WO2014068802A1 - 光学フィルムおよび光学フィルムの製造方法、偏光板および液晶表示装置 - Google Patents
光学フィルムおよび光学フィルムの製造方法、偏光板および液晶表示装置 Download PDFInfo
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- WO2014068802A1 WO2014068802A1 PCT/JP2013/000698 JP2013000698W WO2014068802A1 WO 2014068802 A1 WO2014068802 A1 WO 2014068802A1 JP 2013000698 W JP2013000698 W JP 2013000698W WO 2014068802 A1 WO2014068802 A1 WO 2014068802A1
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
- G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
- G02B5/305—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
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- 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
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
- B29C41/28—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on an endless belt
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- 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
- B29C55/143—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively firstly parallel to the direction of feed and then transversely thereto
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K5/00—Use of organic ingredients
- C08K5/04—Oxygen-containing compounds
- C08K5/15—Heterocyclic compounds having oxygen in the ring
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
- C08L1/08—Cellulose derivatives
- C08L1/10—Esters of organic acids, i.e. acylates
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
- C08L1/08—Cellulose derivatives
- C08L1/10—Esters of organic acids, i.e. acylates
- C08L1/14—Mixed esters, e.g. cellulose acetate-butyrate
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133528—Polarisers
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- 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
- B29K2001/00—Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
- B29K2001/08—Cellulose derivatives
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2301/00—Characterised by the use of cellulose, modified cellulose or cellulose derivatives
- C08J2301/08—Cellulose derivatives
- C08J2301/10—Esters of organic acids
- C08J2301/12—Cellulose acetate
Definitions
- the liquid crystal display device has a liquid crystal cell and a pair of polarizing plates that sandwich the liquid crystal cell.
- the polarizing plate usually has a polarizer and a pair of protective films that sandwich the polarizer. Therefore, with the thinning of the portable liquid crystal display device, it is also required to reduce the thickness of the protective film that is a constituent member thereof.
- Patent Documents 1 to 3 After obtaining a film raw material containing a cellulose ester containing an acyl group having 3 or more carbon atoms such as CAP and CAB by a melt film forming method; obtained by biaxially stretching the film raw material at a high magnification An optical film has also been proposed (Patent Document 4). In addition, an optical film obtained by biaxial stretching after a film raw material containing cellulose acetate and a phosphate ester plasticizer is obtained by a solution casting method has also been proposed (Patent Document 5).
- the film original fabric of Patent Document 5 obtained by the solution casting method is not sufficiently stretchable, and it has been difficult to sufficiently increase the stretch ratio.
- the present invention has been made in view of the above circumstances, and an object of the present invention is to provide an optical film that has little cloudiness, is less likely to cause thermal wrinkles, and has little deterioration in winding shape when stored in a roll body. It is another object of the present invention to provide a liquid crystal display device that includes such an optical film and has high luminance.
- a dope containing a cellulose ester in which the total substitution degree of acyl groups is 2.0 to 3.0 and all of the acyl groups are acetyl groups, and an additive having a ring structure and a molecular weight of 10,000 or less Obtaining a liquid; Casting the dope solution on an endless metal support; Peeling the film-like material obtained by drying the cast dope solution from the metal support; The peeled film is stretched in two directions orthogonal to each other in the plane of the film at a stretching ratio of 1.3 to 4.0 times to obtain an optical film having a thickness of 15 to 35 ⁇ m.
- a liquid crystal cell, a first polarizing plate disposed on one surface of the liquid crystal cell and having a first polarizer, and a second polarizer disposed on the other surface of the liquid crystal cell A liquid crystal display device having a second polarizing plate, wherein the first polarizing plate is disposed on a surface of the first polarizer opposite to the liquid crystal cell [1] to [10] Any one of [1] to [10], wherein the second polarizing plate is disposed on the surface of the second polarizer opposite to the liquid crystal cell.
- a liquid crystal display device comprising the optical film according to claim 1.
- optical film of the present invention contains a cellulose ester and an additive having a ring structure.
- the ⁇ -1,4-bonded glucose unit constituting cellulose has free hydroxy groups (hydroxyl groups) at the 2nd, 3rd and 6th positions.
- the cellulose ester is a polymer (polymer) obtained by acylating a part or all of these hydroxy groups (hydroxyl groups).
- the total substitution degree of the acyl group means the ratio of the hydroxy group (hydroxyl group) of cellulose located at the 2-position, 3-position and 6-position (acylation of 100% is substitution degree 3).
- the weight average molecular weight and molecular weight distribution of the cellulose ester can be measured by gel permeation chromatography (GPC).
- the measurement conditions are as follows. Solvent: Methylene chloride Column: Three Shodex K806, K805, K803G (manufactured by Showa Denko KK) are connected and used.
- the ratio of cellulose ester derived from cellulose linter: cellulose ester derived from wood pulp (coniferous): cellulose ester derived from wood pulp (hardwood) is 100: 0: 0, 90: 10: 0, 85: 15: 0, 50:50: 0, 20: 80: 0, 10: 90: 0, 0: 100: 0, 0: 0: 100, 80:10:10, 85: 0: 15, 40:30:30.
- the aromatic ring structure is preferably a substituted or unsubstituted aromatic hydrocarbon ring or aromatic heterocycle having 6 to 23 carbon atoms, and more preferably a substituted or unsubstituted aromatic hydrocarbon ring.
- the aromatic ring structure include a benzene ring, a naphthalene ring, an anthracene ring, a phenanthrene ring, and the like.
- Examples of the substituent that the aliphatic hydrocarbon ring, aliphatic heterocycle, aromatic hydrocarbon ring or aromatic heterocycle may have include an alkyl group having 1 to 3 carbon atoms, an alkoxy group, a cyano group, and a hydroxyl group. included.
- the carbon number of the alicyclic diol is preferably 4 to 20, and more preferably 4 to 12.
- Examples of the alicyclic diol include 1,4-cyclohexanediol, 1,4-cyclohexanedimethanol and the like.
- the carbon number of the aromatic diol is preferably 6 to 20, and more preferably 6 to 12.
- aromatic diols include 1,2-dihydroxybenzene (catechol), 1,3-dihydroxybenzene (resorcinol), 1,4-dihydroxybenzene (hydroquinone), and the like.
- the diol constituting the polyester compound may be one type or two or more types.
- the diol constituting the polyester compound preferably contains an aliphatic diol.
- the monocarboxylic acid can be an aliphatic monocarboxylic acid, an alicyclic monocarboxylic acid or an aromatic monocarboxylic acid.
- the carbon number of the aliphatic monocarboxylic acid can be preferably 2 to 30, more preferably 2 to 4.
- Examples of the aliphatic carboxylic acid include acetic acid, propionic acid, butanoic acid, caprylic acid, caproic acid, decanoic acid, dodecanoic acid, stearic acid, oleic acid and the like.
- Examples of the alicyclic monocarboxylic acid include cyclohexyl monocarboxylic acid.
- aromatic monocarboxylic acids examples include benzoic acid, para-tert-butyl benzoic acid, orthotoluic acid, metatoluic acid, p-toluic acid, dimethyl benzoic acid, ethyl benzoic acid, normal propyl benzoic acid, aminobenzoic acid, acetoxybenzoic acid, Phenylacetic acid, 3-phenylpropionic acid and the like are included.
- the monoalcohol can be an aliphatic monoalcohol, an alicyclic monoalcohol or an aromatic monoalcohol.
- the aliphatic monoalcohol has 1 to 30 carbon atoms, preferably 1 to 3 carbon atoms.
- Examples of aliphatic monoalcohols are methanol, ethanol, propanol, isopropanol, butanol, isobutanol, pentanol, isopentanol, hexanol, isohexanol, octanol, isooctanol, 2-ethylhexyl alcohol, nonyl alcohol, isononyl alcohol Tert-nonyl alcohol, decanol, dodecanol, dodecahexanol, dodecaoctanol, allyl alcohol, oleyl alcohol and the like.
- Examples of the alicyclic monoalcohol include cyclohexyl alcohol and the like
- polyester compound having a ring structure examples include the following.
- TPA terephthalic acid
- PA phthalic acid
- SA succinic acid
- AA adipic acid
- SEA sebacic acid
- the styrene compound may be a homopolymer of a styrene monomer or a copolymer of a styrene monomer and another copolymer monomer.
- the content of the structural unit derived from the styrenic monomer in the styrenic compound may be preferably 30 to 100 mol%, more preferably 50 to 100 mol%, in order for the molecular structure to have a certain bulkiness.
- the styrene monomer is preferably a compound represented by the following formula (1).
- R 101 to R 103 in the formula (1) each independently represent a hydrogen atom, an alkyl group having 1 to 30 carbon atoms, or an aryl group.
- R 104 is a hydrogen atom, an alkyl group having 1 to 30 carbon atoms, a cycloalkyl group, an aryl group, an alkoxy group having 1 to 30 carbon atoms, an aryloxy group, an alkyloxycarbonyl group having 2 to 30 carbon atoms, an aryloxycarbonyl Group, an alkylcarbonyloxy group having 2 to 30 carbon atoms, an arylcarbonyloxy group, a hydroxyl group, a carboxyl group, a cyano group, an amino group, an amide group, and a nitro group.
- Each of these groups may further have a substituent (for example, a hydroxyl group, a halogen atom, an alkyl group, etc.).
- R 104 may be the same as or different from each other, and may be bonded to each other to form a ring.
- styrenic monomers include styrene; alkyl-substituted styrenes such as ⁇ -methylstyrene, ⁇ -methylstyrene, and p-methylstyrene; halogen-substituted styrenes such as 4-chlorostyrene and 4-bromostyrene; p-hydroxy Hydroxystyrenes such as styrene, ⁇ -methyl-p-hydroxystyrene, 2-methyl-4-hydroxystyrene, 3,4-dihydroxystyrene; vinylbenzyl alcohols; p-methoxystyrene, p-tert-butoxystyrene, m Alkoxy substituted styrenes such as tert-butoxystyrene; vinyl benzoic acids such as 3-vinylbenzoic acid and 4-vinylbenzoic acid; 4-vinylbenzyl acetate; 4-acetoxy
- the copolymerizable monomer combined with the styrenic monomer is a (meth) acrylic acid ester compound represented by the following formula (2), maleic anhydride, citraconic anhydride, cis-1-cyclohexene-1,2-dicarboxylic anhydride, Acid anhydrides such as 3-methyl-cis-1-cyclohexene-1,2-dicarboxylic anhydride and 4-methyl-cis-1-cyclohexene-1,2-dicarboxylic anhydride, and nitrile groups such as acrylonitrile and methacrylonitrile -Containing radical polymerizable monomers; amide bond-containing radical polymerizable monomers such as acrylamide, methacrylamide, trifluoromethanesulfonylaminoethyl (meth) acrylate; fatty acid vinyls such as vinyl acetate; chlorine such as vinyl chloride and vinylidene chloride Containing radically polymerizable monomer; 1,
- R 105 to R 107 in formula (2) each independently represent a hydrogen atom, an alkyl group having 1 to 30 carbon atoms, or an aryl group.
