WO2014119457A1 - 積層位相差フィルム及びその製造方法 - Google Patents
積層位相差フィルム及びその製造方法 Download PDFInfo
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- WO2014119457A1 WO2014119457A1 PCT/JP2014/051343 JP2014051343W WO2014119457A1 WO 2014119457 A1 WO2014119457 A1 WO 2014119457A1 JP 2014051343 W JP2014051343 W JP 2014051343W WO 2014119457 A1 WO2014119457 A1 WO 2014119457A1
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- resin
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- stretching
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- retardation film
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3083—Birefringent or phase retarding elements
-
- 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
-
- 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
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
- B32B7/023—Optical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
- B32B7/027—Thermal properties
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
-
- 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
- B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
- B29K2995/0034—Polarising
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/42—Polarizing, birefringent, filtering
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays
- B32B2457/202—LCD, i.e. liquid crystal displays
Definitions
- the present invention relates to a laminated retardation film and a method for producing the same.
- a liquid crystal display device includes a liquid crystal cell and a pair of polarizing plates (that is, an incident side polarizing plate and an output side polarizing plate) disposed so as to sandwich the liquid crystal cell.
- the pair of polarizing plates is usually arranged so that the absorption axes of the polarizing plates are orthogonal to each other.
- Such a liquid crystal display device normally displays black when there is no electric field. In black display, light transmission is blocked.
- the liquid crystal display device may be provided with an optical compensation film.
- an optical compensation film examples include a laminated retardation film in which two or more retardation films having different retardations are bonded together (see Patent Document 1).
- a laminated retardation film manufactured by laminating a retardation film is complicated to manufacture. Specifically, a step of adjusting the in-plane slow axis relationship between the retardation films to be bonded together, a step of bonding the retardation films together, and the like are required, and the number of steps required for production tends to increase.
- Patent Documents 2 and 3 there is a method in which a laminate including a plurality of layers formed of different materials is prepared and the laminate is stretched under appropriate conditions.
- the laminate before stretching can be easily produced by, for example, a co-casting method or a co-extrusion method. Further, when the laminate is stretched, the layers included in the laminate are also stretched at the same time, so that it is not necessary to individually perform stretching treatment for each retardation film as in the technique described in Patent Document 1, and further, in-plane There is no need to adjust the relationship of the slow axis. Therefore, a laminated retardation film can be easily produced by the methods described in Patent Documents 2 and 3.
- the present invention was devised in view of the above-described problems, and can prevent deviations in the direction of the in-plane slow axis direction of each layer included in the laminated retardation film, and the front luminance during black display in a liquid crystal display device. It is another object of the present invention to provide a laminated retardation film capable of reducing light leakage and a method for producing the laminated retardation film.
- the present inventor has found that the deviation of the in-plane slow axis relationship is made of a resin layer made of a resin having a positive intrinsic birefringence and a resin having a negative intrinsic birefringence. It was found that it occurs between the resin layers. Also, by reducing the in-plane retardation of one of the resin layers made of a resin having a positive intrinsic birefringence and a resin layer made of a resin having a negative intrinsic birefringence to a practically negligible level. It was found that the in-plane slow axis relationship can be easily prevented from deviating from the intended relationship. From the above findings, the present inventor has completed the present invention. That is, the present invention is as follows.
- Resin layer A1 made of resin A1 having positive intrinsic birefringence
- resin layer B made of resin B having negative intrinsic birefringence
- resin layer A2 made of resin A2 having positive intrinsic birefringence
- the resin layer A1 and the resin layer B are in direct contact with each other
- the resin layer B and the resin layer A2 are in direct contact with each other
- Resin layer A1 and resin layer A2 are negative C plates
- Resin layer B is a positive B plate
- [4] The laminated retardation film according to any one of [1] to [3], wherein the in-plane retardation Re is 50 nm or more and 400 nm or less.
- [5] The laminated retardation film according to any one of [1] to [4], wherein retardation Rth in the thickness direction is from ⁇ 50 nm to 50 nm.
- [6] A method for producing a laminated retardation film according to any one of [1] to [5], A resin laminate comprising in this order a layer a1 made of the resin A1, a layer b made of the resin B in direct contact with the layer a1, and a layer a2 made of the resin A2 in direct contact with the layer b.
- a first stretching step of stretching at a stretching ratio of 1.1 times or more and less than 2 times in the first direction at a temperature T1 Second stretching step of obtaining a laminated retardation film by stretching the resin laminate stretched in the first stretching step in a second direction orthogonal to the first direction at a temperature T2 lower than the temperature T1.
- a method for producing a laminated retardation film [7] The method for producing a laminated retardation film according to [6], wherein the resin layer B of the laminated retardation film has an in-plane slow axis parallel to the first direction.
- the glass transition temperature Tg A1 of the resin A1 and the glass transition temperature Tg A2 of the resin A2 are higher than the glass transition temperature Tg B of the resin B, and The method for producing a laminated retardation film according to any one of [6] to [9], wherein the temperature T1 is higher than Tg B and lower than either Tg A1 or Tg A2 + 20 ° C.
- the glass transition temperature Tg A1 of the resin A1 and the glass transition temperature Tg A2 of the resin A2 are higher than the glass transition temperature Tg B of the resin B, and The method for producing a laminated retardation film according to any one of [6] to [10], wherein the temperature T2 is higher than Tg B ⁇ 20 ° C. and lower than Tg B + 5 ° C.
- the laminated retardation film of the present invention it is possible to prevent a deviation in the relationship of the in-plane slow axis direction of each layer included in the laminated retardation film, and the front luminance and light leakage at the time of black display in the liquid crystal display device. Can be made sufficiently low. According to the method for producing a laminated retardation film of the present invention, it is possible to prevent a deviation in the relationship of the in-plane slow axis directions of the respective layers included in the laminated retardation film, and the front luminance at the time of black display in the liquid crystal display device. And the laminated phase difference film which can make light leakage low enough can be manufactured.
- FIG. 1 shows that the resin A1 and the resin A2 are the same resin, the glass transition temperature Tg A1 of the resin A1 (or the resin A2) constituting the layer a1 and the layer a2 is high, and the glass transition of the resin B constituting the layer b.
- Tg B the temperature dependence of the retardation ⁇ based on the stretching direction when the layers a1, a2 and b of the resin laminate were respectively stretched, and the resin laminate were stretched
- FIG. 2 is a perspective view schematically showing an evaluation system set in a simulator for evaluation of front luminance and light leakage during black display in Examples and Comparative Examples.
- positive intrinsic birefringence means that the refractive index in the stretching direction is larger than the refractive index in the direction orthogonal thereto.
- negative intrinsic birefringence means that the refractive index in the stretching direction is smaller than the refractive index in the direction orthogonal thereto.
- the value of intrinsic birefringence can be calculated from the dielectric constant distribution.
- the in-plane retardation of the film or layer is a value represented by (nx ⁇ ny) ⁇ d unless otherwise specified.
- the retardation in the thickness direction of the film or layer is a value represented by ⁇ (nx + ny) / 2 ⁇ nz ⁇ ⁇ d unless otherwise specified.
- the Nz coefficient of the film or layer is a value represented by (nx ⁇ nz) / (nx ⁇ ny) unless otherwise specified.
- nx represents a refractive index in a direction (in-plane direction) perpendicular to the thickness direction of the film or layer and giving the maximum refractive index.
- ny represents the refractive index in the in-plane direction of the film or layer and perpendicular to the nx direction.
- nz represents the refractive index in the thickness direction of the film or layer.
- d represents the film thickness of the film or layer.
- the retardation measurement wavelength is 550 nm.
- the retardation can be measured using a commercially available phase difference measuring apparatus (for example, “KOBRA-21ADH” manufactured by Oji Scientific Instruments, “WPA-micro” manufactured by Photonic Lattice) or the Senarmon method.
- the slow axis of the film or layer represents the in-plane slow axis unless otherwise specified.
- the “polarizing plate”, “1 ⁇ 4 wavelength plate”, “B plate” and “C plate” include not only rigid members but also flexible members such as resin films. . Further, unless the direction of the component is “parallel”, “vertical” or “orthogonal”, unless otherwise specified, it is within a range not impairing the effects of the present invention, for example, usually ⁇ 5 °, preferably ⁇ 2 °, Preferably, an error within a range of ⁇ 1 ° may be included.
- the “long” means one having a length of 5 times or more with respect to the width, preferably 10 times or more, and specifically wound in a roll shape. It has a length that can be stored or transported.
- the MD direction is the film flow direction in the production line, and is usually parallel to the longitudinal direction and the longitudinal direction of the long film.
- the TD direction is a direction parallel to the film surface and perpendicular to the MD direction, and is usually parallel to the width direction and the lateral direction of the long film.
- the laminated retardation film of the present invention includes a resin layer A1, a resin layer B, and a resin layer A2 in this order.
- the resin layer A1 and the resin layer B are in direct contact with each other, and the resin layer B and the resin layer A2 are in direct contact with each other. That is, there is no other layer between the resin layer A1 and the resin layer B, and there is no other layer between the resin layer B and the resin layer A2.
- the resin layer A1 is a layer made of the resin A1.
- the resin A1 any resin having a positive intrinsic birefringence can be used. Among them, it is preferable to use a thermoplastic resin as the resin A1.
- the resin A1 Since the intrinsic birefringence of the resin A1 is positive, the resin A1 usually contains a polymer having a positive intrinsic birefringence.
- this polymer include olefin polymers such as polyethylene and polypropylene; polyester polymers such as polyethylene terephthalate and polybutylene terephthalate; polyarylene sulfide polymers such as polyphenylene sulfide; polyvinyl alcohol polymers, polycarbonate polymers, poly Examples include arylate polymers, cellulose ester polymers, polyethersulfone polymers, polysulfone polymers, polyallyl sulfone polymers, polyvinyl chloride polymers, norbornene polymers, and rod-like liquid crystal polymers.
- polymers may be used individually by 1 type, and may be used combining two or more types by arbitrary ratios.
- the polymer may be a homopolymer or a copolymer.
- a polycarbonate polymer is preferable from the viewpoints of expression of retardation, stretchability at low temperature, and adhesiveness between the resin layer A1 and a layer other than the resin layer A1.
- any polymer having a structural unit containing a carbonate bond (—O—C ( ⁇ O) —O—) can be used.
- the polycarbonate polymer include bisphenol A polycarbonate, branched bisphenol A polycarbonate, o, o, o ', o'-tetramethylbisphenol A polycarbonate, and the like.
- Resin A1 may contain a compounding agent.
