WO2014088112A1 - 偏光フィルムおよび偏光板の製造方法 - Google Patents

偏光フィルムおよび偏光板の製造方法 Download PDF

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Publication number
WO2014088112A1
WO2014088112A1 PCT/JP2013/082901 JP2013082901W WO2014088112A1 WO 2014088112 A1 WO2014088112 A1 WO 2014088112A1 JP 2013082901 W JP2013082901 W JP 2013082901W WO 2014088112 A1 WO2014088112 A1 WO 2014088112A1
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Prior art keywords
film
treatment
air
roll
draining
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PCT/JP2013/082901
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English (en)
French (fr)
Japanese (ja)
Inventor
圭二 網谷
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住友化学株式会社
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Priority to KR1020157017152A priority Critical patent/KR102119291B1/ko
Priority to CN201380062538.9A priority patent/CN104823088B/zh
Publication of WO2014088112A1 publication Critical patent/WO2014088112A1/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
    • 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
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
    • B29C55/06—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/023—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets using multilayered plates or sheets
    • B29C55/026—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets using multilayered plates or sheets of preformed plates or sheets coated with a solution, a dispersion or a melt of thermoplastic material
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
    • B29K2029/04—PVOH, i.e. polyvinyl alcohol
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/0034—Polarising

Definitions

  • the present invention relates to a method for producing a polarizing film and a method for producing a polarizing plate by bonding a protective film to the polarizing film obtained thereby.
  • a polarizing film in which a dichroic dye such as iodine is adsorbed and oriented on a polyvinyl alcohol-based resin film has been used.
  • This polarizing film is usually used as a polarizing plate by attaching a protective film such as triacetyl cellulose via an adhesive on at least one side, usually both sides, and used for liquid crystal displays such as liquid crystal televisions, monitors for personal computers, and mobile phones. Used in equipment.
  • the polarizing film is produced by subjecting a polyvinyl alcohol resin film to swelling treatment, dyeing treatment, stretching treatment, crosslinking treatment (boric acid treatment) and washing treatment, and finally drying.
  • a polyvinyl alcohol resin film is usually lifted from each treatment bath and conveyed to the next process, the film surface is drained using a nip roll or the like.
  • Patent Document 1 As a method for this draining treatment, for example, in paragraph [0034] of JP 2011-180576 A (Patent Document 1), the film is pulled up from each treatment bath in order to prevent dripping that occurs during the production of the polarizing film. In this case, a method is described in which excess water is removed from the film surface by using a liquid break roll such as a pinch roll or by scraping off the liquid with an air knife.
  • Patent Document 2 discloses a guide for stretching a long sheet in order to drain the long sheet that has been cleaned and conveyed to a drying furnace.
  • a water draining apparatus comprising a roll, an air knife that blows air obliquely onto a long sheet stretched around the guide roll, and an exhaust chamber that collects the water blown off by the air blown.
  • An example of applying it to the manufacture of a polarizing film is also shown.
  • Patent Document 1 when an air knife is used for draining, moisture attached to the film surface can be removed efficiently, and foreign matters such as dust can be removed, so that a film with few defects can be manufactured. it can. However, when water droplets on the film surface are removed by blowing off with an air knife, the scattered water may contaminate the production equipment. On the other hand, as in Patent Document 2, by providing an exhaust chamber for collecting moisture, contamination due to scattering of water is prevented.
  • the polarizing film and the polarizing plate are required to be further thinned compared to the conventional film.
  • a polyvinyl alcohol resin film having a thickness of 75 ⁇ m has been used as a raw film of the polarizing film.
  • a polarizing film is also produced from a raw film having a thickness of 60 ⁇ m or less.
  • the film breaks when trying to drain water by blowing air from an air knife onto a thin polarizing film wet with water obtained by dyeing, stretching, cross-linking and washing.
  • the appearance of the polarizing film may be defective due to a partial water drainage defect on the film surface or foreign matter remaining after adhering to the film surface.
  • a polyvinyl alcohol resin film having a thickness of 1 to 60 ⁇ m is subjected to a swelling process, a dyeing process, a crosslinking process, and a washing process in this order, and a stretching process is performed until the crosslinking process is completed.
  • a method for producing a polarizing film wherein after the washing treatment, the film is wound around a first roll provided on one side of the first roll while applying a tension of 200 to 1500 N / m to the film. Blow off air by blowing air on the opposite side of the film, and then wind the air on the opposite side of the second roll while winding the air blown surface around the second roll.
  • the water draining process is performed to collect the water removed by air using the first discharge container and the second discharge container provided in the vicinity of each air spray position. It provides the law.
  • the air blown onto the film can have an air volume of 2 to 20 m 3 / min. Air is blown onto the film from the nozzle at the tip of the air knife, and this nozzle has an angle of 30 to 80 ° with respect to the film surface at the center line passing through the tip of the outlet, and from the tip of the outlet to the film surface.
  • the distance can be arranged to be 1.5 mm or less.
  • the discharge container for collecting the removed water has an opening, and can be arranged so that the distance from the opening to the film surface is 2 mm or less.
  • a drying process can be further performed.
  • it is effective to install a nip roll inside the drying furnace or after the drying furnace in addition to the nip roll installed before the draining process.
  • the film can be formed in a state where a tension of 200 to 800 N / m is applied to the film by a pair of nip rolls provided before and after the film.
  • the present invention also provides a method for producing a polarizing plate by bonding a protective film to a polarizing film produced by the above-described method including a drying treatment using an ultraviolet curable adhesive.
  • a polarizing film having a good appearance can be produced without causing film breakage or poor water drainage. Excellent, few defects and good quality.
  • FIG. 1 is a schematic cross-sectional view showing a preferred arrangement example of apparatuses in a method for producing a polarizing film.
  • FIG. 2 is a schematic cross-sectional view showing an arrangement example in the draining device 23.
  • FIG. 3 is a schematic cross-sectional view showing a preferable arrangement condition in the draining device 23.
  • the polyvinyl alcohol resin film is subjected to a swelling treatment, a dyeing treatment, a crosslinking treatment and a washing treatment in this order, and is subjected to a stretching treatment until the crosslinking treatment is completed, thereby producing a polarizing film.