- R 108 represents a hydrogen atom, an alkyl group having 1 to 30 carbon atoms, a cycloalkyl group, or an aryl group.
- Each of these groups may further have a substituent (for example, a hydroxyl group, a halogen atom, an alkyl group, etc.).
- (meth) acrylic acid ester compounds include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate (i-, n-), butyl (meth) acrylate (n- , I-, s-, tert-), pentyl (meth) acrylate (n-, i-, s-), hexyl (meth) acrylate (n-, i-), heptyl (meth) acrylate (n -, I-), octyl (meth) acrylate (n-, i-), nonyl (meth) acrylate (n-, i-), myristyl (meth) acrylate (n-, i-), (meta ) Acrylic acid (2-ethylhexyl), (meth) acrylic acid ( ⁇ -caprolactone), (meth) acrylic acid (2-hydroxyethyl), acrylic acid (2-hydroxypropyl
- styrene compound examples include styrene / maleic anhydride copolymer, styrene / acrylic ester copolymer, styrene / hydroxystyrene polymer, styrene / acetoxystyrene polymer, and the like. Of these, a styrene / maleic anhydride copolymer is preferable.
- Sugar ester compound A sugar ester compound is a compound obtained by esterifying a hydroxyl group contained in sugar and a monocarboxylic acid.
- the sugar constituting the sugar ester compound is more preferably a compound having a structure in which at least one of the furanose structure and the pyranose structure is bonded to 1 to 12 inclusive.
- sugars constituting the sugar ester compound include monosaccharides such as glucose, galactose, mannose, fructose, xylose and arabinose; disaccharides such as lactose, sucrose, maltitol, cellobiose and maltose; trisaccharides such as cellotriose and raffinose Etc. are included. Of these, sugars having both a pyranose structure and a furanose structure are preferable, and sucrose is particularly preferable.
- the monocarboxylic acid constituting the sugar ester compound can be an aliphatic monocarboxylic acid, an alicyclic monocarboxylic acid or an aromatic monocarboxylic acid.
- the monocarboxylic acid constituting the sugar ester compound preferably contains an alicyclic monocarboxylic acid or an aromatic monocarboxylic acid, and more preferably contains an aromatic monocarboxylic acid. preferable.
- One kind of monocarboxylic acid may be used, or two or more kinds may be combined. For example, an aliphatic monocarboxylic acid and an aromatic monocarboxylic acid may be combined.
- Examples of the aliphatic monocarboxylic acid include acetic acid and propionic acid.
- Examples of the alicyclic monocarboxylic acid include cyclopentanecarboxylic acid, cyclohexanecarboxylic acid and the like.
- Examples of the aromatic monocarboxylic acid include benzoic acid and phenylacetic acid.
- the sugar ester compound is preferably a compound represented by the following formula (3).
- R 1 to R 8 in the formula (3) are derived from a monovalent group derived from an aliphatic monocarboxylic acid, a monovalent group derived from an alicyclic monocarboxylic acid, or an aromatic monocarboxylic acid. At least one of R 1 to R 8 is a monovalent group derived from an alicyclic monocarboxylic acid or a monovalent group derived from an aromatic monocarboxylic acid . R 1 to R 8 may be the same as or different from each other.
- Examples of the monovalent group derived from an aliphatic monocarboxylic acid include a monovalent group derived from an aliphatic monocarboxylic acid having 2 or more carbon atoms such as a methylcarbonyl group (acetyl group).
- Examples of the monovalent group derived from an alicyclic monocarboxylic acid include a monovalent group derived from an alicyclic monocarboxylic acid having 5 or more carbon atoms of cyclopentylcarboxylic acid or cyclohexylcarboxylic acid. .
- Examples of monovalent groups derived from aromatic monocarboxylic acids include monovalent groups derived from aromatic monocarboxylic acids having 7 or more carbon atoms such as phenylcarbonyl groups (benzoyl groups) and phenylmethylcarbonyl groups. A group is included.
- a non-aromatic ring in a monovalent group derived from an alicyclic monocarboxylic acid or an aromatic ring in a monovalent group derived from an aromatic monocarboxylic acid further has a substituent such as an alkyl group or an alkoxyl group. May be.
- R 1 to R 8 are preferably monovalent groups derived from aromatic monocarboxylic acids.
- R in the following table represents R 1 to R 8 in the formula (3).
- the average degree of substitution of the sugar ester compound is preferably 3.0 to 8.0, and particularly preferably 5.0 to 8.0.
- the substituent bonded to the carbon atom constituting the pyranose structure or the furanose structure contains a non-aromatic ring structure or an aromatic ring structure, the bulkiness of the sugar ester compound is easily increased to a certain level or more when the average degree of substitution is in the above range. Because.
- sugar ester compounds having a ring structure may be used in combination with a sugar ester having no ring structure, if necessary.
- sugar ester compounds having no ring structure include the following.
- R in the following table represents R 1 to R 8 in the following formula (A).
- polyester compounds and styrene compounds in which the repeating unit has an aromatic ring structure, and sugar ester compounds having an aromatic ring structure are preferred, and either of the molecular structures is preferred.
- a polyester compound and a styrene compound in which the repeating unit has an aromatic ring structure are more preferable because they have a chain structure and easily improve the stretchability of the film (a plasticizing effect is easily obtained).
- the additive having a ring structure exists between cellulose ester molecules, and can widen the interval between cellulose ester molecular chains. Thereby, it is considered that the stretchability of the film can be improved. Therefore, the additive having a ring structure preferably has a sufficiently high molecular structure, and preferably contains a large amount of the ring structure.
- the “ring structure moiety” in the above formula represents a non-aromatic ring structure or an aromatic ring structure itself.
- the substituent is also regarded as a part of the ring structure.
- the “ring structure moiety” of the exemplified compound 6 of the polyester of Table 1 is a phenylene group (—C 6 H 4 —) derived from terephthalic acid and a phenyl group (—C 6 H 5 ) derived from benzoic acid.
- the “ring structure portion” of the styrene / maleic anhydride copolymer is a phenyl group (—C 6 H 5 ) constituting styrene and —CHC ( ⁇ O) OC ( ⁇ O) CH— derived from maleic anhydride. is there.
- the “ring structure portion” of the styrene / hydroxystyrene copolymer is a phenyl group (—C 6 H 5 ) constituting styrene and a hydroxyphenyl group (—C 6 H 4 OH) constituting hydroxystyrene.
- the “ring structure moiety” of the sugar ester compound represented by the above formula (FA-1) is a phenyl group (—C) contained in a substituent other than the glucoside bond, which is bonded to the carbon atom constituting the pyranose structure or furanose structure. 6 is a H 5).
- the bulk index of the additive having a ring structure is preferably 0.2 or more, and more preferably 0.6 or more.
- the upper limit of the “bulkness index” can be, for example, about 0.9.
- the weight average molecular weight of the additive having a ring structure is preferably 10,000 or less, more preferably 5,000 or less, in order to ensure compatibility with the cellulose ester.
- the weight average molecular weight of the additive having a ring structure is preferably 300 or more, more preferably 400 or more, in order to suppress bleeding out.
- the additive having a ring structure is a polyester compound or a styrene compound in which the repeating unit has an aromatic ring structure
- the weight average molecular weight of these compounds tends to increase the stretchability of the film and the tensile strength of the film after stretching. From the viewpoint of easily increasing the elastic modulus, it is preferably 600 or more, more preferably 1000 or more, and still more preferably 2000 or more.
- the content of the additive having a ring structure is preferably 5 to 30% by mass, more preferably 5 to 20% by mass with respect to the cellulose ester. If the content of the additive having a ring structure is less than 5% by mass, the interval between the cellulose ester molecular chains may not be sufficiently widened. When the content of the additive having a ring structure is more than 30% by mass, not only the film tends to bleed out but also the elongation at break increases.
- the optical film of the present invention can further contain various additives such as a plasticizer, an ultraviolet absorber, and a matting agent (fine particles) as necessary.
- plasticizer examples include polyester compounds having no ring structure, polyhydric alcohol ester compounds, and the like among the polyester compounds.
- examples of the polyhydric alcohol ester-based compound include compounds described in paragraphs 0218 to 0170 of JP 2010-32655 A.
- the content of the plasticizer is preferably 1 to 40% by mass, more preferably 5 to 20% by mass with respect to the cellulose ester.
- the optical film of the present invention may further contain an ultraviolet absorber.
- the ultraviolet absorber include benzotriazole compounds, 2-hydroxybenzophenone compounds, salicylic acid phenyl ester compounds, and the like.
- UV absorbers having a molecular weight of 400 or more are difficult to sublimate or volatilize at a high boiling point, and are difficult to disperse even when the film is dried at high temperature. Therefore, the weather resistance is effectively improved by adding a relatively small amount. From the viewpoint of being able to do so.
- Examples of the ultraviolet absorber having a molecular weight of 400 or more include 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2-benzotriazole, 2,2-methylenebis [4- ( Benzotriazoles such as 1,1,3,3-tetrabutyl) -6- (2H-benzotriazol-2-yl) phenol], bis (2,2,6,6-tetramethyl-4-piperidyl) sebacate, Hindered amines such as bis (1,2,2,6,6-pentamethyl-4-piperidyl) sebacate and 2- (3,5-di-t-butyl-4-hydroxybenzyl) -2-n-butyl Bis (1,2,2,6,6-pentamethyl-4-piperidyl) malonate, 1- [2- [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionyloxy Cis] ethyl] -4- [3- [3
- 2- [2-hydroxy-3,5-bis ( ⁇ , ⁇ -dimethylbenzyl) phenyl] -2-benzotriazole and 2,2-methylenebis [4- (1,1,3,3-tetrabutyl) -6- (2H-benzotriazol-2-yl) phenol] is particularly preferred.
- the UV absorber may be a commercially available product.
- the content of the ultraviolet light inhibitor is preferably 1 ppm to 1000 ppm, more preferably 10 to 1000 ppm in terms of mass ratio in the optical film.
- the optical film of the present invention may further contain a matting agent in order to impart slipperiness.
- the matting agent may be an inorganic compound or an organic compound as long as it does not impair the transparency of the resulting film and has heat resistance during melting.
- a matting agent may be used independently and may use 2 or more types together.
- silicon dioxide which has a refractive index close to that of cellulose ester and excellent in film transparency (haze), is particularly preferably used.
- Specific examples of silicon dioxide include Aerosil 200V, Aerosil R972V, Aerosil R972, R974, R812, 200, 300, R202, OX50, TT600, NAX50 (manufactured by Nippon Aerosil Co., Ltd.), Sea Hoster KEP-10, Sea Hoster KEP- 30, Seahoster KEP-50 (above, manufactured by Nippon Shokubai Co., Ltd.), Silo Hovic 100 (manufactured by Fuji Silysia), Nip Seal E220A (manufactured by Nippon Silica Kogyo), Admafine SO (manufactured by Admatechs), etc. Goods etc. can be preferably used.
- the shape of the particles is not particularly limited, such as indefinite shape, needle shape, flat shape, spherical shape and the like.
- the use of spherical particles is preferable because the resulting film can have good transparency.
