WO2015137515A1 - 積層体、延伸積層体、延伸積層体の製造方法、それらを用いた、偏光膜を含む光学フィルム積層体の製造方法、及び偏光膜 - Google Patents
積層体、延伸積層体、延伸積層体の製造方法、それらを用いた、偏光膜を含む光学フィルム積層体の製造方法、及び偏光膜 Download PDFInfo
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- WO2015137515A1 WO2015137515A1 PCT/JP2015/057754 JP2015057754W WO2015137515A1 WO 2015137515 A1 WO2015137515 A1 WO 2015137515A1 JP 2015057754 W JP2015057754 W JP 2015057754W WO 2015137515 A1 WO2015137515 A1 WO 2015137515A1
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- polyvinyl alcohol
- laminate
- stretching
- resin layer
- stretched
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
- G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
- G02B5/305—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/005—Shaping by stretching, e.g. drawing through a die; Apparatus therefor characterised by the choice of materials
-
- 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
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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/023—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets using multilayered plates or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2029/00—Use of polyvinylalcohols, polyvinylethers, polyvinylaldehydes, polyvinylketones or polyvinylketals or derivatives thereof as moulding material
- B29K2029/04—PVOH, i.e. polyvinyl alcohol
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- 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
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- 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
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- 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
Definitions
- the present invention relates to a laminate, a stretched laminate, a method for producing a stretched laminate, a method for producing an optical film laminate including a polarizing film using them, and a polarizing film.
- the present invention includes a thermoplastic resin substrate and a polyvinyl alcohol-based resin layer formed on the thermoplastic resin substrate, and the polyvinyl alcohol-based resin layer includes a polyvinyl alcohol-based resin and glycerin.
- the present invention relates to a laminate, a stretched laminate, a method for producing a stretched laminate, a method for producing an optical film laminate including a polarizing film using them, and a polarizing film.
- a polarizing film made of a polyvinyl alcohol resin in which iodine is oriented is currently used in televisions, mobile phones, portable information terminals and many other optical display devices.
- iodine is oriented
- televisions, mobile phones, portable information terminals and many other optical display devices In recent years, there is an increasing need for thinning the polarizing film. Although it is difficult to reduce the thickness of the polarizing film and improve its optical characteristics, the level of required optical characteristics is becoming stricter.
- Examples of the method for producing a polarizing film include a production method including a step of stretching a polyvinyl alcohol-based resin layer and a stretching resin base material in a state of a laminate and a step of dyeing. With this production method, even if the polyvinyl alcohol-based resin layer is thin, it can be stretched without problems such as breakage due to stretching because it is supported by the stretching resin substrate.
- Such a production method including a step of stretching in a boric acid aqueous solution is advantageous, and in particular, in-air auxiliary stretching before stretching in a boric acid aqueous solution as in JP 2012-0753563 A and JP 2012-134117 A.
- a production method (two-stage stretching method) including a step of performing is advantageous. Also, as described in JP 2011-2816 A, a method of stretching a PVA resin layer and a stretching resin base material in a laminated state, then excessively dyeing the PVA resin layer, and then decoloring (Over-staining decolorization method) is also advantageous.
- the level of optical properties required for a thin polarizing film is becoming stricter, and the present inventors have added glycerin to the polyvinyl alcohol resin layer on the thermoplastic resin substrate. It has been found that when a stretched laminate obtained by stretching the laminate is dyed, a polarizing film having good optical properties can be produced.
- An object of the present invention is to provide an intermediate material and a manufacturing method for manufacturing a polarizing film having good optical characteristics.
- One embodiment of the present invention includes a thermoplastic resin substrate and a polyvinyl alcohol-based resin layer formed on the thermoplastic resin substrate, and formed on the thermoplastic resin substrate.
- the post-process including at least a dyeing process for dyeing the polyvinyl alcohol-based resin layer with a dichroic substance.
- a laminate used for forming a polarizing film comprising a treated polyvinyl alcohol resin layer, wherein the polyvinyl alcohol resin layer provides a laminate containing a polyvinyl alcohol resin and glycerin. is there.
- the post-process can further include a final stretching process of stretching the polyvinyl alcohol-based resin layer.
- One embodiment of the present invention includes a thermoplastic resin substrate and a polyvinyl alcohol resin layer formed on the thermoplastic resin substrate, and the polyvinyl alcohol resin layer is dyed with a dichroic substance.
- a stretched laminate used for forming a polarizing film comprising a polyvinyl alcohol-based resin layer treated by the post-process by a post-process including at least a dyeing process, wherein the polyvinyl alcohol-based resin layer is made of polyvinyl
- the polyvinyl alcohol-based resin layer containing an alcohol-based resin and glycerin glycerin and formed on the thermoplastic resin base material provides a stretched laminate that is stretched together with the thermoplastic resin base material. .
- the post-process can further include a final stretching process of stretching the polyvinyl alcohol-based resin layer.
- the polyvinyl alcohol-based resin layer formed on the thermoplastic resin substrate can be stretched in the air together with the thermoplastic resin substrate.
- the stretching ratio of the above-mentioned air stretching can be 1.5 times or more and 3.5 times or less.