- compounding agents include: lubricants; layered crystal compounds; inorganic fine particles; stabilizers such as antioxidants, heat stabilizers, light stabilizers, weathering stabilizers, ultraviolet absorbers, near infrared absorbers; plasticizers; dyes And coloring agents such as pigments; antistatic agents; and the like.
- a lubricant and an ultraviolet absorber are preferable because they can improve flexibility and weather resistance.
- a compounding agent may be used individually by 1 type, and may be used combining two or more types by arbitrary ratios.
- the lubricant examples include inorganic particles such as silicon dioxide, titanium dioxide, magnesium oxide, calcium carbonate, magnesium carbonate, barium sulfate, strontium sulfate; polymethyl acrylate, polymethyl methacrylate, polyacrylonitrile, polystyrene, cellulose acetate, cellulose acetate pro Organic particles such as pionate; Among these, organic particles are preferable as the lubricant.
- ultraviolet absorbers examples include oxybenzophenone compounds, benzotriazole compounds, salicylic acid ester compounds, benzophenone ultraviolet absorbers, benzotriazole ultraviolet absorbers, acrylonitrile ultraviolet absorbers, triazine compounds, nickel complex compounds. And inorganic powders.
- UV absorbers include 2,2′-methylenebis (4- (1,1,3,3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol), 2- (2′-hydroxy-3′-tert-butyl-5′-methylphenyl) -5-chlorobenzotriazole, 2,4-di-tert-butyl-6- (5-chlorobenzotriazol-2-yl) ) Phenol, 2,2′-dihydroxy-4,4′-dimethoxybenzophenone, 2,2 ′, 4,4′-tetrahydroxybenzophenone, and the like. Particularly preferred is 2,2'-methylenebis (4- (1,1,3,3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol).
- the amount of the compounding agent can be appropriately determined within a range that does not significantly impair the effects of the present invention.
- the amount of the aligning agent can be, for example, a range in which the total light transmittance in terms of 1 mm thickness of the laminated retardation film can be maintained at 80% or more.
- the weight average molecular weight of the resin A1 is preferable to adjust the weight average molecular weight of the resin A1 within a range in which a method such as a melt extrusion method or a solution casting method can be performed with the resin A1.
- the glass transition temperature Tg A1 of the resin A1 is preferably 80 ° C. or higher, more preferably 90 ° C. or higher, more preferably 100 ° C. or more and especially preferably 110 ° C. or higher, particularly preferably 120 ° C. or higher. Since the glass transition temperature Tg A1 is high as described above, orientation relaxation of the resin A1 can be reduced. Moreover, although there is no restriction
- the breaking elongation of the resin A1 at the glass transition temperature Tg B of the resin B is preferably 50% or more, more preferably 80% or more.
- a laminated retardation film can be stably produced by stretching.
- the breaking elongation can be obtained at a pulling rate of 100 mm / min using a test piece type 1B test piece described in JISK7127.
- it is 200% or less.
- Resin layer A1 is a negative C plate.
- the negative C plate refers to a layer in which the refractive indexes nx, ny and nz of the layer satisfy nx> nz and ny> nz, and the in-plane retardation Re satisfies 0 nm ⁇ Re ⁇ 5 nm. . Further, such a negative C plate has a positive retardation in the thickness direction.
- the specific value of the in-plane retardation Re A1 of the resin layer A1 measured at a wavelength of 550 nm is usually 0 nm or more, usually 5 nm or less, preferably 3 nm or less, more preferably 1 nm or less.
- the specific value of retardation Rth A1 in the thickness direction of the resin layer A1 measured at a wavelength of 550 nm preferably satisfies 100 nm ⁇ Rth A1 ⁇ 160 nm. More specifically, the retardation Rth A1 in the thickness direction of the resin layer A1 is preferably 100nm or more, more preferably 110nm or more, and particularly preferably 120nm or more, preferably 160nm or less, more preferably 150nm or less, particularly preferably 140 nm or less.
- Examples of the method of keeping the in-plane retardation Re A1 and the thickness direction retardation Rth A1 of the resin layer A1 within the above ranges include, for example, a draw ratio when the resin laminate is stretched to produce a laminated retardation film, and The method of adjusting extending
- the thickness of the resin layer A1 is preferably 2 ⁇ m or more, more preferably 4 ⁇ m or more, particularly preferably 5 ⁇ m or more, preferably 12 ⁇ m or less, more preferably 10 ⁇ m or less, and particularly preferably 8 ⁇ m or less.
- the thickness variation of the resin layer A1 is preferably 1 ⁇ m or less over the entire surface. Thereby, variation in color tone in the display device can be reduced. Moreover, the color tone change after a long-term use can be made uniform. In order to realize this, for example, it is preferable that the thickness variation of the layer a1 in the resin laminate is 1 ⁇ m or less over the entire surface.
- the resin layer B is a layer made of the resin B.
- the resin B any resin having a negative intrinsic birefringence can be used.
- the resin B it is preferable to use a thermoplastic resin.
- the resin B Since the intrinsic birefringence of the resin B is negative, the resin B usually contains a polymer having a negative intrinsic birefringence.
- this polymer include styrene or a homopolymer of a styrene derivative, and a polystyrene polymer including a copolymer of styrene or a styrene derivative and any other monomer; a polyacrylonitrile polymer; a polymethyl methacrylate A polymer; or a multi-component copolymer thereof.
- arbitrary monomer which can be copolymerized with styrene or a styrene derivative acrylonitrile, maleic anhydride, methyl methacrylate, and butadiene are mentioned as a preferable thing, for example.
- these polymers may be used individually by 1 type, and may be used combining two or more types by arbitrary ratios.
- a polystyrene polymer is preferable from the viewpoint of high retardation development, and a copolymer of styrene or a styrene derivative and maleic anhydride is particularly preferable from the viewpoint of high heat resistance.
- the amount of maleic anhydride units is preferably 5 parts by weight or more, more preferably 10 parts by weight or more, particularly preferably 15 parts by weight or more, and preferably 30 parts by weight with respect to 100 parts by weight of the polystyrene-based polymer. Parts or less, more preferably 28 parts by weight or less, particularly preferably 26 parts by weight or less.
- the maleic anhydride unit refers to a structural unit having a structure formed by polymerizing maleic anhydride.
- Resin B may contain a compounding agent.
- a compounding agent the thing similar to the compounding agent which resin A1 may contain is mentioned.
- a compounding agent may be used individually by 1 type, and may be used combining two or more types by arbitrary ratios.
- the amount of the compounding agent can be appropriately determined as long as the effects of the present invention are not significantly impaired.
- the amount of the compounding agent can be, for example, a range in which the total light transmittance in terms of 1 mm thickness of the laminated retardation film can be maintained at 80% or more.
- the weight average molecular weight of the resin B is preferable to adjust the weight average molecular weight of the resin B within a range in which the resin B can be subjected to a method such as a melt extrusion method or a solution casting method.
- the glass transition temperature Tg B of the resin B is preferably 80 ° C. or higher, more preferably 90 ° C. or higher, more preferably 100 ° C. or more and especially preferably 110 ° C. or higher, particularly preferably 120 ° C. or higher. With such a high glass transition temperature Tg B, the relaxation of orientation of the resin B can be reduced. Although not particularly limited to the upper limit of the glass transition temperature Tg B, usually it is 200 ° C. or less.
- the breaking elongation of the resin B at the glass transition temperature Tg A1 of the resin A1 is preferably 50% or more, more preferably 80% or more. When the elongation at break is within this range, a laminated retardation film can be stably produced by stretching.
- limiting in particular in the upper limit of the breaking elongation of resin B Usually, it is 200% or less.
- the absolute value of the difference between the glass transition temperature Tg A1 of the resin A1 and the glass transition temperature Tg B of the resin B is preferably greater than 5 ° C, more preferably 8 ° C or more, preferably 40 ° C or less, more preferably It is 20 degrees C or less.
- the absolute value of the difference between the glass transition temperatures is larger than the lower limit value of the range, the temperature dependency of the expression of retardation can be increased.
- the glass transition temperature Tg B of the resin B is preferably lower than the glass transition temperature Tg A1 of the resin A1. Therefore, the resin A1 and the resin B, it is preferable to satisfy the relationship of Tg A1> Tg B + 5 °C .
- Resin layer B is a positive B plate.
- the positive B plate refers to a layer in which the refractive indexes nx, ny, and nz of the layer satisfy nz> nx> ny. Further, such a positive B plate has a negative retardation in the thickness direction.
- the specific value of the in-plane retardation Re B of the resin layer B measured at a wavelength of 550 nm preferably satisfies 110 nm ⁇ Re B ⁇ 150 nm. More specifically, the in-plane retardation Re B of the resin layer B is preferably 110 nm or more, more preferably 115 nm or more, particularly preferably 120 nm or more, preferably 150 nm or less, more preferably 145 nm or less, particularly preferably 140 nm. It is as follows. By keeping the in-plane retardation Re B of the resin layer B within the above range, the optical compensation of the liquid crystal display device can be appropriately performed.
- the specific value of retardation Rth B in the thickness direction of the resin layer B measured at a wavelength of 550 nm preferably satisfies ⁇ 160 nm ⁇ Rth B ⁇ ⁇ 100 nm. More specifically, the thickness direction retardation Rth B of the resin layer B is preferably ⁇ 160 nm or more, more preferably ⁇ 150 nm or more, particularly preferably ⁇ 140 nm or more, preferably ⁇ 100 nm or less, more preferably ⁇ 110 nm. Hereinafter, it is particularly preferably ⁇ 120 nm or less.
- Examples of a method for keeping the in-plane retardation Re B and the thickness direction retardation Rth B of the resin layer B within the above ranges include, for example, a draw ratio when the resin laminate is stretched to produce a laminated retardation film, and The method of adjusting extending
- the thickness of the resin layer B is preferably 40 ⁇ m or more, more preferably 45 ⁇ m or more, particularly preferably 50 ⁇ m or more, preferably 70 ⁇ m or less, more preferably 65 ⁇ m or less, and particularly preferably 60 ⁇ m or less.
- the thickness variation of the resin layer B is preferably 1 ⁇ m or less over the entire surface. Thereby, variation in color tone in the display device can be reduced. Moreover, the color tone change after a long-term use can be made uniform. In order to realize this, for example, it is preferable that the variation in the thickness of the layer b in the resin laminate is 1 ⁇ m or less over the entire surface.
- the resin layer A2 is a layer made of the resin A2. Further, as the resin A2, any resin having a positive intrinsic birefringence can be used. Among these, it is preferable to use a thermoplastic resin as the resin A2. Among these, as the resin A2, it is more preferable to select a material from the same range as the resin A1 described above. Therefore, for example, the types and amounts of the polymer and compounding agent that can be contained in the resin A2, the weight average molecular weight and the glass transition temperature of the resin A2 can be the same as those of the resin A1.