- the particle size is preferably smaller than the wavelength of visible light, and more preferably 1 ⁇ 2 or less of the wavelength of visible light. . If the size of the particles is too small, the slipperiness may not be improved, so the range of 80 nm to 180 nm is preferable.
- the size of the particle means the size of the aggregate when the particle is an aggregate of primary particles. Moreover, when a particle is not spherical, it means the diameter of a circle corresponding to the projected area.
- the content of the matting agent can be about 0.05 to 1.0% by mass, preferably 0.1 to 0.8% by mass with respect to the cellulose ester.
- the thickness of the optical film of the present invention is preferably 15 to 35 ⁇ m, more preferably 15 to 30 ⁇ m. When the thickness is less than 15 ⁇ m, the strength of the film may not be sufficient, and when the thickness exceeds 35 ⁇ m, for example, it may be too thick as an optical film for a portable liquid crystal display device.
- the optical film of the present invention is obtained by biaxially stretching a film-like material mainly composed of cellulose ester whose acyl groups are all acetyl groups at a high magnification. Therefore, the optical film of the present invention has little cloudiness (has a low haze), has a high tensile elastic modulus in the two stretching directions, and has a breaking elongation in the two stretching directions that is not more than a certain value.
- the tensile modulus at 23 ° C. and 55 RH in the slow axis direction and the direction perpendicular to the slow axis direction of the optical film of the present invention is preferably 3.0 to 8.5 GPa, respectively. More preferably, it is from 0.0 to 8.0 GPa.
- a polarizing plate when a polarizing plate is obtained by laminating a polarizer and an optical film by roll-to-roll, in order to increase the tensile elastic modulus in the TD / MD direction of the polarizing plate in a balanced manner, at least the polarizer of the optical film is required. It is preferable that the tensile modulus of elasticity in the direction orthogonal to the absorption axis direction (MD direction) (TD direction) is higher.
- the tensile elastic modulus of the optical film in the direction (TD direction) perpendicular to the absorption axis direction (MD direction) of the polarizer is more preferably 5.0 to 8.0 GPa.
- the tensile elastic modulus in the slow axis direction (for example, MD direction) of the optical film can be measured by the following method. First, the optical film is cut into a size of 100 mm (MD direction) ⁇ 10 mm (TD direction) to obtain a sample film. In accordance with JIS K7127, this sample film was pulled in the slow axis direction (for example, MD direction) using a Tensilon RTC-1225A manufactured by Orientec Co., Ltd., and the slow axis direction (for example, MD direction). Direction) tensile modulus. The measurement can be performed at 23 ° C. and 55% RH.
- the tensile modulus of elasticity in the direction perpendicular to the slow axis of the optical film is the same as described above except that the direction in which the sample film is pulled is changed to the direction perpendicular to the slow axis (eg, TD direction). Can be measured.
- the elongation at break at 23 ° C. and 55% RH in the slow axis direction and the direction perpendicular to the slow axis direction of the optical film of the present invention is preferably 1 to 10%, more preferably 1 to 5%, respectively. preferable.
- the breaking elongation of the optical film in the slow axis direction can be measured by the following method. First, an optical film is cut into a size of 100 mm (MD direction) ⁇ 10 mm (TD direction) to obtain a sample film. Next, the sample film is pulled in the slow axis direction (for example, MD direction) using Tensilon RTC-1225A manufactured by Orientec Co., Ltd., and the elongation at break is determined from the breaking point of the film. The measurement can be performed in a 23 ° C. and 55% RH atmosphere at a tensile speed of 50 mm / min.
- the elongation at break in the direction perpendicular to the slow axis of the optical film (eg, TD direction) is the same as described above except that the direction in which the sample film is pulled is changed to the direction perpendicular to the slow axis (eg, TD direction). Can be measured.
- the optical film of the present invention has less white turbidity and reduced haze.
- the haze value of the optical film of the present invention is preferably 1.0% or less, and more preferably 0.5% or less. When using the optical film of this invention as a scattering film, haze value may exceed said range.
- the haze can be measured with a haze meter (turbidimeter) (model: NDH 2000, manufactured by Nippon Denshoku Co., Ltd.) in accordance with JIS K-7136.
- Retardation R0 and Rth are defined by the following equations, respectively.
- Formula (I): R 0 (nx ⁇ ny) ⁇ d (nm)
- Formula (II): Rth ⁇ (nx + ny) / 2 ⁇ nz ⁇ ⁇ d (nm)
- nx represents the refractive index in the slow axis direction x where the refractive index is maximum in the in-plane direction of the optical film
- ny represents the refractive index in the direction y perpendicular to the slow axis direction x in the in-plane direction of the optical film
- nz represents the refractive index in the thickness direction z of the optical film
- d (nm) represents the thickness of the optical film)
- the retardations R0 and Rth can be determined by the following method, for example. 1) The optical film is conditioned at 23 ° C. and 55% RH. The average refractive index of the optical compensation film after humidity adjustment is measured with an Abbe refractometer or the like. The optical film after 2) humidity, measuring the R 0 when the light is incident in parallel to the measurement wavelength 590nm to normal of the film surface, KOBRA21DH, in Oji Scientific Corporation. 3) With KOBRA21ADH, the slow axis in the plane of the optical film is set as the tilt axis (rotation axis), and light having a measurement wavelength of 590 nm from the angle normal to the surface of the optical film (incident angle ( ⁇ )) is obtained.
- the angle ⁇ 1 (orientation angle) formed by the in-plane slow axis of the optical film and the width direction of the film is preferably ⁇ 1 ° to + 1 °, more preferably ⁇ 0.5 ° to + 0.5 °. .
- the orientation angle ⁇ 1 of the optical film can be measured using an automatic birefringence meter KOBRA-WR (Oji Scientific Instruments).
- the optical film of the present invention preferably has a total light transmittance of 90% or more, more preferably 93% or more.
- the hard coat layer contains a cured product of an actinic radiation curable compound.
- an actinic radiation curable compound a component containing a monomer having an ethylenically unsaturated double bond is preferably used.
- the actinic radiation curable compound include an ultraviolet curable compound and an electron beam curable compound, and a compound that is cured by ultraviolet irradiation is preferable from the viewpoint of excellent mechanical film strength (abrasion resistance, pencil hardness).
- an ultraviolet curable urethane acrylate resin for example, an ultraviolet curable polyester acrylate resin, an ultraviolet curable epoxy acrylate resin, an ultraviolet curable polyol acrylate resin, or an ultraviolet curable epoxy resin is preferable. Used. Of these, ultraviolet curable acrylate resins are preferred.
- the hard coat layer can be obtained by applying a hard coat layer coating solution containing an actinic radiation curable compound and a photopolymerization initiator on an optical film, and then curing it by irradiation with actinic radiation.
- the photopolymerization initiator examples include acetophenone, benzophenone, hydroxybenzophenone, Michler ketone, ⁇ -amyloxime ester, thioxanthone, and derivatives thereof, but are not particularly limited thereto.
- the amount of the photopolymerization initiator in the hard coat layer coating solution is preferably in a range of 20: 100 to 0.01: 100 in terms of mass ratio.
- These hard coat layers are coated using a known method such as a gravure coater, dip coater, reverse coater, wire bar coater, die coater, ink jet method, and the like. And can be formed by UV curing.
- Irradiation conditions vary depending on each lamp, but the irradiation amount of active rays is usually within a range of 5 to 500 mJ / cm 2 , preferably within a range of 5 to 200 mJ / cm 2 .
- the optical film of the present invention may further have an antireflection layer on the hard coat layer. Thereby, the optical film of the present invention can be used as an antireflection film having an external light antireflection function.
- Three layers having different refractive indexes from the support side are divided into medium refractive index layers (high refractive index layers having a higher refractive index than the support). Are preferably laminated in the order of a layer having a lower refractive index) / a high refractive index layer / a low refractive index layer.
- an antireflection layer having a layer structure of four or more layers in which two or more high refractive index layers and two or more low refractive index layers are alternately laminated is also preferably used.
- the layer structure of the antireflection film the following structure can be considered, but it is not limited to this.
- the optical film of the present invention can be produced by a solution casting method or a melt casting method from the viewpoints of suppression of coloring, suppression of foreign matter defects, suppression of optical defects such as die lines, and the like.
- the solution casting method is preferable because the obtained film has good flatness, failure resistance such as streaks, and accuracy of film thickness.
- a filter medium having a collected particle diameter of 0.5 to 5 ⁇ m and a drainage time of 10 to 25 sec / 100 ml.
- the film-like material obtained by evaporating the solvent on the metal support is peeled off at the peeling position. From the viewpoint of surface quality, moisture permeability, and peelability of the obtained film-like product, it is preferable to peel the film-like product from the metal support within 30 to 120 seconds after casting.
- the temperature at the peeling position on the metal support is preferably in the range of 10 to 40 ° C, more preferably in the range of 11 to 30 ° C.
- Residual solvent amount (%) (mass before heat treatment of film-like material ⁇ mass after heat treatment of film-like material) / (mass after heat treatment of film-like material) ⁇ 100 Note that the heat treatment for measuring the residual solvent amount represents performing heat treatment at 140 ° C. for 1 hour.
- the draw ratio is a range of 2.5 to 9 times, preferably 3 to 6 times, more preferably 3.2 to 6 times, as the total of draw ratios in the casting direction (MD direction) and the width direction (TD direction).
- the draw ratios in the casting direction (MD direction) and the width direction (TD direction) can be 1.3 to 4.0 times, preferably 1.5 to 3.0 times, respectively. It can be.
- a film-like material containing a cellulose ester in which all of the acyl groups are acetyl groups and an additive having a ring structure has high stretchability. Therefore, an optical film obtained by biaxially stretching the film-like material at a high magnification is less likely to cause cloudiness, has a high tensile elastic modulus in both directions perpendicular to each other, and has a reduced elongation at break.
- the amount of residual solvent in the film-like material at the start of stretching is preferably in the range of 20 to 100% by mass.
- the film obtained after completion of stretching is preferably dried until the residual solvent amount is 5% by mass or less, preferably 1% by mass or less.
- the optical film of the present invention may be a long film.
- a long film having a length of about 100 m to 10000 m and a width of 1 to 4 m, preferably 1.4 to 3 m can be obtained.
- a long film can be preserve
- the knurling method can process a metal ring having an uneven pattern on its side surface by heating or pressing.
- Polarizing plate The polarizing plate of the present invention has a polarizer and the optical film of the present invention disposed on at least one surface thereof.
- the polarizer is an element that passes only light having a polarization plane in a certain direction, and examples thereof include a polyvinyl alcohol polarizing film.
- the polyvinyl alcohol polarizing film includes those obtained by dyeing iodine on a polyvinyl alcohol film and those obtained by dyeing a dichroic dye.
- the polarizer can be obtained by uniaxially stretching a polyvinyl alcohol film and then dyeing; or after dying a polyvinyl alcohol film and uniaxially stretching, and preferably by further performing a durability treatment with a boron compound.
- the film thickness of the polarizer is preferably in the range of 5 to 30 ⁇ m, and more preferably in the range of 5 to 15 ⁇ m.