- the stretching temperature of the air stretching can be 100 ° C. or higher and 150 ° C. or lower.
- the post-process includes at least a dyeing step for dyeing a polyvinyl alcohol-based resin layer with a dichroic material to form a colored laminate, and a boric acid aqueous solution drawing step for drawing the colored laminate in a boric acid aqueous solution.
- a dyeing step for dyeing a polyvinyl alcohol-based resin layer with a dichroic material to form a colored laminate
- a boric acid aqueous solution drawing step for drawing the colored laminate in a boric acid aqueous solution.
- One embodiment of the present invention provides a roll of a stretched laminate formed by winding the stretched laminate into a roll.
- One embodiment of the present invention includes a thermoplastic resin substrate and a polyvinyl alcohol resin layer formed on the thermoplastic resin substrate, and the polyvinyl alcohol resin layer is dyed with a dichroic substance.
- a method for producing a stretched laminate used for forming a polarizing film comprising a polyvinyl alcohol-based resin layer treated by a post-process by at least a post-process including a dyeing process, on a thermoplastic resin substrate
- a method for producing a stretched laminate comprising: a step of producing a laminate comprising a layer; and a step of producing a stretched laminate by stretching the laminate. It is intended to provide.
- the post-process can further include a final stretching process of stretching the polyvinyl alcohol-based resin layer.
- the stretching of the laminate can be performed in the air.
- the stretching ratio of the above-mentioned air stretching can be 1.5 times or more and 3.5 times or less.
- the stretching temperature of the air stretching can be 100 ° C. or higher and 150 ° C. or lower.
- One embodiment of the present invention is a method for producing a roll of a stretched laminate comprising a step of forming a roll of the stretched laminate by winding the stretched laminate produced by the method for producing a stretched laminate into a roll. Is to provide.
- One embodiment of the present invention is by stretching a laminate including a thermoplastic resin substrate and a polyvinyl alcohol resin layer containing a polyvinyl alcohol resin and glycerin formed on the thermoplastic resin substrate.
- a step of producing a stretched laminate comprising a thermoplastic resin substrate and a stretched polyvinyl alcohol resin layer, and a post-process comprising at least a dyeing step of dyeing the polyvinyl alcohol resin layer with a dichroic substance.
- generates the optical film laminated body containing the polarizing film which consists of the polyvinyl alcohol-type resin layer processed by the said post process and a thermoplastic resin base material is included.
- the post-process can further include a final stretching process of stretching the polyvinyl alcohol-based resin layer.
- the stretching of the laminate can be performed in the air.
- the stretching ratio of the air-assisted stretching can be 1.5 times or more and 3.5 times or less.
- the stretching temperature for the air-assisted stretching can be 100 ° C. or higher and 150 ° C. or lower.
- the post-process includes at least a dyeing step for dyeing a polyvinyl alcohol-based resin layer with a dichroic material to form a colored laminate, and a boric acid aqueous solution drawing step for drawing the colored laminate in a boric acid aqueous solution.
- a dyeing step for dyeing a polyvinyl alcohol-based resin layer with a dichroic material to form a colored laminate
- a boric acid aqueous solution drawing step for drawing the colored laminate in a boric acid aqueous solution.
- One embodiment of the present invention provides a polarizing film produced by the method for producing an optical film laminate.
- the molar ratio of the glycerin to the polyvinyl alcohol resin can be 1.0 or more and 15 or less.
- the thickness of the polarizing film can be 10 ⁇ m or less.
- the thickness of the polarizing film can be 7 ⁇ m or less.
- the thickness of the polarizing film can be 5 ⁇ m or less.
- the stretched laminate obtained by allowing the polyvinyl alcohol-based resin layer on the thermoplastic resin substrate to contain glycerin and then stretching the laminate is dyed, and thus good.
- a polarizing film having excellent optical characteristics can be produced.
- the laminate of the present invention comprises a thermoplastic resin substrate and a polyvinyl alcohol-based resin layer formed on the thermoplastic resin substrate, and the polyvinyl alcohol-based film formed on the thermoplastic resin substrate.
- the post-process is performed after the resin layer is stretched together with the thermoplastic resin substrate, and the post-process is performed by a post-process including at least a dyeing process for dyeing the polyvinyl alcohol-based resin layer with a dichroic substance. It is used to form a polarizing film made of a polyvinyl alcohol resin layer.
- the stretched laminate of the present invention includes a thermoplastic resin substrate and a polyvinyl alcohol resin layer formed on the thermoplastic resin substrate, and dyes the polyvinyl alcohol resin layer with a dichroic substance. It is used to form a polarizing film comprising a polyvinyl alcohol-based resin layer that has been processed by the post-process by a post-process including at least the process.
- the polyvinyl alcohol-based resin layer formed on the thermoplastic resin substrate is stretched together with the thermoplastic resin substrate, and the stretching can be performed in the air (dry stretching).
- the roll (raw material) of the stretched laminate of the present invention is formed by winding the stretched laminate with a winding device.
- the method for producing an optical film laminate of the present invention includes a laminate comprising a thermoplastic resin substrate and a polyvinyl alcohol resin layer containing a polyvinyl alcohol resin and glycerin formed on the thermoplastic resin substrate.