  • a draining process is performed after the cleaning process.
  • the method for producing a polarizing film by performing a draining treatment according to the present invention comprises: bonding a protective film to a polarizing film obtained by performing a drying treatment after the draining treatment via an ultraviolet curable adhesive; Is preferably used in the method of producing
  • the present invention will be described in detail with reference to the drawings as appropriate.
  • the polarizing film is one in which a dichroic dye is adsorbed and oriented on a polyvinyl alcohol resin film.
  • the polyvinyl alcohol resin used as a raw material is usually obtained by saponifying a polyvinyl acetate resin.
  • the degree of saponification is usually 85 mol% or more, preferably 90 mol% or more, more preferably 99 mol% or more.
  • the polyvinyl acetate-based resin include polyvinyl acetate, which is a homopolymer of vinyl acetate, and copolymers of vinyl acetate and other monomers copolymerizable therewith.
  • Examples of other monomers copolymerizable with vinyl acetate include unsaturated carboxylic acids, olefins, unsaturated sulfonic acids, vinyl ethers and the like.
  • the degree of polymerization of the polyvinyl alcohol-based resin is usually about 1000 to 10000, preferably about 1500 to 5000.
  • the polyvinyl alcohol-based resin may be modified.
  • polyvinyl formal modified with aldehydes polyvinyl acetal, polyvinyl butyral, and the like may be used.
  • a polyvinyl alcohol resin film having a thickness of 1 to 60 ⁇ m is used as the original film of the polarizing film.
  • the thickness of the film is preferably about 20 to 60 ⁇ m, more preferably about 30 to 60 ⁇ m.
  • a film having a width of about 1500 to 6000 mm is practical.
  • the polarizing film is obtained by subjecting an original film made of the above polyvinyl alcohol resin to solution treatment in the order of swelling treatment, dyeing treatment, crosslinking treatment, and washing treatment, and during the crosslinking treatment and if necessary, before the crosslinking treatment. Is obtained by performing uniaxial stretching and finally drying. Uniaxial stretching performed during the crosslinking treatment is wet stretching, and even when uniaxial stretching is performed in the previous swelling treatment or dyeing treatment, wet stretching is also performed. However, it is also possible to carry out dry uniaxial stretching before the swelling treatment.
  • uniaxial stretching may be performed only in one step, or may be performed in two or more steps, and a known stretching method can be employed.
  • Specific examples of the stretching method include stretching between rolls for stretching with a difference in peripheral speed between two nip rolls that transport the film, hot roll stretching as described in Japanese Patent No. 2731813, tenter stretching, etc. There is.
  • the order of the steps is basically as described above, but there is no restriction on the number of treatment baths or treatment conditions.
  • processing other than the above can be added for other purposes.
  • treatments that can be added include immersion treatment (iodide treatment) in an aqueous iodide solution that does not contain boric acid, or immersion in an aqueous solution that does not contain boric acid and contains zinc chloride, etc.
  • Treatment (zinc treatment).
  • FIG. 1 is a schematic cross-sectional view showing a suitable arrangement example of a manufacturing apparatus used in the method for manufacturing a polarizing film according to the present invention.
  • a raw film 10 made of a polyvinyl alcohol resin is unwound from a feeding roll 11 and sequentially passes through a swelling tank 13, a dyeing tank 15, a crosslinking tank 17 and a washing tank 19, and then into a draining device 23. It is conveyed so that it finally passes through the drying furnace 25.
  • uniaxial stretching is performed in the crosslinking tank 17 or in front of it.
  • the manufactured polarizing film 30 is conveyed to the process of sticking the next protective film as it is.
  • processing performed in the present invention will be described.
  • the swelling treatment is performed by contacting with water for the purpose of removing foreign substances on the surface of the polyvinyl alcohol-based resin film, removing the plasticizer in the film, imparting easy dyeability in the subsequent dyeing treatment, and plasticizing the film. .
  • the conditions for the swelling treatment are determined within a range in which these objects can be achieved and in a range in which defects such as devitrification and extreme dissolution of the film do not occur.
  • the film When the original film made of polyvinyl alcohol resin is first subjected to a swelling treatment, for example, the film is immersed in a treatment bath at a temperature of about 10 to 50 ° C., preferably about 20 to 40 ° C.
  • the immersion time of the film is preferably about 30 to 300 seconds, more preferably about 60 to 240 seconds.
  • the film When the polyvinyl alcohol resin film previously stretched in the air is subjected to a swelling treatment, for example, the film is immersed in a treatment bath at a temperature of about 20 to 70 ° C., preferably about 30 to 60 ° C.
  • the immersion time of the film is preferably about 30 to 300 seconds, more preferably about 60 to 240 seconds.
  • the polyvinyl alcohol-based resin film swells in the width direction, and problems such as wrinkling of the film are likely to occur. Therefore, widening roll (expander roll), spiral roll, crown roll, cross guider, bend bar, tenter clip, etc. It is preferable to transport the film while removing the wrinkles of the film using a known widening device.
  • the water flow in the swelling tank 13 is controlled by an underwater shower, or the EPC device (Edge Position Control device: detects the edge of the film to prevent the film from meandering. It is also useful to use a combination of such devices.
  • the film swells and expands in the film transport direction, if the film is not actively stretched, for example, a transport roll before and after the swelling tank 13 in order to eliminate sagging of the film in the transport direction. It is preferable to take measures such as controlling the peripheral speed. Further, when the raw film is subjected to swelling treatment, dyeing treatment, and crosslinking treatment in this order, uniaxial stretching may be performed in the swelling treatment, and the stretching ratio in that case is usually 1.2 to 3 times, preferably 1.3 to 2.5 times.
  • the treatment bath used in the swelling tank 13 includes pure water, boric acid (JP-A-10-153709), chloride (JP-A-06-281816), inorganic acid, inorganic salt, water-soluble organic solvent.
  • An aqueous solution to which alcohols and the like are added in an amount of about 0.01 to 10% by weight can also be used.
  • the dyeing treatment is performed by immersing the film in a treatment bath containing a dichroic dye such as iodine and a water-soluble dichroic dye, for the purpose of adsorbing the dichroic dye on the polyvinyl alcohol-based resin film.