- a retardation film may be disposed on the other surface of the polarizer.
- the retardation of the retardation film can be set according to the type of liquid crystal cell to be combined.
- RH 55% of the retardation film is preferably in the range of 30 to 150 nm, and the retardation Rth (590) in the thickness direction is The range of 70 to 300 nm is preferable.
- a retardation film having a retardation in the above range can be preferably used for, for example, a VA liquid crystal cell.
- the polarizing plate is 1) a pretreatment process for easily bonding the surface of the optical film to which the polarizer is bonded, and 2) applying the following photo-curable adhesive to at least one of the bonding surfaces of the polarizer and the optical film. 3) A bonding process in which the polarizer and the optical film are bonded through the obtained adhesive layer, and 4) A state in which the polarizer and the optical film are bonded through the adhesive layer. And a curing step of curing the adhesive layer. What is necessary is just to implement the pre-processing process of 1) as needed.
- Bonding process For example, when a photocurable adhesive is applied to the surface of the polarizer in the previous application step, an optical film is superimposed thereon. When a photocurable adhesive is applied to the surface of the optical film in the previous application step, a polarizer is superimposed thereon. In addition, when a photocurable adhesive is cast between the polarizer and the optical film, the polarizer and the optical film are superposed in that state.
- the optical film is superimposed on the both surfaces of the polarizer via the photocurable adhesive.
- both sides if the optical film is superimposed on one side of the polarizer, the polarizer side and the optical film side, and if the optical film is superimposed on both sides of the polarizer, The film is pressed with a roll or the like from the film side).
- the material of the roll metal, rubber or the like can be used.
- the rolls arranged on both sides may be the same material or different materials.
- the active energy ray is irradiated to the uncured photocurable adhesive to cure the adhesive layer containing the epoxy compound or the oxetane compound.
- the overlapped polarizer and the optical film are bonded via the photocurable adhesive.
- an active energy ray is applied from either one of the optical films in a state where the optical film is superimposed on both surfaces of the polarizer via a photocurable adhesive. It is advantageous to irradiate and simultaneously cure the photocurable adhesive on both sides.
- active energy rays visible rays, ultraviolet rays, X-rays, electron beams and the like can be used, and since they are easy to handle and have a sufficient curing rate, electron beams or ultraviolet rays are generally preferably used.
- the adhesive becomes insufficiently cured, and when it exceeds 100 kGy, the transparent optical film and the polarizer are damaged, resulting in a decrease in mechanical strength and yellowing, thereby obtaining predetermined optical characteristics. I can't.
- Arbitrary appropriate conditions can be employ
- the dose of ultraviolet rays in the range of 50 ⁇ 1500mJ / cm 2 in accumulated light amount, and even more preferably in the range of within the range of 100 ⁇ 500mJ / cm 2.
- the thickness of the adhesive layer is not particularly limited, but is usually in the range of 0.01 to 10, and preferably in the range of 0.5 to 5 ⁇ m.
- the optical film of the present invention has reduced elongation at break in the slow axis direction and the direction perpendicular thereto. Therefore, it is considered that the polarizing plate including the optical film of the present invention is less likely to generate thermal wrinkles even under high temperature and high humidity.
- the liquid crystal display device of the present invention includes a liquid crystal cell and a pair of polarizing plates that sandwich the liquid crystal cell. And at least one of a pair of polarizing plates can be made into the polarizing plate containing the optical film of this invention. At least one polarizing plate has a polarizer and the optical film of the present invention.
- the optical film of the present invention is preferably disposed on the surface of the polarizer opposite to the liquid crystal cell (arranged as F1 or F4 described later).
- FIG. 1 is a schematic diagram showing an example of a basic configuration of a liquid crystal display device.
- the liquid crystal display device 10 of the present invention includes a liquid crystal cell 30, a first polarizing plate 50 and a second polarizing plate 70 that sandwich the liquid crystal cell 30, and a backlight 90.
- the liquid crystal cell 30 has been proposed in various display modes such as STN, TN, OCB, HAN, VA (MVA, PVA), and IPS.
- the VA (MVA, PVA) mode is preferable.
- the VA liquid crystal cell has a pair of transparent substrates and a liquid crystal layer sandwiched between them.
- one transparent substrate is provided with a pixel electrode for applying a voltage to the liquid crystal molecules.
- the counter electrode may be arranged on the one transparent substrate (on which the pixel electrode is arranged) or on the other transparent substrate.
- the pixel electrode on which the pixel electrode is arranged is arranged. It is preferable to arrange on the one transparent substrate.
- the thickness of the transparent substrate is preferably in the range of 0.3 to 0.7 mm, more preferably in the range of 0.3 to 0.5 mm.
- the liquid crystal layer includes liquid crystal molecules having negative or positive dielectric anisotropy.
- the pixel electrode is arranged on one transparent substrate and the counter electrode is arranged on the other transparent substrate, it is preferable to use liquid crystal molecules having negative dielectric anisotropy.
- both the pixel electrode and the counter electrode are disposed on one transparent substrate, it is preferably a liquid crystal molecule having positive dielectric anisotropy.
- the liquid crystal molecules are liquid crystal molecules when no voltage is applied (when an electric field is not generated between the pixel electrode and the counter electrode) due to the alignment regulating force of the alignment film provided on the liquid crystal layer side surface of the transparent substrate. Are oriented so that their long axes are substantially perpendicular to the surface of the transparent substrate.
- an electric field is generated between the pixel electrode and the counter electrode by applying an image signal (voltage) to the pixel electrode.
- the liquid crystal molecules initially aligned perpendicularly to the surface of the transparent substrate are aligned so that the major axis thereof is in the horizontal direction with respect to the substrate surface.
- the liquid crystal layer is driven, and the image display is performed by changing the transmittance and reflectance of each sub-pixel.
- the first polarizing plate 50 includes a first polarizer 51, a protective film 53 (F1) disposed on the viewing side surface of the first polarizer 51, and a liquid crystal cell side of the first polarizer 51. And a protective film 55 (F2) disposed on the surface.
- the second polarizing plate 70 includes a second polarizer 71, a protective film 73 (F3) disposed on the liquid crystal cell side surface of the second polarizer 71, and the backlight side of the second polarizer 71. And a protective film 75 (F4) disposed on the surface.
- One of the protective film 55 (F2) and the protective film 73 (F3) may be omitted as necessary.
- At least one of the protective film 53 (F1) and the protective film 75 (F4); preferably both can be used as the optical film of the present invention.
- the optical film of the present invention has little cloudiness and reduced haze. Therefore, the liquid crystal display device of the present invention having the optical film of the present invention as the protective film F1 / F4 can have high luminance.
- Polyester compound 1 Condensate composed of succinic acid / terephthalic acid / ethylene glycol (50/50/100 molar ratio) (weight average molecular weight 2000, bulk index 0. 23) End unsealed product
- Polyester compound 2 Unblocked end product of condensate (weight average molecular weight 600) consisting of succinic acid / terephthalic acid / ethylene glycol (50/50/100 molar ratio)
- Polyester compound 3 succinic acid / terephthalic acid / ethylene glycol ( 50/50/100 molar ratio) condensate (weight average molecular weight 3000) end-unencapsulated polyester compound 4: succinic acid / terephthalic acid / ethylene glycol (80/20/100 molar ratio) condensate (80/20/100 molar ratio)
- Polyester compound 5 terminal unblocked product of condensate (weight average molecular weight 2000) consisting of succinic acid / terephthalic acid / ethylene glycol (75/25/100 molar ratio)
- Polyester compound 6 Adipic acid / phthalic acid / propylene glycol (50/50/10 Benzoic acid encapsulated product of condensate (weight
- Styrene compound 1 SMA 2625 (styrene / maleic anhydride (67/33 molar ratio) copolymer, weight average molecular weight 9000, bulk index 0.82), manufactured by Sartomer
- Styrene compound 2 Maruzalin CST50 (styrene / hydroxystyrene (50/50 molar ratio) copolymer, weight average molecular weight 2000, bulkiness index 0.76), manufactured by Maruzen Petrochemical Co., Ltd.
- Sugar ester compound 1 Sugar ester compound represented by the following formula (3)
- Sugar ester compound 2 Sugar ester compound in which the average degree of substitution of the benzoyl groups of R 1 to R 8 in Formula (3) is changed to 6.5
- Sugar ester compound 3 In Formula (3) above, R 1 to R 8 Sugar ester compound in which average degree of substitution of benzoyl group is changed to 7.2
- Sugar ester compound 4 Sugar ester compound in which average degree of substitution of benzoyl group of R 1 to R 8 in formula (3) is changed to 8.0
- Polyester compound A Unblocked product of condensate (weight average molecular weight 1700) composed of adipic acid / ethylene glycol TPP: Triphenyl phosphate BDP: Biphenyl diphenyl phosphate
- the obtained dope solution was uniformly cast on a stainless steel band support at a temperature of 22 ° C. and a width of 2 m using a belt casting apparatus. On the stainless steel band support, the solvent in the dope solution was evaporated until the residual solvent amount reached 100%. And the obtained film-like thing was peeled from the stainless steel band support body by peeling tension 162N / m.
- the peeled film was further dried at 35 ° C., and then slit to 1 m width.
- the obtained film-like material was stretched 2.0 times at 200 ° C. in the transport direction (MD direction) between rolls, and stretched 1.5 times at 200 ° C. in the width direction (TD direction) with a tenter.
- the residual solvent amount at the start of stretching by the tenter was 8%.
- the obtained film was slit to a width of 1.5 m, subjected to a knurling process having a width of 10 mm and a height of 5 ⁇ m at both ends in the width direction of the film, and wound around a core. Thereby, the roll body of the optical film 101 was obtained.
- the film thickness of the optical film 101 was 25 ⁇ m, and the winding length was 4000 m.
- Example 2 to 36 Comparative Examples 1 to 6 and 8 to 11
- Optical films 102 to 142 and 144 to 144 were the same as in Example 1 except that any one or more of cellulose ester, additives and their contents, stretching conditions, and film thickness were changed as shown in Table 3 or 4. 147 was obtained.
- the resin composition was charged into a twin screw extruder and melt kneaded.
- the molten resin was filtered with a metal mesh (filter part) having an opening of 100 ⁇ m provided immediately before the die, and then extruded at 240 ° C. from the circular diameter of the die into a strand shape.
- the extruded molten resin was cooled with water and then cut into a cylindrical shape having a major axis of 5 mm and a cross-sectional diameter of 2.5 mm with a strand cutter to obtain a pellet.
- the obtained pellets were dried at 90 ° C. under reduced pressure for 6 hours, and then charged into a single screw extruder. And after melt-kneading at 240 degreeC by nitrogen atmosphere, it extruded from the die
- the extruded resin was cooled and solidified with a plurality of cooling rolls, and then peeled off with a peeling roll to obtain a film-like product.
- the obtained film-like product is slit at both ends 10 cm, and stretched at 200 ° C. at a draw ratio of 2.0 times in the transport direction (MD direction) of the film-like product by a roll stretching apparatus, and the width direction by a tenter. The film was stretched 1.5 times in the (TD direction) at 200 ° C.