- a post-process comprising at least a step of producing a stretched laminate comprising a thermoplastic resin substrate and a stretched polyvinyl alcohol-based resin layer, and a dyeing step of dyeing the polyvinyl alcohol-based resin layer with a dichroic substance.
- an optical film laminate including a polarizing film made of a polyvinyl alcohol-based resin layer treated by the post-process and a thermoplastic resin substrate.
- the method for producing an optical film laminate of the present invention can be applied to various stretching methods, but is particularly advantageous when applied to a two-stage stretching method including an air auxiliary stretching step and a boric acid underwater stretching step.
- the air auxiliary stretching step is performed as the air stretching step
- the boric acid underwater stretching step is performed as the final stretching step.
- the air stretching according to the present invention is a so-called dry stretching performed in a gas.
- the gas is usually air, but may be an inert gas such as nitrogen gas.
- the stretching method is not particularly limited, and a stretching method usually used for film stretching, such as roll stretching or tenter stretching, can be employed. Further, the stretching may be stretching in one direction (uniaxial stretching) in the longitudinal direction or the transverse direction, and may be biaxial stretching or oblique stretching.
- the draw ratio of the air drawing is preferably 1.5 times or more and 3.5 times or less, and more preferably 1.8 times or more and 3.0 times or less.
- stretching shall be 100 degreeC or more and 150 degrees C or less.
- the aerial stretching process of the present invention can be an air-assisted stretching process that is the first stretching process of the two-stage stretching method.
- the post-process in the present invention includes at least a dyeing process for dyeing the polyvinyl alcohol-based resin layer with a dichroic substance.
- the post-process can further include a final stretching process of stretching the polyvinyl alcohol-based resin layer.
- the post-process includes at least a dyeing step for dyeing the polyvinyl alcohol-based resin layer with a dichroic material to form a colored laminate, and a boric acid aqueous solution drawing step for drawing the colored laminate in an aqueous boric acid solution.
- staining process in this invention is a process of dye
- the dyeing step is performed after the step of producing the stretched laminate.
- the dyeing step may be performed subsequent to the step of generating the stretched laminate, or another step as desired may be performed between the step of generating the stretched laminate and the dyeing step.
- dichroic substance used in the present invention examples include iodine and organic dyes (eg, polymethine dyes, cyanine dyes, merocyanine dyes, rhodacyanine dyes, trinuclear merocyanine dyes, allopolar dyes, hemicyanine dyes, styryl dyes, azo dyes).
- iodine is preferable from the viewpoint of excellent optical properties.
- Dyeing of the stretched laminate with the dichroic material can be carried out, for example, by bringing the stretched laminate into contact with a staining solution containing the dichroic material.
- the method for bringing the stretched laminate into contact with the dyeing solution is not particularly limited, and examples thereof include a method of immersing the stretched laminate in a dyeing bath containing the dyeing solution and a method of spraying the dyeing solution onto the stretched laminate. Moreover, you may use these methods together.
- a method of immersing the stretched laminate in a dyeing bath containing a dyeing solution is preferable.
- an aqueous solvent is preferable.
- the aqueous solvent include water or a mixed solvent of water and a small amount of a water-soluble organic solvent. Of these, water is preferred.
- the iodine concentration in the staining solution is not particularly limited as long as it can be dyed, but is usually 0.5 to 10 parts by mass per 100 parts by mass of the solvent (eg, water).
- the iodine concentration refers to a blending ratio of iodine with respect to the total solution amount, and does not include, for example, the amount of iodine added as an iodide such as potassium iodide.
- the term iodine concentration is used in the same meaning.
- the staining solution preferably contains iodide.
- iodide examples include potassium iodide, lithium iodide, sodium iodide, zinc iodide, aluminum iodide, lead iodide, copper iodide, barium iodide, calcium iodide, tin iodide, and iodide. Titanium is mentioned. These may be used alone or in combination of two or more.
- potassium iodide is preferable.
- the iodide content in the staining solution is preferably 3 to 50 parts by mass with respect to 100 parts by mass of the solvent (eg, water).
- the staining solution is an aqueous solution containing iodine and potassium iodide.
- the iodine content is preferably 0.5 to 10 parts by weight with respect to 100 parts by weight of water
- the potassium iodide content is preferably 100 parts by weight of water. The amount is 3 to 50 parts by weight.
- the temperature of the dyeing liquid at the time of immersion and the immersion time may be appropriately set so that the dyeing is appropriately performed according to the concentration of the dyeing liquid and the thickness of the polyvinyl alcohol-based resin layer, respectively.
- the temperature of the dyeing solution is usually 10 ° C. to 60 ° C.
- the immersion time is usually 10 seconds to 20 minutes.
- the boric acid underwater stretching step of the present invention is a step of stretching at least the longitudinal direction while immersing the dyed stretched laminate (colored laminate) in a boric acid aqueous solution.
- the boric acid underwater stretching step can be the second stretching step of the two-stage stretching method.
- the polyvinyl alcohol-based resin layer contained in the colored laminate is changed to a vinyl alcohol-based resin layer in which the adsorbed polyiodine ions are oriented.