  • a dichroic dye such as iodine and a water-soluble dichroic dye
  • the conditions for the dyeing treatment are determined within a range in which these objects can be achieved and in a range in which problems such as extreme dissolution and devitrification of the polyvinyl alcohol-based resin film do not occur.
  • the treatment bath has, for example, a concentration of iodine / potassium iodide / water by weight ratio of about 0.003 to 0.2 / about 0.1 to 10 / An aqueous solution of 100 can be used.
  • potassium iodide other iodides such as zinc iodide may be used, or potassium iodide and other iodides may be used in combination.
  • compounds other than iodide for example, boric acid, zinc chloride, cobalt chloride and the like may coexist. When boric acid is added, it is distinguished from the crosslinking treatment described later in that it contains iodine.
  • the aqueous solution contains about 0.003 parts by weight or more of iodine with respect to 100 parts by weight of water, Can be considered.
  • the temperature of the dyeing bath when dipping the film is about 10 to 45 ° C., preferably 20 to 35 ° C., and the dipping time of the film is about 30 to 600 seconds, preferably 60 to 300 seconds.
  • a dyeing assistant or the like may coexist, and for example, an inorganic salt such as sodium sulfate or a surfactant may be contained.
  • a dichroic dye may be used independently and may use 2 or more types of dichroic dye together.
  • the temperature of the dyeing bath when dipping the film is about 20 to 80 ° C., preferably 30 to 70 ° C., and the dipping time of the film is about 30 to 600 seconds, preferably 60 to 300 seconds.
  • the film is usually stretched in a dyeing tank.
  • the film is stretched by a method such as giving a difference in peripheral speed between nip rolls installed before and after the dyeing tank.
  • the cumulative draw ratio until the dyeing process is usually 1.6 to 4.5 times, preferably 1.8 to 4 times. When the draw ratio is less than 1.6 times, the frequency of film breakage increases, and the yield tends to deteriorate.
  • a widening roll (expander roll), a spiral roll, a crown roll, a cross guider, a bend bar, and the like are provided in the dyeing tank 15 in order to convey the polyvinyl alcohol resin film while removing wrinkles of the film as in the swelling process.
  • the crosslinking treatment is carried out in a treatment bath containing 1 to 10 parts by weight of boric acid with respect to 100 parts by weight of water for the purpose of water resistance and color adjustment (to prevent the film from becoming bluish) by crosslinking. It is carried out by immersing a polyvinyl alcohol-based resin film dyed with a chromatic dye.
  • the treatment bath preferably contains iodide in addition to boric acid, and the amount thereof is 1 to 30 parts by weight with respect to 100 parts by weight of water. be able to.
  • iodide include potassium iodide and zinc iodide.
  • crosslinking treatment for water resistance may be referred to by names such as water resistance treatment, crosslinking treatment, and immobilization treatment.
  • crosslinking process for hue adjustment may be referred to as a complementary color process, a re-dyeing process, or the like.
  • the concentration of boric acid and iodide and the temperature of the treatment bath can be appropriately changed according to the purpose.
  • the crosslinking treatment for water resistance and the crosslinking treatment for adjusting the hue are not particularly distinguished, and are performed under the following conditions.
  • the temperature of the treatment bath is usually about 50 to 70 ° C., preferably 53 to 65 ° C.
  • the immersion time of the film is usually about 10 to 600 seconds, preferably 20 to 300 seconds, more preferably 20 to 200. Seconds.
  • the temperature of the crosslinking treatment bath is usually about 50 to 85 ° C., preferably 55 to 80 ° C.
  • a crosslinking treatment aiming at hue adjustment may be performed.
  • the temperature of the treatment bath is usually about 10 to 45 ° C.
  • the immersion time of the film is usually about 1 to 300 seconds, preferably 2 to 100 seconds.
  • cross-linking treatments may be performed a plurality of times and are usually performed 2 to 5 times.
  • the composition and temperature of each crosslinking treatment bath to be used may be the same or different as long as they are within the above range.
  • the cross-linking treatment for water resistance by cross-linking and the cross-linking treatment for hue adjustment may be performed in a plurality of steps, respectively.
  • the washing treatment is performed for the purpose of removing excess chemicals such as boric acid and iodine attached to the polyvinyl alcohol-based resin film after the crosslinking treatment.
  • the washing treatment is performed, for example, by immersing a polyvinyl alcohol-based resin film crosslinked for water resistance and / or color tone adjustment in water, spraying water as a shower on the film, or using these in combination.
  • FIG. 1 shows an example in which a polyvinyl alcohol-based resin film is immersed in water for cleaning treatment.
  • the temperature of water in the washing treatment is usually about 2 to 40 ° C., and the immersion time is about 2 to 120 seconds.
  • a widening roll can be used for the purpose of conveying the polyvinyl alcohol-based resin film while removing wrinkles.
  • the draining treatment of the polyvinyl alcohol-based resin film performed in the present invention is performed by blowing air on the film surface using an air knife for the purpose of removing deposits such as water and foreign matters on the film surface.
  • the polyvinyl alcohol-based resin film that has undergone the cleaning treatment is conveyed to a draining device 23 in a state where a predetermined tension is applied, and air is blown onto the film surface by an air knife installed in the device.
  • a draining process is performed.
  • the draining process performed in the present invention will be sequentially described with reference to FIGS. 2 and 3 as appropriate.
  • FIG. 2 is a schematic cross-sectional view showing an arrangement example of the devices in the draining device 23.
  • two sets of rolls, air knives, and discharge containers are arranged in draining device 23, and the film is drained one side at a time.
  • the polyvinyl alcohol-based resin film conveyed into the draining device 23 is wound around the first roll 40 provided on one side of the film, and the first air knife is placed on the film surface opposite to the first roll. 42, air is blown off, and then the air blown surface is wound around the second roll 46 provided downstream in the transport direction, while the second air is applied to the film surface opposite to the second roll. Draining is performed by blowing air from the knife 48.
  • the water removed by the air is collected by the first discharge container 44 and the second discharge container 50 provided in the vicinity of the air blowing position.
  • FIG. 3 is a schematic cross-sectional view showing the arrangement conditions in the draining device suitable for performing the draining process.
  • the first air knife 42 is disposed in the downstream space in the film transport direction before the film contacts the first roll 40, and blows air from the downstream side in the film transport direction toward the upstream side.