- compositions and stretching conditions of the optical films of Examples 1 to 19 and Comparative Examples 1 to 3 are shown in Table 3; the compositions and stretching conditions of the optical films of Examples 20 to 36 and Comparative Examples 4 to 11 are shown in Table 4.
- the obtained optical film was measured for the tensile modulus, elongation at break, haze, R 0 and Rth, and winding by the following methods.
- the optical film was cut into a size of 10 mm (MD direction) ⁇ 100 mm (TD direction) to obtain a sample film.
- the sample film was conditioned for 24 hours in an environment of 25 ° C. and 55% RH.
- the sample film after humidity control was pulled in the MD direction using a Tensilon RTC-1225A manufactured by Orientec Co., Ltd., and the tensile modulus in the MD direction and the elongation at break were determined. It was measured.
- the tensile elastic modulus and elongation at break in the TD direction were measured in the same manner except that the direction of pulling the sample film was changed to the TD direction.
- the tensile modulus and elongation at break were measured at 23 ° C. and 55% RH under the condition of a tensile speed of 50 mm / min.
- the obtained optical film was conditioned at 23 ° C. and 55% RH for 5 hours or more.
- the haze of the obtained optical film was measured according to JIS K-7136 under the conditions of 23 ° C. and 55% RH, a haze meter (turbidimeter) (model: NDH 2000, manufactured by Nippon Denshoku Co., Ltd.). ).
- the retardation R0 in the in-plane direction and the retardation Rth in the thickness direction of the optical film were measured by the following methods. 1) The optical film is conditioned at 23 ° C. and 55% RH. The average refractive index of the optical film after humidity control was measured with an Abbe refractometer. 2) R 0 when light having a measurement wavelength of 590 nm was incident on the optical film after humidity adjustment in parallel with the normal line of the film surface was measured by KOBRA 21DH, Oji Scientific Co., Ltd.
- the slow axis in the plane of the optical film is set as the tilt axis (rotation axis), and light having a measurement wavelength of 590 nm from the angle normal to the surface of the optical film (incident angle ( ⁇ )) is obtained.
- the retardation value R ( ⁇ ) when incident was measured.
- the retardation value R ( ⁇ ) was measured at 6 points every 10 °, with ⁇ ranging from 0 ° to 50 °.
- the in-plane slow axis of the optical film was confirmed by KOBRA21ADH.
- nx, ny, and nz were calculated by KOBRA21ADH from the measured R 0 and R ( ⁇ ) and the above-described average refractive index and film thickness, and Rth at a measurement wavelength of 590 nm was calculated.
- a roll body (winding length: 4000 m, width: 1330 m) obtained by winding the optical film in the direction perpendicular to the width direction was prepared.
- This roll body is covered with a polyethylene sheet for preventing dust adhesion, and the length of the core (core) is set to be horizontal in a warehouse of 30 ° C. to 40 ° C. and 65% RH to 85% RH. Stored for months. And the state of winding of the roll body after one month passed was visually observed and evaluated as follows.
- ⁇ No change such as wrinkles or deformation is observed on the roll surface
- ⁇ Slight wrinkles are observed on the roll surface, but no deformation is observed
- ⁇ Weak wrinkles are observed on the roll surface, and some Deformation is also observed
- ⁇ Strong wrinkles on the surface of the roll to the inside, strong deformation on the surface, deformation to the inside
- the films of Examples 1 to 36 each had a breaking elongation in the MD direction / TD direction in the range of 1 to 10%, a haze as low as 1% or less, It can be seen that there is little change in shape.
- the films of Comparative Examples 1 to 9 have a high elongation at break in at least one of the MD direction / TD direction of more than 10%, and it can be seen that the change in winding shape is large.
- the film of Comparative Example 1 contains CAP having a relatively high flexibility, thus causing white turbidity and high elongation at break. It can be seen that the film of Comparative Example 2 has an excessively low draw ratio because the draw ratio is too high. Since the film of Comparative Example 4 is unstretched, the film of Comparative Example 5 is stretched only in the TD direction, and the film of Comparative Example 6 is stretched at a low magnification in both the MD / TD directions, both of which have a breaking elongation. Is high. Since the film of Comparative Example 7 is a melt film-forming film using CAP, it can be seen that it not only causes white turbidity but also has a high elongation at break.
- the TPP / BDP contained in the films of Comparative Examples 9 and 11 is easy to bleed out, and the content in the film in the film forming process is reduced, so the stretchability is low, and the elongation at break of the film after stretching is also low. I understand that it is expensive. In Comparative Examples 8 and 10, it can be seen that the stretchability of the film is low and breaks under the stretching conditions shown in Table 4.
- the above-prepared dope solution 1 was uniformly cast on a stainless steel band support at a temperature of 22 ° C. and a width of 2 m using a belt casting apparatus.
- the solvent in the dope liquid 1 of the stainless steel band support was evaporated until the residual solvent amount reached 100%, and then peeled off from the stainless steel band support with a peeling tension of 162 N / m to obtain a film-like material.
- the solvent in the obtained film-like material was further evaporated at 35 ° C., and then slit to 1 m width.
- the obtained film-like material is dried at a drying temperature of 135 ° C. while being stretched 1.1 times in the transport direction (MD direction) by zone stretching and 1.5 times in the width direction (TD direction) by tenter stretching. It was.
- the residual solvent amount at the start of stretching by the tenter was 8%. After stretching with a tenter, relaxation treatment was performed at 130 ° C. for 5 minutes.
- the resulting film was dried while being transported by a large number of rollers through a drying zone at 120 ° C. and 140 ° C. Thereafter, the film was slit to a width of 1.5 m, and knurling with a width of 10 mm and a height of 5 ⁇ m was applied to both ends in the width direction of the film to obtain a retardation film a having a thickness of 30 ⁇ m.
- composition of dope solution B Cellulose ester CE-2 (acetyl group substitution degree 2.43, total acyl substitution degree 2.43): 100 parts by mass
- Additive A-5 terephthalic acid / succinic acid (55 mol% / 45 mol%) / ethylene
- Dichloromethane 406 parts by mass Methanol: 61 parts by mass
- Retardation film c A pellet of ZEONOR1420 (manufactured by Nippon Zeon Co., Ltd.), which is a norbornene resin, was dried at 100 ° C. for 5 hours. Thereafter, the pellets were supplied to an extruder by a conventional method, melted at 250 ° C., and discharged from a die onto a cooling drum to obtain an unstretched film having a thickness of 150 ⁇ m.
- the above-mentioned unstretched film was stretched 1.2 times in the longitudinal direction (MD direction) at a temperature of 143 ° C. by a longitudinal stretching machine using a float system between rolls. This was supplied to a transverse stretching machine using a tenter method, and further stretched 1.8 times in the transverse direction (TD direction) at a temperature of 150 ° C. while adjusting the take-up tension and the tenter chain tension. Thereby, retardation film c was obtained.
- In-plane direction retardation R0 and thickness direction retardation Rth of the obtained retardation films a to c at a wavelength of 590 nm were measured in the same manner as described above. The evaluation results are shown in Table 7.
- Polarizing Plate (Example 37) 1) Preparation of Polarizer A 30 ⁇ m thick polyvinyl alcohol film was swollen with water at 35 ° C. The obtained film was immersed in an aqueous solution consisting of 0.075 g of iodine, 5 g of potassium iodide and 100 g of water for 60 seconds, and further immersed in an aqueous solution at 45 ° C. consisting of 3 g of potassium iodide, 7.5 g of boric acid and 100 g of water. . The obtained film was uniaxially stretched under conditions of a stretching temperature of 55 ° C. and a stretching ratio of 5 times. This uniaxially stretched film was washed with water and dried to obtain a polarizer having a thickness of 10 ⁇ m.
- Triarylsulfonium hexafluorophosphate was blended as a 50% propylene carbonate solution, and the solid content of triarylsulfonium hexafluorophosphate was shown below.
- the photocurable adhesive prepared above was applied using a microgravure coater so as to have a dry thickness of 5 ⁇ m to form a photocurable adhesive layer. .
- the application was performed under the conditions of gravure roller # 300, rotation speed 140% / line speed.
- the photocurable adhesive prepared above was applied on the optical film 101 so as to have a dry thickness of 5 ⁇ m to form a photocurable adhesive layer.
- the retardation film a on which a photocurable adhesive layer is formed is disposed on one surface of the prepared polarizer, and the optical film 101 on which a photocurable adhesive layer is formed is disposed on the other surface.
- a laminate of retardation film a / photocurable adhesive layer / polarizer / photocurable adhesive layer / optical film 101 was obtained.
- the obtained laminate was bonded with a roller machine. The bonding was performed so that the slow axis of the optical film 101 and the absorption axis of the polarizer were orthogonal to each other.
- the polarizing plate 201 was obtained by irradiating an electron beam from both sides of the laminated laminate to cure the photocurable adhesive layer.
- the line speed was 20 m / min
- the acceleration voltage was 250 kV
- the irradiation dose was 20 kGy.
- Polarizing plates 202 to 247 were obtained in the same manner as in Example 37 except that the types of the optical film and the retardation film were changed as shown in Table 8 or 9.
- the thermal wrinkle of the obtained polarizing plate was evaluated by the following method.
- liquid crystal display device Example 73
- the pair of polarizing plates attached to both sides of the liquid crystal cell is peeled off, and the prepared polarizing plate 201 is attached to both sides of the liquid crystal cell.
- a liquid crystal display device 301 was obtained.
- the polarizing plate 201 was bonded so that the above-described retardation film a was on the liquid crystal cell side.
- Liquid crystal display devices 302 to 347 were obtained in the same manner as in Example 73 except that the polarizing plate 201 to be bonded to both surfaces of the liquid crystal cell was changed as shown in Table 10 or 11.
- the brightness of the obtained liquid crystal display device was measured by the following method.
- Front contrast luminance
- the luminance from the normal direction of the display screen during white display of the liquid crystal display device and the luminance from the normal direction of the display screen during black display were measured using EZ-Contrast 160D manufactured by ELDIM. The obtained value was applied to the following formula to calculate the front contrast. The luminance was measured in an environment of 23 ° C. and 55% RH.
- Front contrast (brightness of white display measured from normal direction of display device) / (brightness of black display measured from normal direction of display device) And the brightness
- the liquid crystal display devices of Examples 73 to 108 have higher luminance than the liquid crystal display devices of Comparative Examples 23 to 25, 29, 31 and 33. It is considered that the F1 / F4 films constituting the liquid crystal display devices of Examples 73 to 108 have little cloudiness and low haze.