- the polyvinyl alcohol-based resin layer in which the polyiodine ions are aligned constitutes the polarizing film of the optical film laminate.
- the boric acid concentration of the boric acid aqueous solution is preferably 2 to 8 parts by mass per 100 parts by mass of water.
- the stretching method is not particularly limited, and a stretching method usually used for film stretching, such as roll stretching or tenter stretching, can be employed. Further, the stretching may be stretching in one direction (eg, longitudinal direction, width direction) (uniaxial stretching), biaxial stretching, or oblique stretching.
- the stretching ratio of boric acid in water stretching can be such that the total stretching ratio of in-air stretching and boric acid in water stretching is 4 to 7 times.
- stretching in boric acid water can be 50 degreeC or more and 80 degrees C or less.
- Examples of the steps implemented as desired include a first insolubilization step, a crosslinking step, a second insolubilization step, a washing step, a water droplet removal step, and a drying step, which will be described in order below.
- the first insolubilization step is a step of immersing the stretched laminate in an aqueous boric acid solution before the dyeing step, and the stretched polyvinyl alcohol resin layer contained in the stretched laminate is dissolved at least in the subsequent dyeing step. This is to prevent this.
- the concentration, temperature and soaking time of the aqueous boric acid solution are preferably 1 to 5 parts by mass, 10 to 50 ° C., and 1 to 300 seconds per 100 parts by mass of water.
- the cross-linking step is preferably performed after the dyeing step, and (1) not to dissolve the stretched polyvinyl alcohol-based resin layer contained in the colored laminate in the boric acid water stretching in the subsequent step, (2) The main purpose is not to elute colored iodine into the stretched polyvinyl alcohol resin layer, and (3) to generate knots by cross-linking molecules of the stretched polyvinyl alcohol resin layer. It is the process of bridge
- Crosslinking can be performed, for example, by bringing a stretched polyvinyl alcohol resin layer into contact with a crosslinking liquid containing a crosslinking agent.
- the method for bringing the stretched polyvinyl alcohol-based resin layer into contact with the crosslinking liquid is not particularly limited.
- the method of immersing the stretched polyvinyl alcohol-based resin layer in a crosslinking bath containing the crosslinking liquid, and the crosslinking liquid are stretched.
- coating to the made polyvinyl alcohol-type resin layer is mentioned. Moreover, you may use these methods together.
- a method of immersing the stretched polyvinyl alcohol resin layer in a crosslinking bath containing a crosslinking solution is preferable.
- crosslinking agent examples include boron compounds.
- examples of the boron compound include boric acid, borax, glyoxal, and glutaraldehyde. These may be used alone or in combination of two or more.
- an aqueous solvent is preferable.
- the aqueous solvent include water or a mixed solvent of water and a small amount of a water-soluble organic solvent. Of these, water is preferred.
- the concentration of the crosslinking agent in the crosslinking solution is not particularly limited as long as crosslinking is possible, but is usually 0.1 to 10 parts by mass per 100 parts by mass of a solvent (eg, water).
- the crosslinking liquid preferably contains iodide.
- the iodide include the same as those exemplified in the above dyeing step.
- the amount of iodide in the crosslinking liquid is usually 0.5 to 15 parts by mass of iodide with respect to 100 parts by mass of the solvent (eg, water).
- the temperature of the crosslinking liquid and the immersion time during immersion are not particularly limited, but the temperature of the crosslinking liquid is usually 20 ° C. to 70 ° C., and the immersion time is usually 1 second to 300 seconds.
- the second insolubilization step is a step of immersing the colored laminate in a boric acid aqueous solution before the stretching step after the crosslinking step and in the boric acid aqueous solution, and at least the stretched step included in the colored laminate in the boric acid submerged drawing step is performed. This prevents the polyvinyl alcohol resin layer from dissolving.
- concentration, liquid temperature, and immersion time of this aqueous boric acid solution are preferably 1 to 6 parts by mass, 10 to 60 ° C., and 1 to 300 seconds per 100 parts by mass of water.
- the washing step is a step of washing away unnecessary residues adhering to the surface of the polarizing film contained in the optical film laminate taken out from the boric acid aqueous solution in the boric acid underwater drawing step, and can be carried out as necessary. .
- the water droplet removing step is a step of removing excess water droplets adhering to the surface of the stretched polyvinyl alcohol-based resin layer, and can be performed as necessary.
- the water droplet removal step is preferably performed after one or more steps selected from, for example, a dyeing step, a crosslinking step, and a washing step.
- the removal of water droplets can be performed using, for example, a pinch roll or an air knife.
- a drying process is a process of drying an optical film laminated body and adjusting the moisture content of the polarizing film contained in an optical film laminated body, and can be implemented as needed.
- the drying step is preferably performed at the end of the series of steps.
- Drying can be carried out by a known method such as air drying or heat drying.
- Drying conditions such as drying time and drying temperature in heat drying may be determined according to a desired moisture content.
- the upper limit of the heat temperature in heat drying is usually about 80 ° C.
- the heating temperature is preferably relatively low.
- the drying time in the heat drying is usually about 1 minute to about 10 minutes.