- the resin A2 a resin different from the resin A1 may be selected from materials in the same range as the resin A1. Therefore, for example, the resin A2 may contain a different type of polymer from the polymer contained in the resin A1.
- the resin A2 may include the same type of polymer as the polymer included in the resin A1, and may include a different type of compounding agent from the compounding agent included in the resin A1.
- the resin A2 may include the same type of polymer and compounding agent as the polymer and compounding agent included in the resin A1, and the amount of the polymer and compounding agent may be different from that of the resin A1.
- the resin A1 and the resin A2 are the same resin, bending and warpage can be prevented in the laminated retardation film.
- Resin layer A2 is a negative C plate. Accordingly, the refractive index nx, ny and nz of the resin layer A2 satisfy nx> nz and ny> nz, and the in-plane retardation Re satisfies 0 nm ⁇ Re ⁇ 5 nm.
- the specific value of the in-plane retardation Re A2 of the resin layer A2 measured at a wavelength of 550 nm is usually 0 nm or more, usually 5 nm or less, preferably 3 nm or less, more preferably 1 nm or less.
- the specific value of retardation Rth A2 in the thickness direction of the resin layer A2 measured at a wavelength of 550 nm preferably satisfies 10 nm ⁇ Rth A2 ⁇ 40 nm. More specifically, the retardation Rth A2 thickness direction of the resin layer A2 is preferably 10nm or more, and more preferably 15nm or more, and particularly preferably 20nm or more, preferably 40nm or less, more preferably 35nm or less, particularly preferably 30 nm or less.
- Examples of a method for keeping the in-plane retardation Re A2 and the thickness direction retardation Rth A2 of the resin layer A2 within the above ranges include, for example, a draw ratio when the resin laminate is stretched to produce a laminated retardation film, and The method of adjusting extending
- the thickness of the resin layer A2 is preferably 0.4 ⁇ m or more, more preferably 0.6 ⁇ m or more, particularly preferably 0.8 ⁇ m or more, preferably 2.0 ⁇ m or less, more preferably 1.8 ⁇ m or less, particularly preferably 1.6 ⁇ m or less.
- the variation in the thickness of the resin layer A2 is preferably 1 ⁇ m or less over the entire surface. Thereby, variation in color tone in the display device can be reduced. Moreover, the color tone change after a long-term use can be made uniform. In order to realize this, for example, it is preferable that the variation in the thickness of the layer a2 in the resin laminate is 1 ⁇ m or less over the entire surface.
- the laminated retardation film of the present invention may further include an optional layer in addition to the above-described resin layer A1, resin layer B, and resin layer A2 as long as the effects of the present invention are not significantly impaired.
- the arbitrary layers are provided so as not to prevent the resin layer A1 and the resin layer B and the resin layer B and the resin layer A2 from directly contacting each other.
- the optional layer include a mat layer capable of improving the slipperiness of the film, a hard coat layer such as an impact-resistant polymethacrylate resin layer, an antireflection layer, and an antifouling layer.
- the resin layer A1 and the resin layer A2 are negative C plates. Therefore, the resin layer A1 and the resin layer A2 have an in-plane slow axis, or even if they have an in-plane retardation, the in-plane retardation in the resin layer A1 and the resin layer A2 is small enough to be ignored. Therefore, even when the in-plane slow axis direction of the resin layer A1 and the resin layer A2 is not set according to the in-plane slow axis direction of the resin layer B, when the liquid crystal display device displays black, The front brightness can be sufficiently reduced. Moreover, normally, since the optical compensation performance of the laminated retardation film can be enhanced, light leakage of the liquid crystal display device can be reduced.
- a resin having a positive intrinsic birefringence and a resin having a negative intrinsic birefringence have different in-plane slow axis directions when stretched. Therefore, a conventional laminated retardation film comprising a combination of a resin layer having a positive intrinsic birefringence and a resin layer having a negative intrinsic birefringence is provided in the direction of the in-plane slow axis direction of each layer when stretched. It was difficult to properly control the relationship. Among them, in the conventional laminated retardation film, it is difficult to express the in-plane slow axis of each layer in a desired direction at the end in the width direction of the film, and as a result, the relationship of the in-plane slow axis direction of each layer.
- the resin layer A1 and the resin layer A2 have substantially no in-plane slow axis. Therefore, in the laminated phase difference film comprising a combination of a resin layer having a positive intrinsic birefringence and a resin layer having a negative intrinsic birefringence, the direction of the in-plane slow axis of the resin layer B is defined as the resin layer A1 and It is not necessary to set according to the direction of the in-plane slow axis of the resin layer A2. Therefore, in the laminated phase difference film of the present invention, it is possible to prevent a deviation in the relationship of the in-plane slow axis directions of the layers included in the laminated phase difference film.
- the Nz coefficient of the laminated retardation film is usually 0 or more, preferably 0.3 or more, more preferably 0.5 or more, and usually 1 or less, preferably 0.9 or less, more preferably 0.8 or less.
- the optical compensation of the liquid crystal display device can be appropriately performed.
- the in-plane retardation Re of the laminated retardation film is preferably 50 nm or more, more preferably 100 nm or more, and preferably 400 nm or less, more preferably 350 nm or less.
- the optical compensation of the liquid crystal display device can be appropriately performed.
- the retardation Rth in the thickness direction of the laminated retardation film is preferably ⁇ 50 nm or more, more preferably ⁇ 40 nm or more, particularly preferably ⁇ 30 nm or more, and preferably 50 nm or less, more preferably 40 nm or less, particularly preferably. Is 30 nm or less.
- the optical compensation of the liquid crystal display device can be appropriately performed.
- the refractive indexes nx, ny, and nz satisfy
- the refractive indexes nx, ny and nz of the laminated phase difference film are the in-plane retardation Re and the thickness direction retardation Rth of the laminated phase difference film, the thickness of the laminated phase difference film, and the average of the laminated phase difference film.
- the total light transmittance of the laminated retardation film is preferably 85% or more and 100% or less.
- the light transmittance can be measured using a spectrophotometer (manufactured by JASCO Corporation, ultraviolet-visible near-infrared spectrophotometer “V-570”) in accordance with JIS K0115.
- the haze of the laminated retardation film is preferably 5% or less, more preferably 3% or less, particularly preferably 1% or less, and ideally 0%.
- the haze can be measured at five locations using “turbidity meter NDH-300A” manufactured by Nippon Denshoku Industries Co., Ltd. in accordance with JIS K7361-1997, and the average value obtained therefrom can be adopted.
- ⁇ YI is preferably 5 or less, and more preferably 3 or less. When this ⁇ YI is in the above range, there is no coloring and the visibility is good.
- the lower limit is ideally zero.
- ⁇ YI can be measured using “Spectral Color Difference Meter SE2000” manufactured by Nippon Denshoku Industries Co., Ltd. according to ASTM E313. The same measurement is performed five times, and the arithmetic average value is obtained.
- the laminated retardation film preferably has a JIS pencil hardness of H or higher.
- This JIS pencil hardness can be adjusted by the type of resin and the thickness of the resin layer.
- the JIS pencil hardness is determined by tilting a pencil of various hardnesses by 45 °, applying a load of 500 g weight from above, scratching the film surface, and starting scratching. That's it.
- the outer surface of the laminated retardation film is substantially flat and does not have irregularly formed linear recesses or linear projections extending in the MD direction.
- a linear concave portion or linear convex portion is a so-called die line.
- “the surface is substantially free of irregularly formed linear concave portions or linear convex portions and is flat” means that even if linear concave portions or linear convex portions are formed, the following condition (X) Preferably satisfying the following condition (Y).
- Condition (X) The depth of the linear concave portion is less than 50 nm or the width is larger than 500 ⁇ m, or the height of the linear convex portion is less than 50 nm or the width is larger than 500 ⁇ m.
- the depth of the linear concave portion is less than 30 nm or the width is larger than 700 ⁇ m, or the height of the linear convex portion is less than 30 nm or the width is larger than 700 ⁇ m.
- the depth of the above-described linear concave portion, the height of the linear convex portion, and the width thereof can be obtained by the following method.
- Light is applied to the laminated phase difference film, and the transmitted light is projected onto the screen, and the lighted or dark stripes of light appearing on the screen (this part is the depth of the linear recess and the height of the linear protrusion) Is a large part.)
- the surface of the cut film piece is observed using a three-dimensional surface structure analysis microscope (field region 5 mm ⁇ 7 mm), converted into a three-dimensional image, and a cross-sectional profile is obtained from the three-dimensional image.
- the cross-sectional profile is obtained at 1 mm intervals in the visual field region. An average line is drawn on this cross-sectional profile.
- the length from the average line to the bottom of the linear concave portion is the linear concave portion depth
- the length from the average line to the top of the linear convex portion is the linear convex portion height
- the distance between the intersection of the average line and the profile is the width.
- the maximum values are obtained from the measured values of the linear concave portion depth and the linear convex portion height, respectively, and the width of the linear concave portion or the linear convex portion showing the maximum value is obtained.
- the maximum value of the linear recess depth obtained from the above is taken as the depth of the linear recess of the film, and the width of the linear recess showing the maximum value is taken as the width of the linear recess of the film.
- the maximum value of the linear convex part height be the height of the linear convex part of the film
- variety of the linear convex part which showed the maximum value be the width
- the laminated retardation film may shrink in the longitudinal direction and the transverse direction by heat treatment at 60 ° C., 90% RH, 100 hours.
- the shrinkage rate is preferably 0.5% or less, more preferably 0.3% or less, and ideally 0%.
- the total thickness of the resin layer A1, the resin layer B, and the resin layer A2 is preferably 10 ⁇ m or more, more preferably 30 ⁇ m or more, preferably 200 ⁇ m or less, more preferably 150 ⁇ m or less. .
- the dimension in the width direction of the laminated retardation film is preferably 500 mm or more, more preferably 1000 mm or more, and preferably 2000 mm or less.
- the laminated retardation film of this invention can make thickness thin, and is advantageous at the point of expression of an optical function.
- a laminated retardation film includes, for example, a layer a1 made of a resin A1, a layer b made of a resin B in direct contact with the layer a1, and a layer made of a resin A2 in direct contact with the layer b, as will be described later. It can be easily produced by stretching a resin composition having a2 and co-stretching the layer a1, the layer b, and the layer a2.
- the resin laminate is stretched by a first stretching step in which the resin laminate is stretched in the first direction at a temperature T1; and the resin laminate stretched in the first stretching step at a temperature T2 lower than the temperature T1.