Abstract
Description
[2] JIS K-7136に準拠して測定されるヘイズが0.5以下である、[1]に記載の光学フィルム。
[3] 前記光学フィルムが、環構造を有する分子量1万以下の添加剤をさらに含有する、[1]または[2]に記載の光学フィルム。
[4] 前記添加剤は、繰り返し単位に含まれる環構造が非芳香環構造または芳香環構造である、ポリエステル化合物もしくはスチレン系化合物、またはピラノース構造またはフラノース構造を有し、前記ピラノース構造またはフラノース構造が非芳香環構造または芳香環構造を含む置換基を有する糖エステル化合物である、[3]に記載の光学フィルム。
[5] 前記環構造は、芳香環である、[3]または[4]に記載の光学フィルム。
[6] 前記添加剤は、繰り返し単位に含まれる環構造が芳香環構造である分子量600以上のポリエステル化合物もしくは分子量600以上のスチレン系化合物である、[3]~[5]のいずれかに記載の光学フィルム。
[7] 前記添加剤の含有量は、前記セルロースエステルに対して5~30質量%である、[3]~[6]のいずれかに記載の光学フィルム。
[8] フィルム面内の遅相軸方向と前記遅相軸方向と直交する方向の少なくとも一方の23℃55%RH下における引張弾性率が、5.0~8.0GPaである、[1]~[7]のいずれかに記載の光学フィルム。
[9] フィルム面内の遅相軸方向と前記遅相軸方向と直交する方向の25℃における破断伸度がいずれも1~5%である、[1]~[8]のいずれかに記載の光学フィルム。
[10] 23℃55%RH下、測定波長590nmにおける面内方向のレターデーションR0(590)が10nm以下である、[1]~[9]のいずれかに記載の光学フィルム。
前記ドープ液を無端状の金属支持体上に流延する工程と、
流延された前記ドープ液を乾燥させて得られる膜状物を、前記金属支持体から剥離する工程と、
剥離された前記膜状物を、前記膜状物の面内の互いに直交する2つの方向にそれぞれ1.3~4.0倍の延伸倍率で延伸して、厚み15~35μmの光学フィルムを得る工程と、
を含む、光学フィルムの製造方法。
[12] 前記添加剤は、繰り返し単位に含まれる環構造が非芳香環構造または芳香環構造である、ポリエステル化合物もしくはスチレン系化合物、またはピラノース構造またはフラノース構造を有し、前記ピラノース構造またはフラノース構造が非芳香環構造または芳香環構造を含む置換基を有する糖エステル化合物である、[11]に記載の光学フィルムの製造方法。
[13] 前記環構造は、芳香環である、[11]または[12]に記載の光学フィルムの製造方法。
[14] 前記添加剤は、繰り返し単位に含まれる環構造が芳香環構造である分子量600以上のポリエステル化合物もしくは分子量600以上のスチレン系化合物である、[10]~[13]のいずれかに記載の光学フィルムの製造方法。
[15] 前記添加剤の含有量は、前記セルロースエステルに対して5~30質量%である、[10]~[14]のいずれかに記載の光学フィルムの製造方法。
[16] 前記光学フィルムの、23℃55%RH下、測定波長590nmにおける面内方向のレターデーションR0(590)が10nm以下である、[10]~[15]のいずれかに記載の光学フィルムの製造方法。
[17] [1]~[10]のいずれかに記載の光学フィルムを含む、偏光板。
[18] [1]~[10]のいずれかに記載の光学フィルムを含む、液晶表示装置。
[19] 液晶セルと、前記液晶セルの一方の面に配置され、第一の偏光子を有する第一の偏光板と、前記液晶セルの他方の面に配置され、第二の偏光子を有する第二の偏光板とを有する液晶表示装置であって、前記第一の偏光板が、前記第一の偏光子の前記液晶セルとは反対側の面に配置された[1]~[10]のいずれかに記載の光学フィルムを有するか、または前記第二の偏光板が、前記第二の偏光子の前記液晶セルとは反対側の面に配置された[1]~[10]のいずれかに記載の光学フィルムを有する、液晶表示装置。
本発明の光学フィルムは、セルロースエステルと、環構造を有する添加剤とを含む。
セルロースを構成するβ-1,4結合しているグルコース単位は、2位、3位及び6位に遊離のヒドロキシ基(水酸基)を有している。セルロースエステルは、これらのヒドロキシ基(水酸基)の一部または全部をアシル化した重合体(ポリマー)である。アシル基の総置換度は、2位、3位および6位に位置するセルロースのヒドロキシ基(水酸基)がアシル化している割合(100%のアシル化は置換度3)を意味する。
溶媒:メチレンクロライド
カラム:Shodex K806、K805、K803G(昭和電工(株)製)を3本接続して使用する。
カラム温度:25℃
試料濃度:0.1質量%
検出器:RI Model 504(GLサイエンス社製)
ポンプ:L6000(日立製作所(株)製)
流量:1.0ml/min
校正曲線:標準ポリスチレンSTK standardポリスチレン(東ソー(株)製)Mw=1.0×106~5.0×102までの13サンプルによる校正曲線を使用する。13サンプルは、ほぼ等間隔に選択することが好ましい。
環構造を有する添加剤は、環構造として非芳香環構造または芳香環構造、好ましくは芳香環構造を含む。
ポリエステル化合物は、ジカルボン酸とジオールとの縮合物に由来する繰り返し単位を含む。繰り返し単位は、非芳香環構造または芳香環構造を含むことが好ましい。即ち、ポリエステル化合物を構成するジカルボン酸とジオールの少なくとも一方が、非芳香環構造または芳香環構造を含むことが好ましいが、ジカルボン酸が非芳香環構造または芳香環構造を含むことがさらに好ましい。
スチレン系化合物は、スチレン系モノマーの単独重合体であってもよいし、スチレン系モノマーとそれ以外の共重合モノマーとの共重合体であってもよい。スチレン系化合物におけるスチレン系モノマー由来の構成単位の含有割合は、分子構造が一定以上の嵩高さを有するためには、好ましくは30~100モル%、より好ましくは50~100モル%でありうる。
糖エステル化合物は、糖に含まれる水酸基とモノカルボン酸とをエステル化反応させて得られる化合物である。
嵩高さ指数=環構造部分の分子量の総和/環構造を有する添加剤全体の分子量
本発明の光学フィルムは、必要に応じて可塑剤、紫外線吸収剤、マット剤(微粒子)等の各種添加剤をさらに含有することができる。
可塑剤の例には、上記ポリエステル化合物のうち環構造を有しないポリエステル化合物、多価アルコールエステル系化合物などが含まれる。多価アルコールエステル系化合物としては、例えば特開2010-32655号公報の段落0218~0170に記載の化合物などが含まれる。
本発明の光学フィルムは、紫外線吸収剤をさらに含有してもよい。紫外線吸収剤の例には、ベンゾトリアゾール系化合物、2-ヒドロキシベンゾフェノン系化合物、サリチル酸フェニルエステル系化合物等が含まれる。
本発明の光学フィルムは、滑り性を付与するためにマット剤をさらに含有してもよい。マット剤としては、得られるフィルムの透明性を損なわず、かつ溶融時の耐熱性があれば無機化合物であっても有機化合物であってもよい。マット剤は、単独で用いてもよいし、2種以上を併用してもよい。
本発明の光学フィルムの遅相軸方向と、該遅相軸方向とそれと直交する方向の、23℃55RH下での引張弾性率は、それぞれ3.0~8.5GPaであることが好ましく、5.0~8.0GPaであることがより好ましい。
本発明の光学フィルムの遅相軸方向とそれと直交する方向の、23℃55%RH下での破断伸度は、それぞれ1~10%であることが好ましく、1~5%であることがより好ましい。
本発明の光学フィルムは、前述の通り、白濁が少なく、ヘイズが低減されている。本発明の光学フィルムのヘイズ値は、1.0%以下であることが好ましく、0.5%以下であることがさらに好ましい。本発明の光学フィルムを散乱フィルムとして用いる場合は、ヘイズ値は上記の範囲を超えていてもよい。ヘイズは、JIS K-7136に準拠して、ヘイズメーター(濁度計)(型式:NDH 2000、日本電色(株)製)にて測定されうる。
本発明の光学フィルムは、測定波長590nm、23℃55%RHの条件下で測定される面内方向のレターデーションR0は、0≦R0≦20nmを満たすことが好ましく、0nm≦R0≦10nmを満たすことがより好ましい。光学フィルムの、測定波長590nm、23℃55%RHの条件下で測定される厚み方向のレターデーションRthは、0nm≦Rth≦80nmを満たすことが好ましく、0nm≦Rth≦50nmを満たすことがより好ましい。このようなレターデーション値を有する光学フィルムは、後述するように、液晶表示装置の保護フィルム(F1/F4)として好ましく用いられる。
式(I):R0=(nx-ny)×d(nm)
式(II):Rth={(nx+ny)/2-nz}×d(nm)
(式(I)および(II)において、
nxは、光学フィルムの面内方向において屈折率が最大になる遅相軸方向xにおける屈折率を表し;
nyは、光学フィルムの面内方向において前記遅相軸方向xと直交する方向yにおける屈折率を表し;
nzは、光学フィルムの厚み方向zにおける屈折率を表し;
d(nm)は、光学フィルムの厚みを表す)
1)光学フィルムを、23℃55%RHで調湿する。調湿後の光学補償フィルムの平均屈折率をアッベ屈折計などで測定する。
2)調湿後の光学フィルムに、当該フィルム表面の法線に平行に測定波長590nmの光を入射させたときのR0を、KOBRA21DH、王子計測(株)にて測定する。
3)KOBRA21ADHにより、光学フィルムの面内の遅相軸を傾斜軸(回転軸)として、光学フィルムの表面の法線に対してθの角度(入射角(θ))から測定波長590nmの光を入射させたときのレターデーション値R(θ)を測定する。レターデーション値R(θ)の測定は、θが0°~50°の範囲で、10°毎に6点行うことができる。光学フィルムの面内の遅相軸は、KOBRA21ADHにより確認することができる。
4)測定されたR0およびR(θ)と、前述の平均屈折率と膜厚とから、KOBRA21ADHにより、nx、nyおよびnzを算出して、測定波長590nmでのRthを算出する。レターデーションの測定は、23℃55%RH条件下で行うことができる。
ハードコート層は、活性線硬化性化合物の硬化物を含有する。活性線硬化性化合物としては、エチレン性不飽和二重結合を有するモノマーを含む成分が好ましく用いられる。活性線硬化性化合物としては、紫外線硬化性化合物や電子線硬化性化合物が挙げられるが、紫外線照射により硬化する化合物が、機械的膜強度(耐擦傷性、鉛筆硬度)に優れる点から好ましい。
本発明の光学フィルムは、ハードコート層の上層に反射防止層をさらに有してもよい。それにより、本発明の光学フィルムを、外光反射防止機能を有する反射防止フィルムとして用いることができる。
光学フィルム/ハードコート層/中屈折率層/低屈折率層
光学フィルム/ハードコート層/中屈折率層/高屈折率層/低屈折率層
光学フィルム/ハードコート層/高屈折率層(導電性層)/低屈折率層
