were made, cut and inspected.
  • Example 1 A polarizing plate was produced, cut and inspected in the same manner as in Example 1 except that the temperature of the heating furnace for performing the heat treatment was changed from 85 ° C. to 23 ° C. (Tg ⁇ 83 ° C.). At this time, the dimensional shrinkage ratio in the width direction after the acrylic resin film exited the heating furnace was 0.1%. As a result of the inspection, defects due to the acrylic resin film were observed on 90 polarizing plates.
  • Example 2 A polarizing plate was produced, cut and inspected in the same manner as in Example 1 except that the temperature of the heating furnace for performing the heat treatment was changed from 85 ° C. to 75 ° C. (Tg ⁇ 31 ° C.). At this time, the dimensional shrinkage ratio in the width direction after the acrylic resin film exited the heating furnace was 0.1%. As a result of the inspection, defects due to the acrylic resin film were observed on the 27 polarizing plates.
  • Example 3 In the same manner as in Example 1, except that the temperature of the heating furnace for performing the heat treatment was changed from 85 ° C. to 75 ° C. (Tg ⁇ 31 ° C.) and the tension applied to the film at that time was changed from 500 N to 300 N.
  • Table 1 summarizes main fluctuation conditions and results in the above Examples and Comparative Examples.
  • the “determination” column of “polarization plate inspection result” is generally good if the number of defects detected is 20 or less (the defect rate is 20% or less) among 100 inspected polarizing plates. If the number of defects recognized is more than 20 (defect rate is more than 20%), it is displayed as “x” meaning failure.
  • Comparative Example 1 in which the temperature of the heating furnace was 23 ° C.
  • room temperature corresponds to an example in which heat treatment is not practically performed, but in this case, most of the polarizing plates have defects, Means that the defect due to the tightening that occurred in the acrylic resin film was transferred to the polarizing plate as it was.
  • Comparative Examples 2 and 3 in which the temperature of the heating furnace was raised to 75 ° C., the number of polarizing plates in which defects were found was reduced as compared with Comparative Example 1, and due to the tightening that had occurred in the acrylic resin film. Although it is recognized that the defect has been repaired to some extent by heat treatment, it is still not sufficient.
  • the acrylic resin before being bonded to the polarizing film is bonded to the polarizing film after being subjected to heat treatment, even if defects due to tightening have occurred.
  • a board can be manufactured. Therefore, even a roll of an acrylic resin film in which winding tightening has occurred can be used, and the productivity of a polarizing plate using the acrylic resin film as a protective film can be significantly increased.

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CN108287425B (zh) * 2018-01-31 2022-01-28 京东方科技集团股份有限公司 一种偏光片及其制备方法、液晶面板
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