  • the first air knife 42 blows out air from the nozzle at the tip.
  • the center line (dotted line in FIG. 3) passing through the tip of the nozzle is 30 to 30 tangent to the first roll 40. It arrange
  • the first discharge container 44 described above is arranged in the film passing over the first roll 40 in the form where the opening of the discharge container faces the air knife side in the vicinity of the position where the air is blown. .
  • the distance from the opening of the discharge container to the film surface on the roll can be arranged to be 0.3 to 2 mm.
  • the distance between the discharge container and the film is 2 mm or less, the air blown from the air knife hits the film and then smoothly enters the discharge container together with the water adhering to the film, so the removed water is efficiently recovered. be able to.
  • the distance between the discharge container and the film is 0.3 mm or more, the film can be prevented from being broken by contact between the discharge container and the film.
  • the water collected in the discharge container is collected from the inner wall by suction in the discharge container and discharged to the waste liquid line through the waste liquid duct.
  • the second roll 46, the second air knife 48, and the second discharge container 50 can be disposed in the same manner as the first roll 40, the first air knife 42, and the first discharge container 44 described above. it can.
  • the draining treatment performed in the present invention is performed while applying a tension of 200 to 1500 N / m to the polyvinyl alcohol resin film after the cleaning treatment.
  • a tension of 200 to 1500 N / m to the polyvinyl alcohol resin film after the cleaning treatment.
  • the tension is within this range, fluttering of the film due to air can be suppressed when performing a draining process with an air knife, so that the film does not touch the discharge container and breaks, improving film productivity.
  • the nip roll can be provided after the draining device 23 or the drying furnace 25 in addition to the one installed after the cleaning tank 19, whereby tension can be applied to the film.
  • the tension between the nip rolls is in the range of 200 to 800 N / m.
  • the above tension can be measured by installing a commercially available load cell or a guide roll incorporating a tension roll sensor using a strain gauge.
  • the tension is measured by bringing these guide rolls into contact with the polyvinyl alcohol resin film.
  • the load cell or tension sensor roll for measuring the tension is used only for the measurement, and is usually arranged so as not to contact the film.
  • the amount of air blown from the air knife can be 2 to 20 m 3 / min. If the air volume is less than 2 m 3 / min, the wind pressure is too weak to drain the water sufficiently, and a polarizing film is produced without removing water and foreign matter adhering to the film surface. There is a possibility of defects when applied. On the other hand, if the air volume is higher than 20 m 3 / min, the wind pressure is too strong and the film may be broken.
  • the draining process described above can be appropriately adjusted within the range of the arrangement condition and the processing condition. Within the above range, even when the thickness of the original film of the polyvinyl alcohol resin is as thin as 60 ⁇ m, the draining treatment can be performed without causing partial draining failure. For this reason, it is possible to suppress the generation of crystal foreign matter on the film surface, and when manufacturing a polarizing plate to which a polarizing film is applied, particularly using an active energy ray curable adhesive such as an ultraviolet curable adhesive, When manufacturing, the defect resulting from said foreign material can be suppressed effectively.
  • a polarizing film can be produced by drying the polyvinyl alcohol-based resin film after the draining treatment.
  • the film can be dried in the drying furnace 25 at a temperature of about 30 to 100 ° C. for about 30 to 600 seconds, for example.
  • the final integrated draw ratio of the polarizing film produced in this manner is usually 4.5 to 7 times, preferably 5 to 6.5 times.
  • a protective film is bonded to at least one surface of the polarizing film produced as described above via an adhesive.
  • the material constituting the protective film examples include cycloolefin resins and cellulose acetate resins, polyester resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate, polycarbonate resins, acrylic resins, and polypropylene resins.
  • cycloolefin resins and cellulose acetate resins polyester resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate
  • polycarbonate resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate
  • polycarbonate resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate
  • polycarbonate resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate
  • polycarbonate resins such as polyethylene terephthalate, polyethylene na
  • the cycloolefin-based resin is a thermoplastic resin having a monomer unit made of a cyclic olefin (cycloolefin) such as norbornene or a polycyclic norbornene-based monomer, and is also called a thermoplastic cycloolefin-based resin.
  • the cycloolefin-based resin may be a hydrogenated product of the above-described cycloolefin ring-opening polymer or a ring-opening copolymer using two or more kinds of cycloolefins. It may be an addition polymer with an aromatic compound having a polymerizable double bond. Moreover, what introduce
  • the first protective film is formed using a copolymer of a cycloolefin and a chain olefin and / or an aromatic compound having a vinyl group
  • examples of the chain olefin include ethylene and propylene.
  • examples of the aromatic compound having a vinyl group include styrene, ⁇ -methylstyrene, and nuclear alkyl-substituted styrene.
  • the unit of the monomer composed of cycloolefin may be 50 mol% or less, but is preferably about 15 to 50 mol%.
  • the monomer unit composed of cycloolefin is compared as described above. Less amount.
  • the unit of monomer comprising a chain olefin is usually 5 to 80 mol%
  • the unit of monomer comprising an aromatic compound having a vinyl group is usually 5 to 80 mol%.
  • examples of the chain olefin include ethylene and propylene
  • examples of the aromatic compound having a vinyl group include styrene
  • the monomer unit composed of cycloolefin may be 50 mol% or less (preferably 15 to 50 mol%).
  • the amount of the monomer unit comprising the cycloolefin can be made relatively small as described above.
  • the unit of monomer comprising a chain olefin is usually 5 to 80 mol%
  • the unit of monomer comprising an aromatic compound having a vinyl group is usually 5 to 80 mol%.
  • Cycloolefin-based resins are commercially available products such as “TOPAS” (Topas Advanced Polymers GmbH), “Arton” (manufactured by JSR Corporation), “ZEONOR”, and “ZEONOR” (Zeonex) “ZEONEX” ”(manufactured by Nippon Zeon Co., Ltd.),“ Apel ”(manufactured by Mitsui Chemicals, Inc.),“ Oxis (OXIS) ”(manufactured by Okura Kogyo Co., Ltd.) and the like can be suitably used.