光学フィルム/ハードコート層/防眩性層/低屈折率層
式(4):Si(OR)4
本発明の光学フィルムは、着色抑制、異物欠点の抑制、ダイラインなどの光学欠点の抑制などの観点から、溶液流延法や溶融流延法により製造されうる。なかでも、得られるフィルムの平面性、筋等の故障耐性、および膜厚の精度などが良好であることなどから、溶液流延法が好ましい。
ドープ液の調製に有用な有機溶媒は、セルロースエステルや環構造を有する添加剤などを同時に溶解するものであれば、制限なく用いることができる。
ドープ液を、送液ポンプ(例えば、加圧型定量ギヤポンプ)を通して加圧ダイに送液する。そして、加圧ダイのスリットから、無限に移送する無端の金属支持体上(例えばステンレスベルト、あるいは回転する金属ドラム等)の流延位置に、ドープ液を流延する。
金属支持体上に流延されたドープ液を金属支持体上で加熱して、ドープ液中の溶媒を蒸発させて、膜状物を得る。
残留溶媒量(%)=(膜状物の加熱処理前質量-膜状物の加熱処理後質量)/(膜状物の加熱処理後質量)×100
なお、残留溶媒量を測定する際の加熱処理とは、140℃で1時間の加熱処理を行うことを表す。
剥離された膜状物を、乾燥装置内を複数配置したローラで搬送させながら乾燥させる。そして、テンター延伸装置にて、膜状物の両端をクリップで挟みながら搬送して、膜状物を延伸する。
流延方向に延伸→幅手方向に延伸
幅手方向に延伸→幅手方向に延伸
流延方向に延伸→幅手方向に延伸→幅手方向に延伸
幅手方向に延伸→幅手方向に延伸→流延方向に延伸
延伸、乾燥後に得られる光学フィルムを、巻き取り機でロール状に巻き取る。巻き取り方法は、一般に使用されているものを用いればよく、定トルク法、定テンション法、テーパーテンション法、内部応力一定のプログラムテンションコントロール法等があり、それらを使い分ければよい。
本発明の偏光板は、偏光子と、その少なくとも一方の面に配置された本発明の光学フィルムとを有する。
前処理工程では、光学フィルムの、偏光子との接着面に易接着処理を行う。偏光子の両面にそれぞれ光学フィルムを接着させる場合は、それぞれの光学フィルムの、偏光子との接着面に易接着処理を行う。易接着処理としては、コロナ処理、プラズマ処理等が挙げられる。
接着剤塗布工程では、偏光子と光学フィルムとの接着面のうち少なくとも一方に、上記光硬化性接着剤を塗布する。偏光子または光学フィルムの表面に直接光硬化性接着剤を塗布する場合、その塗布方法に特別な限定はない。例えば、ドクターブレード、ワイヤーバー、ダイコーター、カンマコーター、グラビアコーター等、種々の塗工方式が利用できる。また、偏光子と光学フィルムの間に、光硬化性接着剤を流延させた後、ロール等で加圧して均一に押し広げる方法も利用できる。
こうして光硬化性接着剤を塗布した後、貼合工程に供される。この貼合工程では、例えば、先の塗布工程で偏光子の表面に光硬化性接着剤を塗布した場合、そこに光学フィルムが重ね合わされる。先の塗布工程で光学フィルムの表面に光硬化性接着剤を塗布した場合は、そこに偏光子が重ね合わされる。また、偏光子と光学フィルムの間に光硬化性接着剤を流延させた場合は、その状態で偏光子と光学フィルムとが重ね合わされる。偏光子の両面に光学フィルムを接着する場合であって、両面とも光硬化性接着剤を用いる場合は、偏光子の両面にそれぞれ、光硬化性接着剤を介して光学フィルムが重ね合わされる。そして通常は、この状態で両面(偏光子の片面に光学フィルムを重ね合わせた場合は、偏光子側と光学フィルム側、また偏光子の両面に光学フィルムを重ね合わせた場合は、その両面の光学フィルム側)からロール等で挟んで加圧することになる。ロールの材質は、金属やゴム等を用いることが可能である。両面に配置されるロールは、同じ材質であってもよいし、異なる材質であってもよい。
硬化工程では、未硬化の光硬化性接着剤に活性エネルギー線を照射して、エポキシ化合物やオキセタン化合物を含む接着剤層を硬化させる。それにより、光硬化性接着剤を介して重ね合わせた偏光子と光学フィルムとを接着させる。偏光子の片面に光学フィルムを貼合する場合、活性エネルギー線は、偏光子側または光学フィルム側のいずれから照射してもよい。また、偏光子の両面に光学フィルムを貼合する場合、偏光子の両面にそれぞれ光硬化性接着剤を介して光学フィルムを重ね合わせた状態で、いずれか一方の光学フィルム側から活性エネルギー線を照射し、両面の光硬化性接着剤を同時に硬化させるのが有利である。
本発明の液晶表示装置は、液晶セルと、それを挟持する一対の偏光板とを含む。そして、一対の偏光板の少なくとも一方を、本発明の光学フィルムを含む偏光板としうる。少なくとも一方の偏光板は、偏光子と、本発明の光学フィルムとを有する。本発明の光学フィルムは、偏光子の液晶セルとは反対側の面に配置されること(後述するF1またはF4として配置されること)が好ましい。
2-1)環構造を有する添加剤
ポリエステル化合物1:コハク酸/テレフタル酸/エチレングリコール(50/50/100モル比)からなる縮合物(重量平均分子量2000、嵩高さ指数0.23)の末端未封止物
ポリエステル化合物3:コハク酸/テレフタル酸/エチレングリコール(50/50/100モル比)からなる縮合物(重量平均分子量3000)の末端未封止物
ポリエステル化合物4:コハク酸/テレフタル酸/エチレングリコール(80/20/100モル比)からなる縮合物(重量平均分子量2000)の末端未封止物
ポリエステル化合物5:コハク酸/テレフタル酸/エチレングリコール(75/25/100モル比)からなる縮合物(重量平均分子量2000)の末端未封止物
ポリエステル化合物6:アジピン酸/フタル酸/プロピレングリコール(50/50/100モル比)からなる縮合物(重量平均分子量400)の安息香酸封止物
ポリエステル化合物7:コハク酸/テレフタル酸/エチレングリコール(75/25/100モル比)からなる縮合物(重量平均分子量2000)の安息香酸封止物
ポリエステル化合物8:アジピン酸/テレフタル酸/プロピレングリコール(50/50/100モル比)からなる縮合物(重量平均分子量1000)の末端未封止物
ポリエステル化合物9:セバシン酸/テレフタル酸/エチレングリコール(50/50/100モル比)からなる縮合物(重量平均分子量1000)の末端未封止物
糖エステル化合物3:上記式(3)においてR1~R8のベンゾイル基の平均置換度を7.2に変更した糖エステル化合物
糖エステル化合物4:上記式(3)においてR1~R8のベンゾイル基の平均置換度を8.0に変更した糖エステル化合物
ポリエステル化合物A:アジピン酸/エチレングリコールからなる縮合物(重量平均分子量1700)の末端未封止物
TPP:トリフェニルホスフェート
BDP:ビフェニルジフェニルホスフェート
(実施例1)
下記成分を、攪拌および加熱しながら十分に溶解させて、ドープ液を調製した。
(ドープ液の組成)
セルロースエステルA1:100質量部
ポリエステル化合物1:10質量部
紫外線吸収剤:Ti928:2-(2H-ベンゾトリアゾール-2-イル)-6-(1-メチル-1-フェニルエチル)-4-(1,1,3,3-テトラメチルブチル)フェノール(チヌビン928、BASFジャパン社製):3.0質量部
マット剤:R972V(日本アエロジル社製、シリカ粒子、平均粒径=16nm):0.30質量部
剥離助剤:エレカットS412(竹本油脂社製):0.50質量部
メチレンクロライド:300質量部
エタノール:40質量部
セルロースエステル、添加剤およびその含有量、延伸条件、膜厚のうちいずれか一以上を、表3または4に示すように変更した以外は実施例1と同様にして光学フィルム102~142および144~147を得た。
ペレットの作製
表1のセルロースエステルC(セルロースアセテートプロピオネート)を、除湿熱風乾燥機にて90℃で6時間以上乾燥させて、水分率を80ppm以下とした。得られたセルロースエステルCと、下記添加剤とをホッパーで混合して樹脂組成物とした。
(樹脂組成物の組成)
セルロースエステルC:100質量部
ポリエステル化合物1:10質量部
GSY-P101(堺化学工業(株)製):0.25質量部
Irganox1010(BASFジャパン(株)製):0.5質量部
SumilizerGS(住友化学(株)製):0.24質量部
R972V(アエロジル社製):0.15質量部
得られたペレットを、減圧下、90℃、6時間乾燥させた後、単軸押し出し機に投入した。そして、窒素雰囲気下、240℃で溶融混練した後、ダイから、表面温度が90℃の冷却ロール上に押し出した。押し出された樹脂を、複数の冷却ロールで冷却固化した後、剥離ロールで剥離して、膜状物を得た。得られた膜状物の両端部10cmをスリットし、ロール延伸装置にて膜状物の搬送方向(MD方向)に、200℃で延伸倍率2.0倍に延伸し、テンターにて幅手方向(TD方向)に200℃で1.5倍延伸した。それ以外は実施例1と同様にして膜厚25μmの光学フィルム143を得た。
まず、光学フィルムを10mm(MD方向)×100mm(TD方向)のサイズに切り取り、サンプルフィルムを得た。このサンプルフィルムを、25℃55%RHの環境下で24時間調湿した。調湿後のサンプルフィルムを、JIS K7127に準拠して、オリエンテック社製テンシロンRTC-1225Aを用いて、チャック間距離を50mmとし、MD方向に引っ張り、MD方向の引張弾性率および破断伸度を測定した。また、サンプルフィルムを引っ張る方向をTD方向に変更した以外は同様にしてTD方向の引張弾性率および破断伸度を測定した。引張弾性率および破断伸度の測定は、23℃55%RH下、引張速度50mm/分の条件で行った。
得られた光学フィルムを、23℃55%RH下で5時間以上調湿した。次いで、得られた光学フィルムのヘイズを、JIS K-7136に準拠して、23℃55%RHの条件下で、ヘイズメーター(濁度計)(型式:NDH 2000、日本電色(株)製)にて測定した。
光学フィルムの面内方向のレターデーションR0と厚み方向のレターデーションRthは、以下の方法で測定した。
1)光学フィルムを、23℃55%RHで調湿する。調湿後の光学フィルムの平均屈折率をアッベ屈折計で測定した。
2)調湿後の光学フィルムに、当該フィルム表面の法線に平行に測定波長590nmの光を入射させたときのR0を、KOBRA21DH、王子計測(株)にて測定した。
3)KOBRA21ADHにより、光学フィルムの面内の遅相軸を傾斜軸(回転軸)として、光学フィルムの表面の法線に対してθの角度(入射角(θ))から測定波長590nmの光を入射させたときのレターデーション値R(θ)を測定した。レターデーション値R(θ)の測定は、θが0°~50°の範囲で、10°毎に6点行った。光学フィルムの面内の遅相軸は、KOBRA21ADHにより確認した。
4)測定されたR0およびR(θ)と、前述の平均屈折率と膜厚とから、KOBRA21ADHにより、nx、nyおよびnzを算出して、測定波長590nmでのRthを算出した。