- the optical film laminate may be exposed to dry air in order to promote drying.
- thermoplastic resin substrate Arbitrary appropriate thermoplastic resins may be employ
- the thermoplastic resin include ester resins such as polyethylene terephthalate resins, cycloolefin resins such as norbornene resins, olefin resins such as polypropylene, polyamide resins, polycarbonate resins, and copolymer resins thereof. Can be mentioned. Among these, preferred are norbornene resins and amorphous (non-crystallized) polyethylene terephthalate resins.
- amorphous (non-crystallized) polyethylene terephthalate resins amorphous (hard to crystallize) polyethylene terephthalate resins are particularly preferably used.
- Specific examples of the amorphous polyethylene terephthalate resin include a copolymer further containing isophthalic acid as a dicarboxylic acid, and a copolymer further containing cyclohexanedimethanol as a glycol.
- thermoplastic resin base material As a thermoplastic resin base material, it is only necessary to be able to stretch integrally with the PVA resin layer in the stretching process. Even if it is a single layer body, it is a single polymeric material, or at least two or more types of materials.
- a multilayer laminate in which the polymer material is laminated may be used.
- the polymeric material may be a homopolymer, a copolymer, or a blend polymer.
- the component which consists of an inorganic material and / or an organic material may be added in the said polymeric material.
- the base material those having functions such as reflection characteristics, light scattering properties, optical characteristics such as hue adjustment, antistatic, and antiblocking may be used.
- an easy-adhesion layer may be applied on the substrate, or a material that assists adhesion may be added to the polymeric material.
- the thermoplastic resin substrate absorbs water, and the water can act as a plasticizer to be plasticized.
- the stretching stress can be greatly reduced, the film can be stretched at a high magnification, and the stretchability can be superior to that during air stretching.
- a polarizing film having excellent optical characteristics can be produced.
- the water absorption rate of the thermoplastic resin substrate is preferably 0.2% or more, and more preferably 0.3% or more.
- the water absorption rate of the thermoplastic resin substrate is preferably 3.0% or less, more preferably 1.0% or less.
- thermoplastic resin substrate By using such a thermoplastic resin substrate, it is possible to prevent problems such as a significant decrease in dimensional stability during production and deterioration of the appearance of the resulting polarizing film. Moreover, it can prevent that a base material fractures
- the water absorption rate of the thermoplastic resin substrate can be adjusted, for example, by introducing a modifying group into the forming material.
- the water absorption is a value determined according to JIS K 7209.
- the glass transition temperature (Tg) of the thermoplastic resin substrate is preferably 170 ° C. or lower.
- Tg The glass transition temperature of the thermoplastic resin substrate.
- the temperature is more preferably 120 ° C. or lower.
- the glass transition temperature of the resin substrate is preferably 60 ° C. or higher.
- the stretching of the polyvinyl alcohol-based resin layer can be favorably performed at a suitable temperature (for example, about 60 ° C.).
- a suitable temperature for example, about 60 ° C.
- the glass transition temperature lower than 60 ° C. may be used as long as the thermoplastic resin substrate is not deformed.
- the glass transition temperature of the thermoplastic resin substrate can be adjusted by, for example, introducing a modifying group into the forming material or heating it with a crystallization material.
- the glass transition temperature (Tg) is a value determined according to JIS K7121.
- the thickness of the thermoplastic resin substrate before stretching is preferably 20 ⁇ m to 300 ⁇ m, more preferably 50 ⁇ m to 200 ⁇ m. If it is less than 20 ⁇ m, it may be difficult to form a polyvinyl alcohol thermoplastic thermoplastic resin layer. On the other hand, if it exceeds 300 ⁇ m, for example, in stretching in boric acid solution, it takes a long time for the thermoplastic resin substrate to absorb water, and an excessive load may be required for stretching.
- the polyvinyl alcohol-based resin layer included in the laminate of the present invention or the stretched polyvinyl alcohol-based resin layer included in the stretched laminate includes a polyvinyl alcohol-based resin and glycerin.
- any appropriate resin can be adopted as the polyvinyl alcohol resin.
- Examples thereof include polyvinyl alcohol and ethylene-vinyl alcohol copolymer.
- Polyvinyl alcohol is obtained by saponifying polyvinyl acetate.
- the ethylene-vinyl alcohol copolymer can be obtained by saponifying an ethylene-vinyl acetate copolymer.
- the degree of saponification of the polyvinyl alcohol resin is usually 85 to 100 mol%, preferably 95.0 to 99.95 mol%, more preferably 99.0 to 99.93 mol%. is there.
- the degree of saponification can be determined according to JIS K 6726-1994. By using a polyvinyl alcohol resin having such a saponification degree, a polarizing film having excellent durability can be obtained. If the degree of saponification is too high, there is a risk of gelation.
- the polyvinyl alcohol-based resin may partially contain modified polyvinyl alcohol containing a modifying group in the side chain.
- modified group of the modified polyvinyl alcohol include an acetoacetyl group, a carbonyl group, a carboxyl group, and an alkyl group.
- the degree of modification of the modified polyvinyl alcohol is not particularly limited, but is preferably 0.1 to 10 mol%.