  • TOPAS Topicas Advanced Polymers GmbH
  • Arton manufactured by JSR Corporation
  • ZEONOR ZeroOR
  • Zeonex ZeroX
  • Apel (manufactured by Mitsui Chemicals, Inc.)
  • Oxis (OXIS) manufactured by Okura Kogyo Co., Ltd.
  • a known method such as a solvent casting method or a melt extrusion method is appropriately used.
  • the cycloolefin resin film may be uniaxially stretched or biaxially stretched.
  • Stretching is usually performed continuously while unwinding a film roll, and in a heating furnace, the roll traveling direction (film longitudinal direction), the direction perpendicular to the traveling direction (film width direction), or both Stretched.
  • the temperature of the heating furnace a range from the vicinity of the glass transition temperature of the cycloolefin resin to the glass transition temperature + 100 ° C. is usually employed.
  • the stretching ratio is usually 1.1 to 6 times, preferably 1.1 to 3.5 times.
  • the films tend to adhere to each other and easily cause blocking. Therefore, the cycloolefin-based resin film is usually rolled after the protective film is bonded.
  • surface treatment such as plasma treatment, corona treatment, saponification treatment, ultraviolet irradiation treatment and flame (flame) treatment is performed on the surface to be bonded to the polarizing film. Is preferred.
  • plasma treatment that can be carried out relatively easily, particularly atmospheric pressure plasma treatment and corona treatment are preferable.
  • the cellulose acetate-based resin is a cellulose partial or completely esterified product, and examples thereof include a film made of cellulose acetate ester, propionate ester, butyrate ester, and mixed ester thereof. More specifically, a triacetyl cellulose film, a diacetyl cellulose film, a cellulose acetate propionate film, a cellulose acetate butyrate film, and the like can be given. As such a cellulose ester-based resin film, an appropriate commercially available product can be suitably used.
  • “Fujitac TD80”, “Fujitac TD80UF”, “Fujitac TD80UZ” and “Fujitac TD60UL” [ As mentioned above, “Fuji Film Co., Ltd.”, “KC8UX2M”, “KC8UY”, “KC4UYW” and “KC6UAW” [above, manufactured by Konica Minolta Advanced Layer Co., Ltd.], and the like.
  • a cellulose acetate resin film imparted with retardation characteristics is also preferably used.
  • a cellulose acetate resin film provided with such retardation characteristics “WV BZ 438” (manufactured by Fuji Film Co., Ltd.), “KC4FR-1”, “KC4CR-1” and “ KC4AR-1 ′′ [manufactured by Konica Minolta Advanced Layer Co., Ltd.] and the like.
  • Cellulose acetate is also called acetyl cellulose or cellulose acetate.
  • the thickness of the protective film used in the method for producing a polarizing plate of the present invention is preferably thin, but if it is too thin, the strength is lowered and the processability is poor. On the other hand, when it is too thick, problems such as a decrease in transparency and a longer curing time after lamination occur. Accordingly, an appropriate thickness of the protective film is, for example, 5 to 200 ⁇ m, preferably 10 to 150 ⁇ m, and more preferably 10 to 100 ⁇ m.
  • the polarizing film and / or protective film may be subjected to corona treatment, flame treatment, plasma treatment, ultraviolet treatment, primer coating treatment, saponification treatment, etc.
  • a surface treatment may be applied.
  • the protective film may be subjected to surface treatments such as anti-glare treatment, anti-reflection treatment, hard coat treatment, antistatic treatment and antifouling treatment, either singly or in combination of two or more.
  • the protective film may contain an ultraviolet absorber such as a benzophenone compound and a benzotriazole compound, and a plasticizer such as a phenyl phosphate compound and a phthalate compound.
  • the protective film has a function as a retardation film, a function as a brightness enhancement film, a function as a reflection film, a function as a transflective film, a function as a diffusion film, and a function as an optical compensation film.
  • Functional functions can be provided. In this case, for example, such a function can be achieved by laminating an optical functional film such as a retardation film, a brightness enhancement film, a reflection film, a transflective film, a diffusion film, and an optical compensation film on the surface of the protective film.
  • the protective film itself can be given such a function.
  • a protective film may have a plurality of functions such as a diffusion film having a function of a brightness enhancement film.
  • the function as the retardation film is, for example, applied to the above-described protective film by a stretching treatment described in Japanese Patent No. 2841377, Japanese Patent No. 3094113, or described in Japanese Patent No. 3168850. It can be given by performing the processed.
  • the retardation characteristics of the retardation film can be appropriately selected, for example, such that the front retardation value is 5 to 100 nm and the thickness direction retardation value is 40 to 300 nm.
  • the function as a brightness enhancement film can be achieved by forming fine holes in the above protective film by a method as described in JP-A No. 2002-169025 or JP-A No. 2003-29030, or by selective reflection. It can be provided by superimposing two or more cholesteric liquid crystal layers having different center wavelengths.
  • the function as a reflective film or transflective film is formed by forming a metal thin film on the protective film by vapor deposition or sputtering, and the function as a diffusion film is obtained by coating the protective film with a resin solution containing fine particles, respectively. Can be granted.
  • the function as an optical compensation film can be imparted by coating and aligning a protective film with a liquid crystal compound such as a discotic liquid crystal compound.
  • the protective film may contain a compound that develops a retardation, and various optical functional films may be directly bonded to the polarizing film using an appropriate adhesive. Examples of commercially available optical functional films include brightness enhancement films such as “DBEF” (manufactured by Sumitomo 3M Co., Ltd.
  • Adhesive layer examples of the adhesive constituting the adhesive layer include a water-based adhesive and an active energy ray-curable adhesive.
  • water-based adhesive examples include a polyvinyl alcohol-based resin aqueous solution and a water-based two-component urethane emulsion adhesive.
  • Polyvinyl alcohol resins used as adhesives include vinyl alcohol homopolymers obtained by saponifying polyvinyl acetate, which is a homopolymer of vinyl acetate, as well as other single quantities copolymerizable with vinyl acetate. And vinyl alcohol copolymers obtained by saponifying the copolymer with the polymer, and modified polyvinyl alcohol polymers obtained by partially modifying the hydroxyl groups.
  • a polyhydric aldehyde, a water-soluble epoxy compound, a melamine compound, a zirconia compound, a zinc compound, or the like may be added as an additive to the water-based adhesive.