光学フィルムを幅方向に対して垂直方向に巻き取ったロール体(巻き長:4000m、幅:1330m)を準備した。このロール体に、埃の付着防止用のポリエチレンシートを被せて、30℃~40℃、65%RH~85%RHの倉庫で、コア(巻芯)の長さ方向が水平になるように1ヶ月間保管した。そして、1ヶ月経過後のロール体の巻きの状態を、目視観察し、下記のように評価した。
◎:ロールの表面に皺、変形等の変化は認められない
○:ロールの表面に僅かに皺が認められるが、変形は認められない
△:ロールの表面に弱い皺が認められ、一部に変形も認められる
×:ロールの表面~内部に強い皺、表面に強い変形が有り、内部まで変形有り
1)位相差フィルムa
下記成分を、攪拌および加熱しながら十分に溶解させて、ドープ液1を調製した。
(ドープ液1の組成)
セルロースエステル(アセチル基置換度2.3、重量平均分子量Mw18.5万のジアセチルセルロース):100質量部
下記化合物A-022(リターデーション上昇剤):4質量部
下記式(5)で表される糖エステル化合物:10質量部
R972V(日本アエロジル社製、シリカ粒子、平均粒径=16nm、マット剤):0.30質量部
メチレンクロライド:300質量部
エタノール:40質量部
ドープ液の調製
下記成分を混合してドープ液AおよびBをそれぞれ調製した。
(ドープ液Aの組成)
セルロースエステルCE-1(アセチル基置換度2.81、アシル基の総置換度2.81):100質量部
添加剤A-5:テレフタル酸/コハク酸(55モル%/45モル%)/エチレングリコール/プロピレングリコール(45モル%/55モル%)の酢酸末端封止物(数平均分子量800):12質量部
下記化合物A:4質量部
マット剤分散液(AEROSIL R972、日本エアロジル株式会社製、2次平均粒子サイズ1.0μm以下):セルロースエステル100質量部に対して固形分0.13質量部
ジクロロメタン:406質量部
メタノール:61質量部
セルロースエステルCE-2(アセチル基置換度2.43、アシル基の総置換度2.43):100質量部
添加剤A-5:テレフタル酸/コハク酸(55モル%/45モル%)/エチレングリコール/プロピレングリコール(45モル%/55モル%)の酢酸末端封止物(数平均分子量800):18質量部
マット剤分散液(AEROSIL R972、日本エアロジル株式会社製、2次平均粒子サイズ1.0μm以下):セルロースエステル100質量部に対して固形分0.13質量部
ジクロロメタン:406質量部
メタノール:61質量部
得られたドープ液AおよびBを、走行する流延バンド上に流延ダイからドープ液A/ドープ液B/ドープ液Aの順に積層されるように、同時多層流延を行った。各ドープの流延量を調整して、コア層(ドープ液Bの層)が最も厚くなるようにした。残留溶剤量が約30質量%で流延バンドから剥ぎ取ったフィルムを、テンターにより140℃の熱風を当てつつ幅方向に30%延伸した。その後、テンター搬送からロール搬送に移行し、さらに120℃から150℃で乾燥し、位相差フィルムbを得た。得られた位相差フィルムbの膜厚は、スキン層(ドープ液Aの層)/コア層(ドープ液Bの層)/スキン層(ドープ液Aの層)が2.5μm/55μm/2.5μmであった。
ノルボルネン系樹脂であるZEONOR1420(日本ゼオン(株)製)のペレットを100℃で5時間乾燥した。その後、該ペレットを、常法によって押出し機に供給して250℃で溶融し、ダイから冷却ドラム上に吐出させて、厚み150μmの未延伸フィルムを得た。
(実施例37)
1)偏光子の調製
厚さ30μmのポリビニルアルコールフィルムを、35℃の水で膨潤させた。得られたフィルムを、ヨウ素0.075g、ヨウ化カリウム5gおよび水100gからなる水溶液に60秒間浸漬し、さらにヨウ化カリウム3g、ホウ酸7.5g及び水100gからなる45℃の水溶液に浸漬した。得られたフィルムを、延伸温度55℃、延伸倍率5倍の条件で一軸延伸した。この一軸延伸フィルムを、水洗した後、乾燥させて、厚さ10μmの偏光子を得た。
下記成分を混合した後、脱泡して、光硬化性接着剤を調製した。なお、トリアリールスルホニウムヘキサフルオロホスフェートは、50%プロピレンカーボネート溶液として配合し、下記にはトリアリールスルホニウムヘキサフルオロホスフェートの固形分量を表示した。
(光硬化性接着剤の組成)
3,4-エポキシシクロヘキシルメチル-3,4-エポキシシクロヘキサンカルボキシレート:45質量部
エポリードGT-301(ダイセル化学社製の脂環式エポキシ樹脂):40質量部
1,4-ブタンジオールジグリシジルエーテル:15質量部
トリアリールスルホニウムヘキサフルオロホスフェート:2.3質量部
9,10-ジブトキシアントラセン:0.1質量部
1,4-ジエトキシナフタレン:2.0質量部
作製した位相差フィルムa上に、上記調製した光硬化性接着剤を、マイクログラビアコーターを用いて乾燥厚みが5μmになるように塗布して、光硬化性接着剤層を形成した。塗布は、グラビアローラ#300、回転速度140%/ライン速の条件で行った。
光学フィルムおよび位相差フィルムの種類を、表8または9に示されるように変更した以外は実施例37と同様にして偏光板202~247を得た。
得られた偏光板201を、85℃95%の条件で168時間保存した後の、熱ジワの発生の有無を目視観察した。
◎:熱ジワが認められない
○:熱ジワが少し発生しているが、実用上問題ないレベル
×:熱ジワが大きく発生している
(実施例73)
市販のVA型液晶表示装置(SONY製40型ディスプレイKLV-40J3000)の、液晶セルの両面に貼り合わされていた一対の偏光板を剥離し、上記作製した偏光板201を液晶セルの両面にそれぞれ貼り合わせて液晶表示装置301を得た。偏光板201の貼り合わせは、前述の位相差フィルムaが液晶セル側となるように行った。
液晶セルの両面に貼り合わせる偏光板201を、表10または11に示されるように変更した以外は実施例73と同様にして液晶表示装置302~347を得た。
液晶表示装置の白表示時の表示画面の法線方向からの輝度と、黒表示時の表示画面の法線方向からの輝度とを、それぞれELDIM社製EZ-Contrast160Dを用いて測定した。得られた値を、下記式に当てはめて正面コントラストとして算出した。輝度の測定は、23℃55%RHの環境下で行った。
正面コントラスト=(表示装置の法線方向から測定した白表示の輝度)/(表示装置の法線方向から測定した黒表示の輝度)
そして、液晶表示装置の輝度を、以下の基準に基づいて評価した。
◎:正面コントラストが1200以上
○:正面コントラストが1000以上1200未満
×:正面コントラストが1000未満
30 液晶セル
50 第一の偏光板
51 第一の偏光子
53 保護フィルム(F1)
55 保護フィルム(F2)
70 第二の偏光板
71 第二の偏光子
73 保護フィルム(F3)
75 保護フィルム(F4)
90 バックライト
Claims (19)
- アシル基の総置換度が2.0~3.0であり、かつアシル基の全てがアセチル基であるセルロースエステルを含有し、
フィルム面内の遅相軸方向と前記遅相軸方向と直交する方向の25℃における破断伸度がいずれも1~10%であり、かつ
厚みが15~35μmである、光学フィルム。 - JIS K-7136に準拠して測定されるヘイズが0.5以下である、請求項1に記載の光学フィルム。
- 前記光学フィルムが、環構造を有する分子量1万以下の添加剤をさらに含有する、請求項1に記載の光学フィルム。
- 前記添加剤は、繰り返し単位に含まれる環構造が非芳香環構造または芳香環構造である、ポリエステル化合物もしくはスチレン系化合物、またはピラノース構造またはフラノース構造を有し、前記ピラノース構造またはフラノース構造が非芳香環構造または芳香環構造を含む置換基を有する糖エステル化合物である、請求項3に記載の光学フィルム。
- 前記環構造は、芳香環である、請求項3に記載の光学フィルム。
- 前記添加剤は、繰り返し単位に含まれる環構造が芳香環構造である分子量600以上のポリエステル化合物もしくは分子量600以上のスチレン系化合物である、請求項3に記載の光学フィルム。
- 前記添加剤の含有量は、前記セルロースエステルに対して5~30質量%である、請求項3に記載の光学フィルム。
- フィルム面内の遅相軸方向と前記遅相軸方向と直交する方向の少なくとも一方の23℃55%RH下における引張弾性率が、5.0~8.0GPaである、請求項1に記載の光学フィルム。
- フィルム面内の遅相軸方向と前記遅相軸方向と直交する方向の25℃における破断伸度がいずれも1~5%である、請求項1に記載の光学フィルム。
- 23℃55%RH下、測定波長590nmにおける面内方向のレターデーションR0(590)が10nm以下である、請求項1に記載の光学フィルム。
- アシル基の総置換度が2.0~3.0であり、かつアシル基の全てがアセチル基であるセルロースエステルと、環構造を有する分子量1万以下の添加剤とを含有するドープ液を得る工程と、
前記ドープ液を無端状の金属支持体上に流延する工程と、
流延された前記ドープ液を乾燥させて得られる膜状物を、前記金属支持体から剥離する工程と、
剥離された前記膜状物を、前記膜状物の面内の互いに直交する2つの方向にそれぞれ1.3~4.0倍の延伸倍率で延伸して、厚み15~35μmの光学フィルムを得る工程と、
を含む、光学フィルムの製造方法。 - 前記添加剤は、繰り返し単位に含まれる環構造が非芳香環構造または芳香環構造である、ポリエステル化合物もしくはスチレン系化合物、またはピラノース構造またはフラノース構造を有し、前記ピラノース構造またはフラノース構造が非芳香環構造または芳香環構造を含む置換基を有する糖エステル化合物である、請求項11に記載の光学フィルムの製造方法。
- 前記環構造は、芳香環である、請求項11に記載の光学フィルムの製造方法。
- 前記添加剤は、繰り返し単位に含まれる環構造が芳香環構造である分子量600以上のポリエステル化合物もしくは分子量600以上のスチレン系化合物である、請求項11に記載の光学フィルムの製造方法。
- 前記添加剤の含有量は、前記セルロースエステルに対して5~30質量%である、請求項11に記載の光学フィルムの製造方法。
- 前記光学フィルムの、23℃55%RH下、測定波長590nmにおける面内方向のレターデーションR0(590)が10nm以下である、請求項11に記載の光学フィルムの製造方法。
- 請求項1に記載の光学フィルムを含む、偏光板。
- 請求項1に記載の光学フィルムを含む、液晶表示装置。
- 液晶セルと、前記液晶セルの一方の面に配置され、第一の偏光子を有する第一の偏光板と、前記液晶セルの他方の面に配置され、第二の偏光子を有する第二の偏光板とを有する液晶表示装置であって、
前記第一の偏光板が、前記第一の偏光子の前記液晶セルとは反対側の面に配置された請求項1に記載の光学フィルムを有するか、または
前記第二の偏光板が、前記第二の偏光子の前記液晶セルとは反対側の面に配置された請求項1に記載の光学フィルムを有する、液晶表示装置。
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