- the amount of the modified polyvinyl alcohol added is preferably 0.1 mol% to 30 mol%.
- the degree of modification and the amount added may be appropriately set. it can.
- the average degree of polymerization of the polyvinyl alcohol resin can be appropriately selected according to the purpose.
- the average degree of polymerization is usually 1000 to 10000, preferably 1200 to 5000, and more preferably 1500 to 4500.
- the average degree of polymerization can be determined according to JIS K 6726-1994.
- the amount of glycerin added to the polyvinyl alcohol resin layer contained in the laminate is preferably such that the molar ratio of glycerin to polyvinyl alcohol resin in the polyvinyl alcohol resin layer is 1.0 or more and 15 or less, and is 2.0 or more. An amount that is 8.0 or less is more preferable.
- the stretched laminate is only a dry stretch of the laminate, the molar ratio of glycerin to the polyvinyl alcohol resin in the stretched polyvinyl alcohol resin layer contained in the stretched laminate is It is not different from the molar ratio of glycerin to polyvinyl alcohol resin in the included polyvinyl alcohol resin layer.
- the molar ratio of glycerin to the polyvinyl alcohol-based resin in the stretched polyvinyl alcohol-based resin layer included in the stretched laminate is also preferably 1.0 or more and 15 or less, and more preferably 2.0 or more and 8.0 or less. preferable.
- the addition of glycerin in an amount such that the molar ratio of glycerin to polyvinyl alcohol resin is 1.0 or more in the polyvinyl alcohol resin layer improves the optical properties of the polarizing film as compared to the case where it is not added.
- the amount of glycerin added is increased, the optical properties are further improved.
- the amount of glycerin added is a certain value or more, the improvement of the optical properties is saturated.
- the amount of glycerin to be added is further increased and the molar ratio of glycerin to the polyvinyl alcohol resin contained in the polyvinyl alcohol resin exceeds 15, the film surface becomes sticky.
- the polarizing film of the present invention is composed of a polyvinyl alcohol-based resin layer in which the dichroic material contained in the optical film laminate obtained by the production method of the present invention is oriented. That is, the polarizing film is prepared by stretching a polyvinyl alcohol-based resin film impregnated and adsorbed with a dichroic substance in a dyeing process and orienting the impregnated dichroic substance.
- iodine molecules (I 2 ) are not dissolved in water only with iodine molecules. Therefore, iodine and potassium iodide aqueous solution are prepared by dissolving iodine in water together with potassium iodide (KI).
- polyiodine ions I 3 ⁇ and I 5 ⁇ in which iodine ions and iodine molecules are combined exist.
- iodine ions and polyiodine ions penetrate into the polyvinyl alcohol resin layer and are adsorbed by the molecules of the polyvinyl alcohol resin.
- the polyiodine ions are also oriented in the stretching direction.
- the oriented polyiodine ions have different incident light transmittances depending on the angle of the polarization direction of the incident light with respect to the orientation direction of the polyiodine ions. Therefore, the dyed and stretched polyvinyl alcohol resin layer functions as a polarizer. .
- the polarizing film contains at least a polyvinyl alcohol-based resin and polyiodine ions.
- the polyiodine ion exists in a state where a polyvinyl alcohol (PVA) -iodine complex (PVA ⁇ I 3 ⁇ or PVA ⁇ I 5 ⁇ ) is formed in the polarizer by interaction with the polyvinyl alcohol resin molecule.
- PVA polyvinyl alcohol
- I ⁇ I 3 ⁇ or PVA ⁇ I 5 ⁇ polyvinyl alcohol
- Iodine ion (I ⁇ ) has an absorption peak around 230 nm.
- triiodide ion (PVA ⁇ I 3 ⁇ ) in a complex state with polyvinyl alcohol has an absorption peak in the vicinity of 470 nm.
- the absorption peak of pentaiodide ion (PVA ⁇ I 5 ⁇ ) in a complex state with polyvinyl alcohol exists in the vicinity of 600 nm.
- the wavelength of light to be absorbed changes, so that the absorption peak of polyiodine ions is wide.
- a PVA-iodine complex absorbs visible light.
- iodine ions do not absorb visible light because they have a peak near 230 nm. Therefore, the polyiodine ion complexed with polyvinyl alcohol affects the performance of the polarizing film.
- the thickness of the polarizing film of the present invention is preferably 10 ⁇ m or less, more preferably 7 ⁇ m or less, and even more preferably 5 ⁇ m or less.
- Example 10 The laminate, stretched laminate, stretched laminate production method, optical film laminate production method, and polarizing film of the present invention will be further described using the following examples.
- stretching laminated body, the manufacturing method of an optical film laminated body, and a polarizing film are not limited only to these Examples.
- amorphous PET Amorphous isophthalic acid copolymerized polyethylene terephthalate (hereinafter referred to as “amorphous PET”) film having a long length, water absorption of 0.60% and glass transition temperature (Tg) of 80 ° C. as a thermoplastic resin substrate (Thickness: 100 ⁇ m) was used.