  • the adhesive layer obtained therefrom is usually much thinner than 1 ⁇ m.
  • the aqueous adhesive is applied at a temperature of 15 to 40 ° C. after its preparation, and the bonding temperature is usually in the range of 15 to 30 ° C.
  • an epoxy compound that does not contain an aromatic ring in the molecule is preferably used as the adhesive from the viewpoint of weather resistance, refractive index, cationic polymerization, and the like.
  • an epoxy compound include a glycidyl ether of a polyol having an alicyclic ring, an aliphatic epoxy compound, and an alicyclic epoxy compound.
  • the glycidyl ether of a polyol having an alicyclic ring is obtained by glycidyl etherifying a nuclear hydrogenated polyhydroxy compound obtained by selectively hydrogenating an aromatic polyol under pressure in the presence of a catalyst.
  • a catalyst for selectively hydrogenating an aromatic polyol under pressure in the presence of a catalyst.
  • the aromatic polyol include bisphenol type compounds such as bisphenol A, bisfer F, and bisphenol S; novolac type resins such as phenol novolac resin, cresol novolac resin, and hydroxybenzaldehyde phenol novolac resin; tetrahydroxydiphenylmethane, Examples thereof include tetrahydroxybenzophenone and polyfunctional compounds such as polyvinylphenol.
  • Glycidyl ether can be obtained by reacting an alicyclic polyol obtained by hydrogenating the aromatic ring of these aromatic polyols with epichlorohydrin.
  • an alicyclic polyol obtained by hydrogenating the aromatic ring of these aromatic polyols with epichlorohydrin.
  • the aliphatic epoxy compound can 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 Diglycidyl ether of glycol; polyether polyol obtained by adding one or more alkylene oxides (ethylene oxide or propylene oxide) to an aliphatic polyhydric alcohol such as ethylene glycol, propylene glycol or glycerin Examples thereof include glycidyl ether.
  • the alicyclic epoxy compound means an epoxy compound having one or more epoxy groups bonded to the alicyclic ring in the molecule.
  • the “epoxy group bonded to the alicyclic ring” means a bridged oxygen atom —O— in the structure represented by the following formula (I).
  • m is an integer of 2 to 5.
  • a compound in which a group in a form in which one or more hydrogen atoms in (CH 2 ) m in the above formula (I) are removed is bonded to another chemical structure can be an alicyclic epoxy compound.
  • One or more hydrogen atoms in (CH 2 ) m may be appropriately substituted with a linear alkyl group such as a methyl group or an ethyl group.
  • the alicyclic epoxy compound used preferably below is specifically illustrated, it is not limited to these compounds.
  • Epoxycyclohexylmethyl epoxycyclohexanecarboxylates represented by the following formula (II), wherein R 1 and R 2 are each independently a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms. Represents.
  • Epoxycyclohexanecarboxylates of alkanediol represented by the following formula (III), wherein R 3 and R 4 are independently of each other a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms. N represents an integer of 2 to 20.
  • Epoxycyclohexylmethyl esters of dicarboxylic acid represented by the following formula (IV), wherein R 5 and R 6 are each independently a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms. And p represents an integer of 2 to 20.
  • Epoxycyclohexyl methyl ethers of polyethylene glycol represented by the following formula (V), wherein R 7 and R 8 are independently of each other a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.
  • Q represents an integer of 2 to 10.
  • Epoxycyclohexylmethyl ethers of alkanediol represented by the following formula (VI), wherein R 9 and R 10 are independently of each other a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms. And r represents an integer of 2 to 20.
  • Diepoxy trispiro compound represented by the following formula (VII), wherein R 11 and R 12 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.
  • Diepoxy monospiro compound represented by the following formula (VIII), wherein R 13 and R 14 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.
  • Vinylcyclohexene diepoxides represented by the following formula (IX), wherein R 15 represents a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.
  • Epoxycyclopentyl ethers represented by the following formula (X), wherein R 16 and R 17 each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.
  • Diepoxytricyclodecane represented by the following formula (XI), wherein R 18 represents a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.
  • the epoxy compound may be used alone or in combination of two or more.
  • the epoxy equivalent of the epoxy compound used in this composition is usually in the range of 30 to 3000 g / equivalent, preferably 50 to 1500 g / equivalent.
  • the epoxy equivalent is less than 30 g / equivalent, there is a possibility that the flexibility of the protective film after curing is lowered or the adhesive strength is lowered.
  • compatibility with other components may be lowered.
  • the active energy ray-curable adhesive may contain an oxetane compound in addition to the above epoxy compound.
  • an oxetane compound By adding an oxetane compound, the viscosity of the adhesive described above can be lowered and the curing rate can be increased.
  • the oxetane compound is a compound having at least one oxetane ring (four-membered ether) in the molecule, such as 3-ethyl-3-hydroxymethyloxetane, 1,4-bis [(3-ethyl-3 -Oxetanyl) methoxymethyl] benzene, 3-ethyl-3- (phenoxymethyl) oxetane, di [(3-ethyl-3-oxetanyl) methyl] ether, 3-ethyl-3- (2-ethylhexyloxymethyl) oxetane And phenol novolac oxetane.
  • oxetane ring four-membered ether
  • the blending amount of the oxetane compound is usually 50% by weight or less, preferably 10 to 40% by weight, based on the whole active energy ray-curable compound.
  • Oxetane compounds can be easily obtained as commercial products. For example, they are trade names sold by Toagosei Co., Ltd., “Aron Oxetane OXT-101”, “Aron Oxetane OXT-121”. , “Aron Oxetane OXT-211”, “Aron Oxetane OXT-221”, “Aron Oxetane OXT-212”, and the like.
  • cationic polymerization is preferably used as a curing reaction of the epoxy compound, and a cationic polymerization initiator is preferably added to the composition.
  • 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, and electron beams, and initiates an epoxy group polymerization reaction.
  • active energy rays such as visible light, ultraviolet rays, X-rays, and electron beams
  • a cationic polymerization initiator that generates a cationic species or a Lewis acid by irradiation of active energy rays and initiates a polymerization reaction of an epoxy group is referred to as a “photo cationic polymerization initiator”.