- this manufacturing method will be described.
- the resin laminate includes the layer a1 made of the resin A1, the layer b made of the resin B, and the layer a2 made of the resin A2 in this order.
- the layer a1 and the layer b are in direct contact with each other, and the layer b and the layer a2 are in direct contact with each other. That is, there is no other layer between the layer a1 and the layer b, and there is no other layer between the layer b and the layer a2.
- This resin laminate is stretched in different directions orthogonal to each other at different temperatures T1 and T2, so that the layers a1, b, and a2 correspond to the temperatures T1 and T2, the stretching ratio, and the stretching direction, respectively. Therefore, it has the property of causing retardation. Utilizing this property, the laminated retardation film of the present invention can be produced. Specifically, in the retardation film obtained by stretching this resin laminate, the retardation generated in the layer a1, the retardation generated in the layer b, and the retardation generated in the layer a2 are synthesized. As a result, desired in-plane retardation and retardation in the thickness direction can be obtained for the entire laminated retardation film.
- the size of retardation generated in the layers a1, b, and a2 by stretching depends on conditions such as the structure of the resin laminate (for example, the number and thickness of each layer), stretching temperature, and stretching ratio. Therefore, the configuration of the resin laminate is preferably determined according to an optical function such as an optical compensation function to be developed.
- the resin laminate has a direction of stretching in a certain direction (a direction of stretching in a certain direction, that is, a uniaxial stretching direction) as the X axis, and a direction perpendicular to the uniaxial stretching direction in the film plane as Y.
- a direction of stretching in a certain direction that is, a uniaxial stretching direction
- Y a direction perpendicular to the uniaxial stretching direction in the film plane
- the phase for linearly polarized light in the YZ plane is When one of the temperatures T1 and T2 is uniaxially stretched in the X-axis direction, it is delayed, When the other of the temperatures T1 and T2 is uniaxially stretched in the X-axis direction, It is preferable to satisfy the requirements.
- the linearly polarized light that is incident perpendicularly to the film surface and has the vibration plane of the electric vector in the XZ plane is hereinafter referred to as “XZ polarized light” as appropriate.
- YZ polarized light linearly polarized light that is incident perpendicularly to the film surface and has a vibration plane of an electric vector on the YZ plane.
- the above requirement is hereinafter referred to as “requirement P” as appropriate.
- the phase of the resin laminate with respect to the YZ polarization of the XZ polarization is delayed when uniaxially stretched in the X-axis direction at the temperature T1 and advances when uniaxially stretched in the X-axis direction at the temperature T2.
- the above-mentioned requirement P is satisfied when at least one of the various directions in the plane of the resin laminate is the X axis.
- the resin laminate is an isotropic (that is, has no anisotropy) raw film, if any one direction in the plane is taken as the X axis, if any of the other directions is satisfied,
- the requirement P can also be satisfied when the X axis is used.
- the phase of XZ polarized light is delayed from that of YZ polarized light.
- the phase of XZ polarized light advances with respect to YZ polarized light.
- the resin laminate satisfying the above requirement P is a laminate utilizing these properties, and is usually a film whose in-plane slow axis or fast axis appears depending on the stretching temperature. The temperature dependence of the expression of such retardation can be adjusted, for example, by adjusting the relationship between the photoelastic coefficients of the resin A1, the resin B, and the resin A2, the thickness ratio of each layer, and the like.
- the conditions to be satisfied by the resin laminate will be described by taking “in-plane retardation with reference to the stretching direction” as an example.
- the in-plane retardation based on the stretching direction that can be expressed in the entire resin laminate when the resin laminate including the layer a1, the layer b, and the layer a2 is stretched is defined by the stretching direction expressed in the layer a1.
- the in-plane retardation based on the reference It is synthesized from the in-plane retardation based on the reference, the in-plane retardation based on the stretching direction expressed in the layer b, and the in-plane retardation based on the stretching direction expressed in the layer a2. Therefore, the sign of the in-plane retardation based on the stretching direction developed when the resin laminate including the layer a1, the layer b, and the layer a2 is stretched is reversed between stretching at the high temperature T1 and stretching at the low temperature T2. Therefore, it is preferable to adjust the thicknesses of the layer a1, the layer b, and the layer a2 so as to satisfy the following conditions (i) and (ii).
- the requirement P (the requirement P, that is, the phase of the XZ polarization with respect to the YZ polarization is the temperature T1 and T2).
- FIG. 1 shows that the resin A1 and the resin A2 are the same resin, the glass transition temperature Tg A1 of the resin A1 (or the resin A2) constituting the layer a1 and the layer a2 is high, and the glass transition of the resin B constituting the layer b.
- Tg B the temperature dependence of the retardation based on the stretching direction when the layer a1, the layer a2, and the layer b of the resin laminate are respectively stretched at a certain stretching ratio and stretching speed
- An example of the temperature dependence of the retardation ⁇ based on the stretching direction when the resin laminate is stretched is shown.
- the stretching at the temperature Tb is based on the negative stretching direction expressed in the layer b as compared with the retardation based on the positive stretching direction expressed in the layers a1 and a2. Therefore, the retardation ⁇ is expressed as a whole based on the negative stretching direction.
- the retardation based on the negative stretching direction expressed in the layer b is smaller than the retardation based on the positive stretching direction expressed in the layer a1 and the layer a2.
- a retardation ⁇ based on the positive stretching direction is developed. Therefore, by combining the stretching at such different temperatures Ta and Tb, the retardation produced by stretching at each temperature is synthesized to have a desired retardation and hence a desired optical function.
- a phase difference film can be realized stably.
- the first stretching step is performed at the temperature Ta, and the retardation based on the positive stretching direction is expressed in the layers a1 and a2, and the retardation based on the negative stretching direction is expressed in the layer b.
- the second stretching step is performed at a temperature Tb at a stretching ratio lower than that of the first stretching step in a direction orthogonal to the stretching direction in the first stretching step.
- the in-plane retardation developed in the first stretching step in the layer a1 and the layer a2 is offset, and the retardation is developed in the direction perpendicular to the retardation developed in the first stretching step in the layer b.
- Specific thicknesses of the layer a1, the layer b, and the layer a2 can be set according to the retardation of the laminated retardation film to be manufactured so as to satisfy the requirement P described above.
- the ratio of the sum of the thicknesses of the layers a1 and a2 and the sum of the thicknesses of the layers b is preferably within a desired range.
- the ratio is expressed as “(total thickness of layer a1 + total thickness of layer a2) / (total thickness of layer b)”.
- the specific range of the ratio is preferably 1/15 or more, more preferably 1/10 or more, and preferably 1/4 or less. Thereby, the temperature dependence of the retardation expression by extending
- the total thickness of the layers a1, b, and a2 is preferably 10 ⁇ m or more, more preferably 20 ⁇ m or more, particularly preferably 30 ⁇ m or more, preferably 500 ⁇ m or less, more preferably 200 ⁇ m or less, and particularly preferably 150 ⁇ m or less. .
- the total thickness of the layer a1, the layer b, and the layer a2 is preferably 10 ⁇ m or more, more preferably 20 ⁇ m or more, particularly preferably 30 ⁇ m or more, preferably 500 ⁇ m or less, more preferably 200 ⁇ m or less, and particularly preferably 150 ⁇ m or less.
- the variation in the thickness of each of the layers a1, b, and a2 is preferably 1 ⁇ m or less over the entire surface.
- (1) to (6) may be used.
- a polymer filter having an opening of 20 ⁇ m or less is provided in the extruder.
- the gear pump is rotated at 5 rpm or more.
- An enclosure means is arranged around the die.
- the air gap is 200 mm or less.
- Edge pinning is performed when the film is cast on a cooling roll.
- a twin-screw extruder or a single-flight extruder with a double flight type screw is used as the extruder.
- the thickness of each layer is determined by measuring the total thickness of the film using a commercially available contact thickness meter, then cutting the thickness measurement portion and observing the cross section with an optical microscope, and determining the thickness ratio of each layer. It can be calculated. Further, this operation is performed at regular intervals in the MD direction and the TD direction of the film, and the arithmetic average value and variation of the thickness can be obtained.
- the total light transmittance, haze, ⁇ YI, JIS pencil hardness, and the point that the outer surface is substantially flat with no linear concave portions or linear convex portions are preferred. It is the same as the phase difference film.
- the resin laminate may have an arbitrary layer other than the layer a1, the layer b, and the layer a2 as long as the effect of the present invention is not significantly impaired.
- an arbitrary layer the layer similar to the arbitrary layers which the lamination
- the arbitrary layers are provided.
- the forming material may be coextruded with the resin A1, the resin B, and the resin A2.
- the dimension in the width direction of the resin laminate is preferably 500 mm or more, and preferably 2000 mm or less.
- the dimension of the longitudinal direction of a resin laminated body is arbitrary, and it is preferable to make a resin laminated body into a elongate film.
- the co-extrusion method is a method of extruding and molding a plurality of resins in a molten state.
- the coextrusion method is excellent in terms of production efficiency and in that a volatile component such as a solvent does not remain in the resin laminate.
- the coextrusion method examples include a coextrusion T-die method, a coextrusion inflation method, and a coextrusion lamination method.
- the coextrusion T-die method is preferable.
- the coextrusion T-die method includes a feed block method and a multi-manifold method.
- the multi-manifold method is particularly preferable in that variation in the thickness of the layer a1 and the layer a2 can be reduced.
- the melting temperature of the resin in the extruder having the T-die is preferably (Tg + 80 ° C.) or higher, and (Tg + 100 ° C.) or higher, where the glass transition temperature of each resin is Tg. More preferably, it is preferably (Tg + 180 ° C.) or less, and more preferably (Tg + 150 ° C.) or less.
- the film-like molten resin extruded from the opening of the die is preferably brought into close contact with the cooling drum.
- the method for bringing the molten resin into close contact with the cooling drum is not particularly limited, and examples thereof include an air knife method, a vacuum box method, and an electrostatic contact method.
- the number of cooling drums is not particularly limited, but is usually two or more. Examples of the arrangement method of the cooling drum include, but are not limited to, a linear type, a Z type, and an L type. Further, the way of passing the molten resin extruded from the opening of the die through the cooling drum is not particularly limited.
- the degree of adhesion of the extruded film-like resin to the cooling drum usually changes depending on the temperature of the cooling drum. Therefore, the temperature of the cooling drum is preferably (Tg + 30 ° C.) or less, more preferably (Tg ⁇ 5 ° C.) to (Tg), where Tg is the glass transition temperature of the resin in the layer that contacts the drum out of the resin extruded from the die. ⁇ 45 ° C.).