- Polyvinyl alcohol aqueous solution is composed of polyvinyl alcohol having a polymerization degree of 4200 and a saponification degree of 99.2 mol%, an acetoacetyl-modified polyvinyl alcohol (trade name “Gosefimer Z200” (registered trademark) manufactured by Nippon Synthetic Chemical Industry Co., Ltd.) (average polymerization 1200, saponification degree 98.5 mol%, acetoacetyl degree 5 mol%)) in a 9: 1 mixture, and the molar ratio of glycerin (molecular weight 93) to the polyvinyl alcohol resin (average molecular weight 44).
- glycerin so as to be 2.4 mol.
- the polyvinyl alcohol concentration in the polyvinyl alcohol aqueous solution was 4 w%.
- the obtained aqueous polyvinyl alcohol solution was applied onto an amorphous PET substrate and dried at 60 ° C. to prepare a laminate on which a polyvinyl alcohol resin layer having a thickness of 12 ⁇ m was formed.
- the obtained laminate was subjected to the following steps including a two-step stretching process of air-assisted stretching and boric acid-water stretching to produce a polarizing film having a thickness of 5 ⁇ m.
- the obtained laminate was uniaxially stretched 1.8 times in the longitudinal direction (longitudinal direction) between rolls having different peripheral speeds in an oven at 120 ° C., and stretched with an amorphous PET substrate.
- a stretched laminate including a polyvinyl alcohol-based resin layer was obtained (air auxiliary stretching step).
- the polyvinyl alcohol resin layer was changed to a vinyl alcohol resin layer in which polyvinyl alcohol molecules were oriented.
- the obtained stretched laminate was immersed for 30 seconds in an insolubilizing bath (a boric acid aqueous solution obtained by blending 4 parts by weight of boric acid with respect to 100 parts by weight of water) at a liquid temperature of 30 ° C. 1 insolubilization step).
- an insolubilizing bath a boric acid aqueous solution obtained by blending 4 parts by weight of boric acid with respect to 100 parts by weight of water
- the stretched laminate subjected to the first insolubilization treatment was adjusted to an iodine concentration so that the transmittance of the polarizing plate was an arbitrary value, and a dyeing bath having a liquid temperature of 30 ° C. (for 100 parts by weight of water, Iodine aqueous solution containing iodine and potassium iodide in a weight ratio of 1: 7) was dipped for 60 seconds to produce a colored laminate in which polyiodine ions were adsorbed on the stretched polyvinyl alcohol resin layer (dyeing step) .
- the colored laminate obtained was mixed with a crosslinking bath having a liquid temperature of 30 ° C. (boric acid obtained by blending 3 parts by weight of potassium iodide and 3 parts by weight of boric acid with respect to 100 parts by weight of water) It was immersed in an aqueous solution for 30 seconds (crosslinking step).
- the colored laminate subjected to the crosslinking treatment was obtained by mixing 4 parts by weight of boric acid and 5 parts by weight of potassium iodide with respect to 100 parts by weight of boric acid aqueous solution having a liquid temperature of 70 ° C.
- the uniaxial stretching is performed so that the total stretching ratio of air-assisted stretching and boric acid-water stretching is 6.0 times.
- An optical film laminate was obtained (boric acid underwater stretching step).
- boric acid underwater stretching treatment the vinyl alcohol resin layer contained in the colored laminate was changed to a 5 ⁇ m thick vinyl alcohol resin layer in which the adsorbed polyiodide ions were oriented.
- the vinyl alcohol resin layer in which the polyiodine ions are aligned constitutes a polarizing film of the optical film laminate.
- the obtained optical film laminate was immersed in a washing bath having a liquid temperature of 30 ° C. (an aqueous solution obtained by blending 4 parts by weight of potassium iodide with respect to 100 parts by weight of water) (washing step). .
- the cleaned optical film laminate was dried with hot air at 60 ° C. (drying process).
- the thickness of the polarizing film contained in the obtained optical film laminate was 5 ⁇ m.
- an aqueous polyvinyl alcohol resin solution manufactured by Nippon Synthetic Chemical Industry Co., Ltd., trade name “Gosefimer Z200”, resin concentration: 3% by weight
- a triacetyl cellulose film Konica Minolta, trade name “KC4UY”, thickness 40 ⁇ m
- the polarizing film was transferred to a triacetyl cellulose film to produce an optical laminate (polarizing plate).
- the amount of iodine adsorbed was adjusted by changing the iodine concentration of the aqueous iodine solution in the dyeing process so that the single transmittance of the finally produced polarizing film was 40 to 44%.
- Optical film laminates containing various polarizing films with different transmittance and degree of polarization were produced.
- the obtained polarizing film (optical laminate) and the laminate obtained after the coating / drying process of the polyvinyl alcohol aqueous solution to which glycerin was added onto the amorphous PET substrate were subjected to various evaluations as follows. It was. The characteristics of the obtained polarizing film are shown in FIG. 1, and the characteristics of the polarizing film having a polarization degree P of 99.99% estimated from the graph of FIG. 1 and the amorphous PET group of the polyvinyl alcohol aqueous solution to which glycerin is added. Table 1 shows the properties of the laminate obtained after the coating / drying process on the material.