  • the method of curing the adhesive by irradiation with active energy rays using a cationic photopolymerization initiator enables curing at room temperature, reducing the need for considering the heat resistance of the polarizing film or distortion due to expansion, and the polarizing film. It is advantageous in that the protective film can be adhered well.
  • the cationic photopolymerization initiator acts catalytically by light, it is excellent in storage stability and workability even when mixed with an adhesive.
  • the photocationic polymerization initiator may be of any type, but specific examples include aromatic diazonium salts; onium salts such as aromatic iodonium salts and aromatic sulfonium salts; iron-arene There are complexes.
  • aromatic diazonium salt examples include benzenediazonium hexafluoroantimonate, benzenediazonium hexafluorophosphate, benzenediazonium hexafluoroborate, and the like.
  • aromatic iodonium salt examples include diphenyliodonium tetrakis (pentafluorophenyl) borate, diphenyliodonium hexafluorophosphate, diphenyliodonium hexafluoroantimonate, di (4-nonylphenyl) iodonium hexafluorophosphate, and the like.
  • aromatic diazonium salt examples include benzenediazonium hexafluoroantimonate, benzenediazonium hexafluorophosphate, benzenediazonium hexafluoroborate, and the like.
  • aromatic iodonium salt examples include diphenyliodonium tetrakis (pentafluorophenyl) borate, diphenyliodonium hexafluorophosphate, diphenyliodonium hexafluoroantimonate, di (4-nonylphenyl) iodonium hexafluorophosphate, and the like.
  • aromatic sulfonium salt examples include triphenylsulfonium hexafluorophosphate, triphenylsulfonium hexafluoroantimonate, triphenylsulfonium tetrakis (pentafluorophenyl) borate, 4,4′-bis (diphenylsulfonio) diphenylsulfide bishexa.
  • Fluorophosphate 4,4'-bis [di ( ⁇ -hydroxyethoxy) phenylsulfonio] diphenyl sulfide, bishexafluoroantimonate, 4,4'-bis [di ( ⁇ -hydroxyethoxy) phenylsulfonio] diphenyl sulfide, bis Hexafluorophosphate, 7- [di (p-toluyl) sulfonio] -2-isopropylthioxanthone, hexafluoroantimonate, 7- [di (p- Toluyl) sulfonio] -2-isopropylthioxanthone tetrakis (pentafluorophenyl) borate, 4-phenylcarbonyl-4'-diphenylsulfonio-diphenyl sulfide, hexafluorophosphate, 4- (p-tert-buty
  • iron-arene complex examples include xylene-cyclopentadienyl iron (II) hexafluoroantimonate, cumene-cyclopentadienyl iron (II) hexafluorophosphate, xylene-cyclopentadienyl iron (II). And tris (trifluoromethylsulfonyl) methanide.
  • photocationic polymerization initiators can be easily obtained.
  • “Kayarad PCI-220” and “Kayarad PCI-620” [Nippon Kayaku Co., Ltd. "UVI-6990” (manufactured by Dow Chemical Co., Ltd.), “Adekaoptomer SP-150” and “Adekaoptomer SP-170” (manufactured by ADEKA Corporation), “CI-5102”, “ “CIT-1370", “CIT-1682”, “CIP-1866S”, “CIP-2048S” and “CIP-2064S” (manufactured by Nippon Soda Co., Ltd.), “DPI-101", “DPI-102” , “DPI-103”, “DPI-105”, “MPI-103”, “MPI-105”, “BBI-101”, “BBI-102”, “B I-103, BBI-105, TPS-101, TPS-102, TPS-103, TPS-105, MDS-
  • photocationic polymerization initiators may be used alone or in combination of two or more.
  • the aromatic sulfonium salt has an ultraviolet absorption property even in a wavelength region of 300 nm or more, so it has excellent curability, gives good mechanical strength, and is good between the polarizing film and the protective film. Since it can give the hardened
  • the compounding amount of the photo cationic polymerization initiator is usually 0.5 to 20 parts by weight, preferably 1 to 6 parts by weight with respect to 100 parts by weight of the total of the cationic polymerizable compounds including the epoxy compound and the oxetane compound. is there. If the amount of the cationic photopolymerization initiator is small, the curing becomes insufficient, and the mechanical strength and the adhesion between the polarizing film and the protective film tend to be lowered.
  • the amount of the cationic photopolymerization initiator is too large, the amount of ionic substances in the cured product will increase, resulting in an increase in the hygroscopicity of the cured product, which may reduce the durability of the resulting adhesive layer. is there.
  • Active energy ray-curable adhesives include ion trapping agents, antioxidants, chain transfer agents, tackifiers, thermoplastic resins, fillers, flow regulators, leveling agents, plasticizers, antifoaming agents, etc. Additives can be blended. Examples of ion trapping agents include antimony-based, powdered bismuth-based, magnesium-based, aluminum-based, calcium-based, and titanium-based inorganic compounds, and antioxidants include hindered phenol-based antioxidants. Agents and the like.
  • Active energy ray-curable adhesives can be used as solventless adhesives that are substantially free of solvent components, but each coating method has an optimum viscosity range, A solvent may be included.
  • the solvent it is preferable to use a solvent that dissolves the epoxy compound constituting the adhesive well without degrading the optical performance of the polarizing film.
  • hydrocarbons typified by toluene, typified by ethyl acetate, etc.
  • organic solvents such as esters.
  • the viscosity of the active energy ray-curable adhesive used in the present invention is, for example, in the range of about 5 to 1000 mPa ⁇ s, preferably 10 to 200 mPa ⁇ s, and more preferably 20 to 100 mPa ⁇ s. .
  • a protective film or a polarizing film can be applied by various coating methods such as a doctor blade, a wire bar, a die coater, a comma coater, and a gravure coater. What is necessary is just to apply to a bonding surface.
  • the above-mentioned protective film is bonded onto the adhesive layer formed on the polarizing film.
  • two protective films may be bonded one step at a time, and both surfaces may be bonded in one step.
  • the laminated body of the polarizing film and the protective film is irradiated with active energy rays to cure the adhesive.