- Tg is the glass transition temperature of the resin in the layer that contacts the drum out of the resin extruded from the die. ⁇ 45 ° C.
- Means for that purpose include (1) reducing the residual solvent of the resin used as a raw material; and (2) pre-drying the resin before molding the resin laminate.
- the preliminary drying is performed by a hot air dryer or the like in the form of pellets or the like.
- the drying temperature is preferably 100 ° C. or more, and the drying time is preferably 2 hours or more.
- the resin laminate is stretched in one direction at a temperature T1. That is, the resin laminate is uniaxially stretched at the temperature T1. At this time, the direction in which the resin laminate is stretched in the first stretching step is the first direction.
- the layers a1, b, and a2 included in the resin laminate are co-stretched.
- retardation occurs in each of the layer a1, the layer b, and the layer a2 depending on the configuration of the resin laminate and the stretching conditions such as the stretching temperature T1 and the stretching ratio, and the layers a1, b, and Retardation also occurs in the entire resin laminate including the layer a2.
- the phase of the XZ polarized light with respect to the YZ polarized light is delayed or advanced.
- the temperature T1 can be set to an appropriate temperature so that a desired retardation is obtained.
- the temperature T1 is preferably set as follows. That is, the temperature T1 is preferably higher than Tg B based on the glass transition temperature Tg A1 of the resin A1 , the glass transition temperature Tg B of the resin B , and the glass transition temperature Tg A2 of the resin A2, and (Tg B + 5 ° C.).
- the temperature is lower than (high temperature + 10 ° C.).
- the in-plane retardation Re B and the thickness direction retardation Rth B of the resin layer B can be stably stored in a desired range.
- the in-plane retardation Re A1 and the thickness direction retardation Rth A1 of the resin layer A1 , and the in-plane retardation Re A2 and the thickness direction of the resin layer A2 are measured.
- Retardation Rth A2 can be stably stored in a desired range.
- the draw ratio in the first drawing step is preferably 1.1 times or more, preferably less than 2.0 times, more preferably less than 1.8 times, and particularly preferably less than 1.6 times.
- the draw ratio in the first drawing step is preferably 1.1 times or more, preferably less than 2.0 times, more preferably less than 1.8 times, and particularly preferably less than 1.6 times.
- the stretching speed in the first stretching step is preferably 1.1 times / minute or more, preferably 2.0 times / minute or less, more preferably 1.8 times / minute or less, and particularly preferably 1.6 times / minute. Is less than a minute.
- Productivity can be improved by making extending
- variation in retardation can be reduced by making it below an upper limit.
- the uniaxial stretching can be performed by a conventionally known method.
- a method of uniaxially stretching in the longitudinal direction usually coincides with the MD direction
- lateral direction using a tenter (transverse direction is usually TD direction)
- a tenter transverse direction is usually TD direction
- the method of uniaxially stretching in the machine direction include an IR heating method and a float method between rolls. Among them, a float method is preferable because a laminated retardation film having high optical uniformity can be obtained. It is.
- a tenter method can be mentioned as a method of uniaxially stretching in the transverse direction.
- a temperature difference may be made in the width direction of the resin laminate in the stretching zone.
- a known technique such as adjusting the opening degree of the hot air nozzle in the width direction or controlling the heating by arranging the IR heaters in the width direction can be used. Good.
- the resin layer B usually has an in-plane slow axis parallel to the first direction in which the resin laminate is stretched in the first stretching step. Therefore, the in-plane slow axis of the entire laminated retardation film is usually parallel to the first direction. Therefore, the first direction is preferably set in parallel with the direction in which the in-plane slow axis is desired to be produced in the laminated retardation film to be produced.
- Second stretching step After the first stretching step, a second stretching step is performed. In the second stretching step, the resin laminate stretched in the first direction in the first stretching step is stretched in a second direction perpendicular to the first direction in the plane.
- the resin laminate is stretched at a temperature T2 lower than the temperature T1. That is, the resin laminate is uniaxially stretched at a relatively low temperature T2.
- retardation occurs in each of the layers a1, b, and a2 depending on the configuration of the resin laminate and stretching conditions such as the stretching temperature T2 and the stretching ratio, and the layers a1, b, and Retardation also occurs in the entire resin laminate including the layer a2.
- the resin laminate satisfies the requirement P
- the phase of the XZ polarized light with respect to the YZ polarized light is delayed by the stretching in the first stretching step
- the XZ polarized YZ polarized light is stretched by the stretching in the second stretching step.
- the phase of the XZ polarized light with respect to the YZ polarized light is advanced by stretching in the first stretching step
- the phase of the XZ polarized light with respect to the YZ polarized light is delayed by stretching in the second stretching step.
- the temperature T2 can be set to an appropriate temperature so that a desired retardation is obtained.
- the temperature T2 is preferably set as follows. That is, the temperature T2, based on the glass transition temperature Tg B of the resin B, it is preferably higher than (Tg B -20 °C), more preferably higher than (Tg B -10 °C), also, (Tg B + 5 ° C.), and more preferably lower than Tg B.
- the difference between the temperature T1 and the temperature T2 is preferably 5 ° C or higher, more preferably 10 ° C or higher.
- the polarizing plate compensation function can be stably exhibited in the laminated retardation film.
- it is 100 degrees C or less from a viewpoint of industrial productivity.
- the stretching ratio in the second stretching step is preferably smaller than the stretching ratio in the first stretching step.
- the specific draw ratio in the second drawing step is preferably 1.1 times or more, more preferably 1.2 times or more, particularly preferably 1.3 times or more, and preferably 2.4 times or less. More preferably, it is 2.2 times or less, and particularly preferably 2.0 times or less.
- the stretching speed in the second stretching step is preferably 1.1 times / minute or more, more preferably 1.2 times / minute or more, particularly preferably 1.3 times / minute or more, and preferably 2.4 times / minute or more.
- Min. Or less more preferably 2.2 times / min or less, particularly preferably 2.0 times / min or less.
- Productivity can be improved by making extending
- variation in retardation can be reduced by making it below an upper limit.
- ⁇ Uniaxial stretching is performed as stretching in the second stretching step.
- a specific method of this uniaxial stretching a method similar to the method that can be adopted in the uniaxial stretching in the first stretching step can be used.
- the film may be stretched in the longitudinal direction in the first stretching process and stretched in the transverse direction in the second stretching process.
- the film may be stretched in the transverse direction in the first stretching process and stretched in the longitudinal direction in the second stretching process.
- the film may be stretched in an oblique direction in the first stretching process, and may be stretched in an oblique direction orthogonal to the oblique direction in the second stretching process.
- the diagonal direction represents a direction not parallel to both the vertical direction and the horizontal direction.
- the stretching temperature is applied to the layer a1, the layer b, and the layer a2.
- Retardation according to stretching conditions such as stretching direction and stretching ratio occurs.
- the retardation generated in the layer a1, the layer b, and the layer a2 is synthesized in each of the first stretching step and the second stretching step.
- retardation sufficient to develop an optical function such as a polarizing plate compensation function occurs. Therefore, a laminated retardation film having a desired retardation can be obtained by a production method including a first stretching step and a second stretching step.
- the in-plane letters of the resin layer A1, the resin layer B, and the resin layer A2 of the laminated retardation film are adjusted by adjusting the stretching ratio and the stretching temperature in the first stretching step and the second stretching step. And retardation in the thickness direction can be adjusted.
- any process In the manufacturing method of the laminated phase difference film mentioned above, you may perform arbitrary processes other than the 1st extending process and the 2nd extending process mentioned above. For example, a step of preheating the resin laminate (preheating step) may be provided before stretching the resin laminate.
- a step of preheating the resin laminate examples include an oven-type heating device, a radiation heating device, or immersion in a liquid. Of these, an oven-type heating device is preferable.
- the heating temperature in the preheating step is preferably (stretching temperature ⁇ 40 ° C.) or higher, more preferably (stretching temperature ⁇ 30 ° C.) or higher, preferably (stretching temperature + 20 ° C.) or lower, more preferably (stretching temperature + 15 ° C.).
- the stretching temperature means a set temperature of the heating device.
- the stretched film may be fixed after the first stretching step, after the second stretching step, or after both the first stretching step and the second stretching step.
- the temperature in the fixing treatment is preferably room temperature or higher, more preferably (stretching temperature ⁇ 40 ° C.) or higher, preferably (stretching temperature + 30 ° C.) or lower, more preferably (stretching temperature + 20 ° C.) or lower.
- a step of providing an arbitrary layer such as a mat layer, a hard coat layer, an antireflection layer, or an antifouling layer on the surface of the obtained laminated retardation film may be performed.
- the laminated retardation film of the present invention has an excellent polarizing plate compensation function. Therefore, this laminated retardation film can be used alone or in combination with other members to provide a liquid crystal display device, organic electroluminescence display device, plasma display device, FED (field emission) display device, SED (surface electric field) display device. It may be applied to a display device such as. Among these, the laminated retardation film of the present invention is suitable for use in a liquid crystal display device.
- the liquid crystal display device usually includes a pair of polarizers (light incident side polarizer and light emitting side polarizer) whose absorption axes are orthogonal to each other, and a liquid crystal cell provided between the pair of polarizers.
- a laminated retardation film can be provided between the pair of polarizers.
- the laminated retardation film may be provided, for example, between the liquid crystal cell and the light incident side polarizer.
- the laminated retardation film may be provided, for example, both between the liquid crystal cell and the light incident side polarizer and between the liquid crystal cell and the light output side polarizer.
- the pair of polarizers, the laminated retardation film, and the liquid crystal cell are integrally provided as a liquid crystal panel.
- stacking retardation film normally exhibits the outstanding polarizing plate compensation function, it is possible to reduce the light leakage at the time of seeing the display surface of a liquid crystal display device from diagonally.
- the liquid crystal display device provided with the laminated retardation film of the present invention can sufficiently reduce the front luminance during black display. Furthermore, since the laminated retardation film of the present invention usually has an excellent optical function in addition to the polarizing plate compensation function, it is possible to further improve the visibility of the liquid crystal display device.
- Liquid crystal cell driving methods include, for example, in-plane switching (IPS) method, vertical alignment (VA) method, multi-domain vertical alignment (MVA) method, continuous spin wheel alignment (CPA) method, hybrid alignment nematic (HAN) Examples thereof include a twisted nematic (TN) method, a super twisted nematic (STN) method, and an optically compensated bend (OCB) method.