  • the light source used for the irradiation of the active energy ray is not particularly limited, but has a light emission distribution at a wavelength of 400 nm or less, for example, a low pressure mercury lamp, a medium pressure mercury lamp, a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a chemical lamp, a black light lamp, microwave excitation A mercury lamp, a metal halide lamp, etc. can be used.
  • the light irradiation intensity is determined for each target composition and is not particularly limited. However, the irradiation intensity in the wavelength region effective for activation of the initiator is preferably 10 to 5000 mW / cm 2. .
  • the reaction time becomes too long, and when it exceeds 5000 mW / cm 2 , yellowing of the adhesive layer occurs due to heat radiated from the lamp and heat generated during polymerization of the composition. And the polarizer may be deteriorated.
  • the irradiation time of the active energy ray is controlled for each composition to be cured and is not particularly limited, but the integrated light amount expressed as the product of the irradiation intensity and the irradiation time is 10 to 5000 mJ / cm 2. It is preferable to set to. When the above integrated light quantity is less than 10 mJ / cm 2 , active species derived from the initiator are not sufficiently generated, and the resulting protective film may be insufficiently cured, while the integrated light quantity is 5000 mJ. If it exceeds / cm 2 , the irradiation time becomes very long, which is disadvantageous for improving productivity.
  • the thickness of the adhesive layer after curing is usually 0.1 to 10 ⁇ m, more preferably 0.2 to 4 ⁇ m.
  • the polarizing plate produced as described above includes a polarizing film and a protective film bonded to at least one surface of the polarizing film, and can be used as a polarizing plate that is a constituent member of a liquid crystal display device.
  • a film piece having a width of 1 m and a length (film transport direction) of 20 m was cut out from the produced polarizing film, and this piece was visually observed through a light source such as a backlight to detect 100 ⁇ m or more. The number of foreign matters was counted, and the number of foreign matters per 1 m 2 of the polarizing film was calculated.
  • Example 1 A 60 ⁇ m-thick polyvinyl alcohol film (trade name “Kuraray Vinylon VF-PE # 6000” manufactured by Kuraray Co., Ltd., polymerization degree 2400, saponification degree 99.9 mol% or more) with swelling at 30 ° C. in pure water The film was immersed in the bath for 100 seconds while maintaining a tension state so that the film did not loosen, and the film was sufficiently swollen. Next, after uniaxial stretching was carried out for 90 seconds in a dyeing bath at 30 ° C.
  • a dyeing bath at 30 ° C.
  • flow volume of 10 m ⁇ 3 > / min was sprayed to the surface of the film one side at a time using the draining device as shown in FIG.
  • the conditions of each draining process are as follows: the film tension is 600 N / m (the tension between the nip rolls 21 and 27 in FIG. 1), the angle between the air nozzle and the film is 40 °, and the distance between the air nozzle and the film. was 0.6 mm, and the distance between the discharge container and the film was 1 mm. After draining, it was dried at 70 ° C. for 3 minutes to produce a polarizing film. As a result of the transmission inspection of this polarizing film, the number of defects of 100 ⁇ m or more was 0.05 pieces / m 2 .
  • Example 2 Using a 50 ⁇ m-thick polyvinyl alcohol film (trade name “Kuraray Vinylon VF-PE # 5000” manufactured by Kuraray Co., Ltd., polymerization degree 2400, saponification degree 99.9 mol% or more), the tension applied to the film during draining treatment A polarizing film was produced in the same manner as in Example 1 except that was changed to 500 N / m. As a result of performing a transmission inspection on the obtained polarizing film, the number of defects of 100 ⁇ m or more was 0.05 pieces / m 2 .
  • Example 3 Using a 30 ⁇ m thick polyvinyl alcohol film (trade name “Kuraray Vinylon VF-PE # 3000” manufactured by Kuraray Co., Ltd., polymerization degree 2400, saponification degree 99.9 mol% or more), the tension applied to the film during draining treatment A polarizing film was produced in the same manner as in Example 1 except that was changed to 450 N / m. As a result of conducting a transmission inspection on the obtained polarizing film, the number of defects of 100 ⁇ m or more was 0.10 pieces / m 2 .
  • Example 4 A polarizing film was produced in the same manner as in Example 1 except that the angle between the nozzle at the tip of the air knife and the film was changed to 20 ° in the draining process. As a result of conducting a transmission inspection on the obtained polarizing film, the number of defects of 100 ⁇ m or more was 0.8 / m 2 .
  • Example 5 A polarizing film was produced in the same manner as in Example 1 except that the angle between the nozzle at the tip of the air knife and the film was changed to 90 ° in the draining process. As a result of conducting a transmission inspection on the obtained polarizing film, the number of defects of 100 ⁇ m or more was 1.2 pieces / m 2 .
  • Example 6 A polarizing film was produced in the same manner as in Example 1 except that the distance between the nozzle at the tip of the air knife and the film was changed to 2 mm in the draining process. As a result of conducting a transmission inspection on the obtained polarizing film, the number of defects of 100 ⁇ m or more was 2.1 pieces / m 2 .
  • Example 7 A polarizing film was produced in the same manner as in Example 1 except that the distance between the discharge container and the film was changed to 3 mm in the draining treatment. As a result of performing a transmission inspection on the obtained polarizing film, the number of defects of 100 ⁇ m or more was 2.3 pieces / m 2 .
  • Example 1 A polarizing film was produced in the same manner as in Example 1 except that the polyvinyl alcohol film was drained only with a nip roll after the washing tank without draining with a draining device. As a result of performing a transmission inspection on the obtained polarizing film, the number of defects of 100 ⁇ m or more was 5.2 pieces / m 2 .
  • Table 1 below shows the manufacturing conditions and the results of the transmission inspection of Examples 1 to 7 and Comparative Examples 1 and 2 described above.
  • a polarizing film having a good appearance can be produced without causing film breakage or poor water drainage. Excellent, few defects and good quality.

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JP5970117B1 (ja) * 2015-08-11 2016-08-17 住友化学株式会社 偏光フィルムの製造方法及び製造装置
WO2017056579A1 (ja) * 2015-09-30 2017-04-06 日本合成化学工業株式会社 偏光膜の製造方法、偏光膜及び偏光板
JP6898071B2 (ja) * 2015-10-15 2021-07-07 住友化学株式会社 光学フィルムの搬送方法及び偏光板の製造方法
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