- IPS in-plane switching
- VA vertical alignment
- MVA multi-domain vertical alignment
- CPA continuous spin wheel alignment
- HAN hybrid alignment nematic
- TN twisted nematic
- STN super twisted nematic
- OOB optically compensated bend
- the in-plane switching type liquid crystal cell has a wide viewing angle, and the viewing angle can be further widened by applying the laminated retardation film as described above.
- the laminated retardation film may be bonded to a liquid crystal cell or a polarizer.
- a known adhesive can be used for bonding.
- a laminated phase difference film may be used individually by 1 sheet, and may use 2 or more sheets.
- the laminated retardation film of the present invention is provided in a liquid crystal display device having a vertical alignment type liquid crystal cell, the viewing angle characteristics are improved in addition to the laminated retardation film of the present invention between a pair of polarizers.
- Another retardation film may be provided.
- the laminated retardation film of the present invention can also be used for uses other than those described above.
- the in-plane retardation Re of the laminated retardation film of the present invention to 120 nm to 160 nm to make the laminated retardation film a quarter wavelength plate, and combining this quarter wavelength plate with a linear polarizer, A circularly polarizing plate can be obtained.
- the angle formed by the in-plane slow axis of the quarter-wave plate and the absorption axis of the linear polarizer is preferably 45 ⁇ 2 °.
- the laminated retardation film can be used as a protective film for a polarizing plate.
- the polarizing plate usually includes a polarizer and protective films bonded to both sides thereof. If a laminated retardation film is bonded to a polarizer, the laminated retardation film can be used as a protective film. In this case, since the protective film is omitted, the thickness of the liquid crystal display device can be reduced.
- the in-plane retardation and thickness direction retardation of the laminated retardation film, and the in-plane retardation and thickness direction retardation of each layer included in the laminated retardation film were measured by a spectroscopic ellipsometer (JA. Woollam "M-2000U").
- the measurement wavelength was 550 nm.
- the measurement was performed at a position where the distance from the right end portion was 50 mm in the traveling direction of the laminated retardation film.
- the in-plane retardation and the retardation in the thickness direction of each layer included in the laminated retardation film were measured as follows. First, the surface of the laminated retardation film was polished with a plastic polishing cloth to make each layer a single layer. In this state, the refractive index nx in the in-plane direction of each layer and giving the maximum refractive index, the refractive index ny in the in-plane direction of each layer and perpendicular to the nx direction, and the thickness direction of each layer The refractive index nz of was measured. From the values of these refractive indexes nx, ny and nz and the thickness d of each layer, the in-plane retardation Re and the thickness direction retardation Rth of each layer were calculated.
- FIG. 2 is a perspective view schematically showing an evaluation system set in a simulator for evaluation of front luminance and light leakage during black display in Examples and Comparative Examples.
- An evaluation system as shown in FIG. 2 was set using a simulator for liquid crystal display (“LCD MASTER” manufactured by Shintech Co., Ltd.).
- the incident side polarizing plate (10), the liquid crystal cell (20), the laminated retardation film (100), and the output side polarizing plate (30) were stacked.
- the incident side polarizing plate (10), the liquid crystal cell (20), the resin layer A2 (110), the resin layer B (120), the resin layer A1 (130), and the output side polarizing plate (30) are in this order.
- the absorption axis (10A) of the incident side polarizing plate (10) and the absorption axis (30A) of the output side polarizing plate (30) were perpendicular to each other as viewed from the thickness direction. Furthermore, the absorption axis (10A) of the incident side polarizing plate (10) and the slow axis (120A) of the resin layer B (120) were made parallel. In addition, as indicated by an arrow L from a backlight (not shown), the incident side polarizing plate (10) is irradiated with light from the thickness direction.
- the luminance when the liquid crystal display device is viewed from the front and the maximum luminance (light leakage) when the liquid crystal display device is viewed from all directions is measured by simulation in black display. It was expressed as a relative value with 1 being 1.
- the following optical member data was used for the calculation. 1.
- data of the liquid crystal cell data of the liquid crystal cell for iPad2 was used.
- the data of this liquid crystal cell was obtained by decomposing iPad2 and measuring the liquid crystal material and the liquid crystal alignment. 2.
- data of the polarizing plate data of G1029DU (manufactured by Nitto Co.) attached to the LCD Master was used.
- the backlight data D65 data attached to the LCD Master was used.
- Example 1 A film forming apparatus for coextrusion molding of two types and three layers was prepared.
- This film molding apparatus is a type of apparatus that forms a film composed of three layers with two kinds of resins.
- a pellet of polycarbonate resin (“Wonderlite PC-115” manufactured by Chi Mei, glass transition temperature: 140 ° C.) was prepared. The pellets were put into one uniaxial extruder equipped with a double flight type screw and melted.
- pellets of a styrene-maleic anhydride copolymer resin (“Dylark D332” manufactured by Nova Chemicals, glass transition temperature: 130 ° C.) were prepared. The pellets were put into another single screw extruder equipped with a double flight type screw and melted.
- a polycarbonate resin and a styrene-maleic anhydride copolymer resin were simultaneously extruded from the multi-manifold die at 260 ° C., and a layer a made of polycarbonate resin a1 / a layer b made of styrene-maleic anhydride copolymer resin / from a polycarbonate resin
- a film-like molten resin having a three-layer structure including the layer a2 was obtained.
- This film-like molten resin was cast on a cooling roll adjusted to a surface temperature of 130 ° C., and then passed between two cooling rolls adjusted to a surface temperature of 50 ° C. to obtain a resin laminate.
- This resin laminate comprises a polycarbonate resin layer (layer a1: thickness 12 ⁇ m), a styrene-maleic anhydride copolymer resin layer (layer b: thickness 89 ⁇ m), and a polycarbonate resin layer (layer a2: thickness 2 ⁇ m). Prepared in order. Both end portions in the width direction of the obtained resin laminate were cut off to obtain a resin laminate having a width of 1450 mm.
- the resin laminate thus obtained was supplied to a tenter transverse uniaxial stretching machine and stretched in the transverse direction for 1 minute at a stretching temperature of 135 ° C. and a stretching ratio of 1.5 times (first stretching step). After stretching, both end portions in the width direction of the resin laminate were removed to make the width 1600 mm.
- this resin laminate was supplied to a longitudinal uniaxial stretching machine, and stretched in the longitudinal direction for 1 minute at a stretching temperature of 120 ° C. and a stretching ratio of 1.17 to obtain a laminated retardation film (second phase) Stretching step).
- stacking phase difference film was cut off, and the width
- the laminated retardation film was then heated to 122 ° C. for 1 minute to fix the orientation state (fixing treatment). At this time, by fixing both end portions in the width direction of the laminated retardation film, the width direction dimension of the laminated retardation film is fixed to 0.995 times the dimension immediately after the stretching in the longitudinal direction is completed. I left it. Then, the width direction both ends of the lamination
- Examples 2 to 6 and Comparative Examples 1 and 2 By changing the opening width of the multi-manifold die, the thickness of the layer included in the resin laminate was changed as shown in Table 1 or Table 2 below. In addition, the film width, stretching ratio, stretching temperature, and stretching time after cutting off both ends in the width direction were changed as shown in Table 1 or Table 2 below. Except for the above, a laminated retardation film comprising a resin layer A1, a resin layer B, and a resin layer A2 in this order was obtained in the same manner as in Example 1. The obtained laminated retardation film was evaluated in the manner described above.
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Abstract
Description
すなわち、本発明は以下の通りである。
前記樹脂層A1と前記樹脂層Bが、直接に接しており、
前記樹脂層Bと前記樹脂層A2が、直接に接しており、
樹脂層A1及び樹脂層A2が、ネガティブCプレートであり、
樹脂層Bが、ポジティブBプレートであり、
Nz係数が0~1の範囲にある、積層位相差フィルム。
〔2〕 波長550nmで測定した、前記樹脂層A1の面内レターデーションReA1、前記樹脂層A1の厚み方向のレターデーションRthA1、前記樹脂層Bの面内レターデーションReB、前記樹脂層Bの厚み方向のレターデーションRthB、前記樹脂層A2の面内レターデーションReA2、及び、前記樹脂層A2の厚み方向のレターデーションRthA2が、
0nm≦ReA1≦5nm
100nm≦RthA1≦160nm
110nm≦ReB≦150nm
-160nm≦RthB≦-100nm
0nm≦ReA2≦5nm
10nm≦RthA2≦40nm
を満たす、〔1〕記載の積層位相差フィルム。
〔3〕 前記樹脂A1のガラス転移温度TgA1と前記樹脂Bのガラス転移温度TgBとの差の絶対値が、5℃より大きく、40℃以下である、〔1〕又は〔2〕記載の積層位相差フィルム。
〔4〕 面内レターデーションReが、50nm以上400nm以下である、〔1〕~〔3〕のいずれか一項に記載の積層位相差フィルム。
〔5〕 厚み方向のレターデーションRthが、-50nm以上50nm以下である、〔1〕~〔4〕のいずれか一項に記載の積層位相差フィルム。
〔6〕 〔1〕~〔5〕のいずれか一項に記載の積層位相差フィルムの製造方法であって、
前記樹脂A1からなる層a1、前記層a1に直接に接した前記樹脂Bからなる層b、及び、前記層bに直接に接した前記樹脂A2からなる層a2をこの順に備える樹脂積層体を、温度T1で第一の方向に1.1倍以上2倍未満の延伸倍率で延伸する第一延伸工程と、
前記第一延伸工程で延伸された前記樹脂積層体を、前記温度T1より低い温度T2において前記第一の方向に直交する第二の方向へ延伸して、積層位相差フィルムを得る第二延伸工程と、を含む、積層位相差フィルムの製造方法。
〔7〕 前記積層位相差フィルムの前記樹脂層Bが、前記第一の方向に平行な面内遅相軸を有する、〔6〕記載の積層位相差フィルムの製造方法。
〔8〕 (層a1の厚みの総和+層a2の厚みの総和)/(層bの厚みの総和)が、1/15以上1/4以下である、〔6〕又は〔7〕記載の積層位相差フィルムの製造方法。
〔9〕 前記樹脂積層体が、前記樹脂A1、前記樹脂B及び前記樹脂A2を用いて、共押出し法により製造されたものである、〔6〕~〔8〕のいずれか一項に記載の積層位相差フィルムの製造方法。
〔10〕 前記樹脂A1のガラス転移温度TgA1及び樹脂A2のガラス転移温度TgA2が、前記樹脂Bのガラス転移温度TgBよりも高く、かつ、
前記温度T1が、TgBより高く、TgA1及びTgA2のいずれか高い温度+20℃より低い、〔6〕~〔9〕のいずれか一項に記載の積層位相差フィルムの製造方法。
〔11〕 前記樹脂A1のガラス転移温度TgA1及び樹脂A2のガラス転移温度TgA2が、前記樹脂Bのガラス転移温度TgBよりも高く、かつ、
前記温度T2が、TgB-20℃より高く、TgB+5℃より低い、〔6〕~〔10〕のいずれか一項に記載の積層位相差フィルムの製造方法。
本発明の積層位相差フィルムの製造方法によれば、当該積層位相差フィルムに含まれる各層の面内遅相軸の方向の関係のズレを防止でき、液晶表示装置において黒表示の際に正面輝度及び光漏れを十分に低くすることが可能な積層位相差フィルムを製造することができる。
また、構成要素の方向が「平行」、「垂直」又は「直交」とは、特に断らない限り、本発明の効果を損ねない範囲内、例えば、通常±5°、好ましくは±2°、より好ましくは±1°の範囲内での誤差を含んでいてもよい。
本発明の積層位相差フィルムは、樹脂層A1、樹脂層B及び樹脂層A2を、この順に備える。また、樹脂層A1と前記樹脂層Bとは直接に接しており、さらに、樹脂層Bと樹脂層A2とは直接に接している。すなわち、樹脂層A1と樹脂層Bとの間には他の層は無く、また、樹脂層Bと樹脂層A2との間に他の層は無い。
樹脂層A1は、樹脂A1からなる層である。また、樹脂A1は、固有複屈折が正である任意の樹脂を用いうる。中でも、樹脂A1としては、熱可塑性樹脂を用いることが好ましい。
樹脂層Bは、樹脂Bからなる層である。また、樹脂Bは、固有複屈折が負である任意の樹脂を用いうる。中でも、樹脂Bとしては、熱可塑性樹脂を用いることが好ましい。
配合剤の量は、本発明の効果を著しく損なわない範囲で適宜定めうる。配合剤の量は、例えば、積層位相差フィルムの1mm厚換算での全光線透過率が80%以上を維持できる範囲としうる。
ここで、樹脂Bのガラス転移温度TgBは樹脂A1のガラス転移温度TgA1よりも低いことが好ましい。よって、樹脂A1と樹脂Bとは、TgA1>TgB+5℃の関係を満たすことが好ましい。
樹脂層A2は、樹脂A2からなる層である。また、樹脂A2は、固有複屈折が正である任意の樹脂を用いうる。中でも、樹脂A2としては、熱可塑性樹脂を用いることが好ましい。その中でも特に、樹脂A2としては、上述した樹脂A1と同様の範囲から材料を選択することがより好ましい。したがって、例えば樹脂A2が含みうる重合体及び配合剤の種類及び量、樹脂A2の重量平均分子量及びガラス転移温度は、樹脂A1と同様にしうる。
本発明の積層位相差フィルムは、本発明の効果を著しく損なわない限り、上述した樹脂層A1、樹脂層B及び樹脂層A2に加えて、更に任意の層を備えていてもよい。ただし、任意の層は、樹脂層A1と樹脂層B、及び、樹脂層Bと樹脂層A2が、それぞれ直接に接することを妨げないように設けられる。
任意の層としては、例えば、フィルムの滑り性を良くできるマット層、耐衝撃性ポリメタクリレート樹脂層等のハードコート層、反射防止層、防汚層等が挙げられる。
本発明の積層位相差フィルムは、上述したように、樹脂層A1及び樹脂層A2がネガティブCプレートとなっている。そのため、樹脂層A1及び樹脂層A2は、面内遅相軸を有さないか、有するとしてもその樹脂層A1及び樹脂層A2における面内レターデーションが無視できる程度に小さい。そのため、樹脂層A1及び樹脂層A2の面内遅相軸の方向を、樹脂層Bの面内遅相軸の方向に応じて設定しなくても、液晶表示装置を黒表示にした際に、正面輝度を十分に低減できる。また、通常は、積層位相差フィルムの光学補償性能を高くできるので、液晶表示装置の光漏れを低減できる。
nave=Σ(ni×Li)/ΣLi
ni:i層の樹脂の屈折率
Li:i層の膜厚
ここで、「不規則に生じる線状凹部又は線状凸部を実質的に有さず、平坦」とは、仮に線状凹部又は線状凸部が形成されたとしても、下記条件(X)を満たすことであり、好ましくは下記条件(Y)を満たすことである。
条件(X) 線状凹部の深さが50nm未満もしくは幅が500μmより大きいか、又は、線状凸部の高さが50nm未満もしくは幅が500μmより大きい。
条件(Y) 線状凹部の深さが30nm未満もしくは幅が700μmより大きいか、又は、線状凸部の高さが30nm未満もしくは幅が700μmより大きい。
このような構成とすることにより、線状凹部又は線状凸部での光の屈折等に基づく、光の干渉及び光漏れの発生を防止でき、光学性能を向上できる。また、不規則に生じるとは、意図しない位置に意図しない寸法及び形状で形成されるということである。
この断面プロファイルに、平均線を引く。この平均線から線状凹部の底までの長さが線状凹部深さとなり、また、平均線から線状凸部の頂までの長さが線状凸部高さとなる。平均線とプロファイルとの交点間の距離が幅となる。これら線状凹部深さ及び線状凸部高さの測定値からそれぞれ最大値を求め、その最大値を示した線状凹部又は線状凸部の幅をそれぞれ求める。以上から求められた線状凹部深さの最大値をそのフィルムの線状凹部の深さとし、その最大値を示した線状凹部の幅を、そのフィルムの線状凹部の幅とする。また、線状凸部高さの最大値をそのフィルムの線状凸部の高さとし、その最大値を示した線状凸部の幅を、そのフィルムの線状凸部の幅とする。
本発明の積層位相差フィルムの製造方法に制限は無く、例えば、樹脂A1からなる層a1、層a1に直接に接した樹脂Bからなる層b、及び、層bに直接に接した樹脂A2からなる層a2をこの順に備える樹脂積層体を延伸することにより製造しうる。この際、樹脂積層体の延伸は、樹脂積層体を温度T1で第一の方向に延伸する第一延伸工程と;第一延伸工程で延伸された樹脂積層体を、温度T1より低い温度T2において第一の方向に直交する第二の方向へ延伸して積層位相差フィルムを得る第二延伸工程と;を行うことが好ましい。以下、この製造方法について説明する。
樹脂積層体は、前記のように、樹脂A1からなる層a1、樹脂Bからなる層b、及び、樹脂A2からなる層a2をこの順に備える。また、層a1と層bとは直接に接しており、層bと層a2とは直接に接している。すなわち、層a1と層bとの間には他の層は無く、また、層bと層a2との間に他の層は無い。
温度T1及びT2のうちの一方でX軸方向に一軸延伸したときには遅れ、
温度T1及びT2のうちの他方でX軸方向に一軸延伸したときには進む、
との要件を満たすことが好ましい。
フィルム面に垂直に入射しかつ電気ベクトルの振動面がXZ面にある直線偏光を、以下、適宜「XZ偏光」という。また、フィルム面に垂直に入射しかつ電気ベクトルの振動面がYZ面にある直線偏光を、以下、適宜「YZ偏光」という。さらに、前記の要件を、以下、適宜「要件P」という。通常、樹脂積層体のXZ偏光のYZ偏光に対する位相は、温度T1でX軸方向に一軸延伸したときに遅れ、温度T2でX軸方向に一軸延伸したときに進む。
(i)低い温度T2における延伸で、ガラス転移温度の高い樹脂が発現するレターデーションの絶対値が、ガラス転移温度の低い樹脂が発現するレターデーションの絶対値よりも、小さくなる。
(ii)高い温度T1における延伸で、ガラス転移温度の低い樹脂が発現するレターデーションの絶対値が、ガラス転移温度の高い樹脂が発現するレターデーションの絶対値よりも、小さくなる。
したがって、このような異なる温度Ta及びTbの延伸を組み合わせることにより、各温度での延伸で生じるレターデーションを合成して、所望のレターデーションを有し、ひいては所望の光学的機能を発揮する積層位相差フィルムを安定して実現できる。
(1)押出機内に目開きが20μm以下のポリマーフィルターを設ける。
(2)ギヤポンプを5rpm以上で回転させる。
(3)ダイス周りに囲い手段を配置する。
(4)エアギャップを200mm以下とする。
(5)フィルムを冷却ロール上にキャストする際にエッジピニングを行う。
(6)押出機として二軸押出機又はスクリュー形式がダブルフライト型の単軸押出機を用いる。
厚みのばらつきは、上記で測定した測定値の算術平均値Taveを基準とし、測定した厚みTの内の最大値をTmax、最小値をTminとして、以下の式から算出する。
厚みのばらつき(μm)=「Tave-Tmin」及び「Tmax-Tave」のうちの大きい方。
溶融樹脂を冷却ドラムに密着させる方法は、特に制限されず、例えば、エアナイフ方式、バキュームボックス方式、静電密着方式などが挙げられる。
冷却ドラムの数は特に制限されないが、通常は2本以上である。また、冷却ドラムの配置方法としては、例えば、直線型、Z型、L型などが挙げられるが特に制限されない。またダイスの開口部から押出された溶融樹脂の冷却ドラムへの通し方も特に制限されない。
第一延伸工程では、樹脂積層体を温度T1で一方向に延伸する。即ち、樹脂積層体を温度T1で一軸延伸する。この際、第一延伸工程で樹脂積層体を延伸する方向が、第一の方向である。このような第一延伸工程を行うことにより、樹脂積層体に含まれる層a1、層b及び層a2が共延伸される。温度T1で延伸すると、層a1、層b及び層a2のそれぞれにおいて、樹脂積層体の構成、並びに、延伸温度T1及び延伸倍率などの延伸条件に応じてレターデーションが生じ、層a1、層b及び層a2を含む樹脂積層体全体としてもレターデーションを生じる。この際、例えば樹脂積層体が要件Pを満たす場合には、XZ偏光のYZ偏光に対する位相は、遅れるか、若しくは進む。
第一延伸工程の後、第二延伸工程を行う。第二延伸工程では、第一延伸工程で第一の方向に延伸された樹脂積層体を、前記第一の方向に面内で直交する第二の方向へ延伸する。
上述した積層位相差フィルムの製造方法においては、上述した第一延伸工程及び第二延伸工程以外に、任意の工程を行ってもよい。
例えば、樹脂積層体を延伸する前に、樹脂積層体を予め加熱する工程(予熱工程)を設けてもよい。樹脂積層体を加熱する手段としては、例えば、オーブン型加熱装置、ラジエーション加熱装置、又は液体中に浸すことなどが挙げられる。中でもオーブン型加熱装置が好ましい。予熱工程における加熱温度は、好ましくは(延伸温度-40℃)以上、より好ましくは(延伸温度-30℃)以上であり、好ましくは(延伸温度+20℃)以下、より好ましくは(延伸温度+15℃)以下である。ここで延伸温度とは、加熱装置の設定温度を意味する。
本発明の積層位相差フィルムは、優れた偏光板補償機能を有する。そのため、この積層位相差フィルムは、それ単独で、あるいは他の部材と組み合わせて、液晶表示装置、有機エレクトロルミネッセンス表示装置、プラズマ表示装置、FED(電界放出)表示装置、SED(表面電界)表示装置等の表示装置に適用してもよい。これらの中でも、本発明の積層位相差フィルムは、液晶表示装置に用いて好適である。
また、積層位相差フィルムは、1枚を単独で用いてもよく、2枚以上を用いてもよい。
さらに、積層位相差フィルムを液晶表示装置に設ける場合、本発明の積層位相差フィルムと、更に別の位相差フィルムとを組み合わせて用いてもよい。例えば、本発明の積層位相差フィルムをバーチカルアラインメント方式の液晶セルを備えた液晶表示装置に設ける場合、一対の偏光子の間に、本発明の積層位相差フィルムに加えて、視野角特性を改善するための別の位相差フィルムを設けてもよい。
本発明の積層位相差フィルムは、上述した以外の用途に用いることも可能である。
例えば、本発明の積層位相差フィルムの面内レターデーションReを120nm~160nmとすることによって積層位相差フィルムを1/4波長板とし、この1/4波長板を直線偏光子と組み合わせれば、円偏光板を得ることができる。この際、1/4波長板の面内遅相軸と直線偏光子の吸収軸とのなす角度は、45±2°にすることが好ましい。
以下の説明において、量を表す「%」及び「部」は、別に断らない限り重量基準である。また、以下に説明する操作は、別に断らない限り、常温及び常圧の条件において行った。
(厚みの測定方法)
フィルムの厚みは、接触式の厚み計を用いて測定した。
また、フィルムに含まれる各層の厚みは、そのフィルムをエポキシ樹脂に包埋したのち、ミクロトーム(大和工業社製「RUB-2100」)を用いてスライスし、走査電子顕微鏡を用いて断面を観察し、測定した。
積層位相差フィルムの面内レターデーション及び厚み方向のレターデーション、並びに、当該積層位相差フィルムに含まれる各層の面内レターデーション及び厚み方向のレターデーションの測定は、分光エリプソメーター(J.A.Woollam社製「M-2000U」)を用いて行った。また、測定波長は550nmとした。さらに、測定は、積層位相差フィルムの進行方向に向かって右側端部からの距離が50mmの位置において行った。
前記の分光エリプソメーターにより、積層位相差フィルムの進行方向に向かって右側端部からの距離が50mmの位置における面内遅相軸の方向を測定した。
図2は、実施例及び比較例で黒表示時の正面輝度及び光漏れの評価のためにシミュレーターにおいて設定した評価系を模式的に示す斜視図である。
液晶表示器用シミュレーター(シンテック社製「LCD MASTER」)を用いて、図2に示すような評価系を設定した。図2に示す評価系において、入射側偏光板(10)、液晶セル(20)、積層位相差フィルム(100)及び出射側偏光板(30)を重ねたものとした。この際、入射側偏光板(10)、液晶セル(20)、樹脂層A2(110)、樹脂層B(120)、樹脂層A1(130)及び出射側偏光板(30)は、この順になるようにした。また、入射側偏光板(10)の吸収軸(10A)と出射側偏光板(30)の吸収軸(30A)とは、厚み方向から見て垂直となるようにした。さらに、入射側偏光板(10)の吸収軸(10A)と樹脂層B(120)の遅相軸(120A)は、平行になるようにした。また、図示しないバックライトから矢印Lで示すように、入射側偏光板(10)へ厚み方向から光が照射されているものとした。
計算には下記の光学部材のデータを使用した。
1.液晶セルのデータとしては、iPad2用液晶セルのデータを用いた。また、この液晶セルのデータは、iPad2を分解し、液晶材料と液晶配向を測定して得られたデータを使用した。
2.偏光板のデータとしては、LCD Master付属のG1029DU(日東社製)のデータを用いた。
3.バックライトのデータとしては、LCD Master付属のD65のデータを用いた。
二種三層の共押出成形用のフィルム成形装置を準備した。このフィルム成型装置は、2種類の樹脂により3層からなるフィルムを形成するタイプの装置である。
マルチマニホールドダイの開口幅を変更することにより、樹脂積層体に含まれる層の厚みを下記表1又は表2のように変更した。また、幅方向両端部を切り除いた後のフィルム幅、延伸倍率、延伸温度及び延伸時間を下記表1又は表2のように変更した。
以上の事項以外は実施例1と同様にして、樹脂層A1、樹脂層B及び樹脂層A2をこの順に備える積層位相差フィルムを得た。得られた積層位相差フィルムについて、上述した要領で評価を行った。
前記の実施例1~6並びに比較例1及び2の結果を、下記の表1及び表2に示す。また、表における略称の意味は、以下の通りである。
Re:面内レターデーション
Rth:厚み方向のレターデーション
遅相軸方向:出射側偏光板の吸収軸の方向を90°方向としたときの、各層の面内遅相軸の方向。ここでは、積層位相差フィルムの進行方向に向かって右側端部からの距離が50mmの位置における遅相軸の方向を示す。
表1から、実施例1~6において、黒表示時の正面輝度及び光漏れの両方を小さくできることが分かる。ここで、実施例2及び6は、光漏れの値が比較例1より大きくなっている。しかし、実施例2及び6は、黒表示時の正面輝度については比較例1より大幅に小さくなっている。よって、実施例2及び6は、黒表示時の正面輝度及び光漏れの両方を総合して評価すれば、比較例1よりも優れた結果が得られていることが分かる。
したがって、本発明により、積層位相差フィルムに含まれる各層の面内遅相軸の関係のズレを防止でき、液晶表示装置において黒表示の際に正面輝度及び光漏れを小さくすることが可能であることが確認された。
10A 入射側偏光板の吸収軸
20 液晶セル
30 出射側偏光板
100 積層位相差フィルム
110 樹脂層A2
120A 樹脂層Bの面内遅相軸
120 樹脂層B
130 樹脂層A1
Claims (11)
- 固有複屈折が正である樹脂A1からなる樹脂層A1、固有複屈折が負である樹脂Bからなる樹脂層B、及び、固有複屈折が正である樹脂A2からなる樹脂層A2をこの順に備え、
前記樹脂層A1と前記樹脂層Bが、直接に接しており、
前記樹脂層Bと前記樹脂層A2が、直接に接しており、
樹脂層A1及び樹脂層A2が、ネガティブCプレートであり、
樹脂層Bが、ポジティブBプレートであり、
Nz係数が0~1の範囲にある、積層位相差フィルム。 - 波長550nmで測定した、前記樹脂層A1の面内レターデーションReA1、前記樹脂層A1の厚み方向のレターデーションRthA1、前記樹脂層Bの面内レターデーションReB、前記樹脂層Bの厚み方向のレターデーションRthB、前記樹脂層A2の面内レターデーションReA2、及び、前記樹脂層A2の厚み方向のレターデーションRthA2が、
0nm≦ReA1≦5nm
100nm≦RthA1≦160nm
110nm≦ReB≦150nm
-160nm≦RthB≦-100nm
0nm≦ReA2≦5nm
10nm≦RthA2≦40nm
を満たす、請求項1記載の積層位相差フィルム。 - 前記樹脂A1のガラス転移温度TgA1と前記樹脂Bのガラス転移温度TgBとの差の絶対値が、5℃より大きく、40℃以下である、請求項1又は2記載の積層位相差フィルム。
- 面内レターデーションReが、50nm以上400nm以下である、請求項1~3のいずれか一項に記載の積層位相差フィルム。
- 厚み方向のレターデーションRthが、-50nm以上50nm以下である、請求項1~4のいずれか一項に記載の積層位相差フィルム。
- 請求項1~5のいずれか一項に記載の積層位相差フィルムの製造方法であって、
前記樹脂A1からなる層a1、前記層a1に直接に接した前記樹脂Bからなる層b、及び、前記層bに直接に接した前記樹脂A2からなる層a2をこの順に備える樹脂積層体を、温度T1で第一の方向に1.1倍以上2倍未満の延伸倍率で延伸する第一延伸工程と、
前記第一延伸工程で延伸された前記樹脂積層体を、前記温度T1より低い温度T2において前記第一の方向に直交する第二の方向へ延伸して、積層位相差フィルムを得る第二延伸工程と、を含む、積層位相差フィルムの製造方法。 - 前記積層位相差フィルムの前記樹脂層Bが、前記第一の方向に平行な面内遅相軸を有する、請求項6記載の積層位相差フィルムの製造方法。
- (層a1の厚みの総和+層a2の厚みの総和)/(層bの厚みの総和)が、1/15以上1/4以下である、請求項6又は7記載の積層位相差フィルムの製造方法。
- 前記樹脂積層体が、前記樹脂A1、前記樹脂B及び前記樹脂A2を用いて、共押出し法により製造されたものである、請求項6~8のいずれか一項に記載の積層位相差フィルムの製造方法。
- 前記樹脂A1のガラス転移温度TgA1及び樹脂A2のガラス転移温度TgA2が、前記樹脂Bのガラス転移温度TgBよりも高く、かつ、
前記温度T1が、TgBより高く、TgA1及びTgA2のいずれか高い温度+20℃より低い、請求項6~9のいずれか一項に記載の積層位相差フィルムの製造方法。 - 前記樹脂A1のガラス転移温度TgA1及び樹脂A2のガラス転移温度TgA2が、前記樹脂Bのガラス転移温度TgBよりも高く、かつ、
前記温度T2が、TgB-20℃より高く、TgB+5℃より低い、請求項6~10のいずれか一項に記載の積層位相差フィルムの製造方法。
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CN104956243A (zh) | 2015-09-30 |
KR20150114946A (ko) | 2015-10-13 |
KR102114358B1 (ko) | 2020-05-22 |
US9535202B2 (en) | 2017-01-03 |
CN104956243B (zh) | 2017-07-28 |
JPWO2014119457A1 (ja) | 2017-01-26 |
TWI644129B (zh) | 2018-12-11 |
TWI655098B (zh) | 2019-04-01 |
US20150378079A1 (en) | 2015-12-31 |
JP5585747B1 (ja) | 2014-09-10 |
TW201432325A (zh) | 2014-08-16 |
TW201900404A (zh) | 2019-01-01 |
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