- Example 2 A polarizing film (optical laminate) was produced under the same conditions as in Example 1 except that the molar ratio of glycerin to polyvinyl alcohol resin in the aqueous polyvinyl alcohol solution applied to the amorphous PET substrate was 4.7.
- Various evaluations were performed as follows.
- the characteristics of the obtained polarizing film are shown in FIG. 1, and the characteristics of the polarizing film having a polarization degree P of 99.99% estimated from the graph of FIG. 1 and the amorphous PET group of the polyvinyl alcohol aqueous solution to which glycerin is added.
- Table 1 shows the properties of the laminate obtained after the coating / drying process on the material.
- Example 3 A polarizing film (optical laminate) was produced under the same conditions as in Example 1 except that the molar ratio of glycerin to polyvinyl alcohol resin in the aqueous polyvinyl alcohol solution applied to the amorphous PET substrate was 7.1.
- Various evaluations were performed as follows.
- the characteristics of the obtained polarizing film are shown in FIG. 1, and the characteristics of the polarizing film having a polarization degree P of 99.99% estimated from the graph of FIG. 1 and the amorphous PET group of the polyvinyl alcohol aqueous solution to which glycerin is added.
- Table 1 shows the properties of the laminate obtained after the coating / drying process on the material.
- Example 4 A polyvinyl alcohol aqueous solution to which glycerin was added under the same conditions as in Example 1 except that the molar ratio of glycerin to polyvinyl alcohol resin in the aqueous polyvinyl alcohol solution applied to the amorphous PET substrate was 9.5.
- the film was coated on a crystalline PET substrate and dried, and the stickiness of the film was evaluated as follows.
- Table 1 shows the properties of the laminate obtained after the coating / drying step of the aqueous polyvinyl alcohol solution to which glycerin was added on the amorphous PET substrate.
- Example 5 A polyvinyl alcohol aqueous solution to which glycerin was added under the same conditions as in Example 1 except that the molar ratio of glycerin to polyvinyl alcohol resin in the aqueous polyvinyl alcohol solution applied to the amorphous PET substrate was 11.8.
- the film was coated on a crystalline PET substrate and dried, and the stickiness of the film was evaluated as follows.
- Table 1 shows the properties of the laminate obtained after the coating / drying step of the aqueous polyvinyl alcohol solution to which glycerin was added on the amorphous PET substrate.
- Example 6 A polyvinyl alcohol aqueous solution to which glycerin was added under the same conditions as in Example 1 except that the molar ratio of glycerin to polyvinyl alcohol resin in the polyvinyl alcohol aqueous solution applied to the amorphous PET substrate was 14.2. The film was coated on a crystalline PET substrate and dried, and the stickiness of the film was evaluated as follows.
- Table 1 shows the properties of the laminate obtained after the coating / drying step of the aqueous polyvinyl alcohol solution to which glycerin was added on the amorphous PET substrate.
- Example 7 A polyvinyl alcohol aqueous solution to which glycerin was added under the same conditions as in Example 1 except that the molar ratio of glycerin to polyvinyl alcohol resin in the polyvinyl alcohol aqueous solution applied to the amorphous PET substrate was 23.7.
- the film was coated on a crystalline PET substrate and dried, and the stickiness of the film was evaluated as follows.
- Table 1 shows the properties of the laminate obtained after the coating / drying step of the aqueous polyvinyl alcohol solution to which glycerin was added on the amorphous PET substrate.
- Example 8 A polyvinyl alcohol aqueous solution to which glycerin was added under the same conditions as in Example 1 was used except that the molar ratio of glycerin to polyvinyl alcohol resin in the polyvinyl alcohol aqueous solution applied to the amorphous PET substrate was 33.1. The film was coated on a crystalline PET substrate and dried, and the stickiness of the film was evaluated as follows.
- Table 1 shows the properties of the laminate obtained after the coating / drying step of the aqueous polyvinyl alcohol solution to which glycerin was added on the amorphous PET substrate.
- a polarizing film (optical laminate) was produced under the same conditions as in Example 1 except that glycerin was not added to the polyvinyl alcohol aqueous solution applied to the amorphous PET substrate, and various evaluations were performed as follows. .
- the characteristics of the obtained polarizing film are shown in FIG. 1, and the characteristics of the polarizing film having a polarization degree P of 99.99% estimated from the graph of FIG. 1 and the amorphous PET group of the polyvinyl alcohol aqueous solution to which glycerin is added.
- Table 1 shows the properties of the laminate obtained after the coating / drying process on the material.
- Polarization degree P (%) ⁇ (Tp ⁇ Tc) / (Tp + Tc) ⁇ 1/2 ⁇ 100
- the substrate is provided with functions that affect the transmission characteristics such as reflection characteristics, light scattering properties, and hue adjustment, only the polyvinyl alcohol resin layer containing a dichroic substance such as iodine is measured.
- glycerin is added to an aqueous polyvinyl alcohol solution to be applied to an amorphous PET substrate, and the molar ratio of glycerin to polyvinyl alcohol resin contained in the polyvinyl alcohol resin is 1.0 or more.
- the polarizing film obtained when it is added has improved optical characteristics (relationship between the single transmittance T and the degree of polarization P) and is added compared to the polarizing film obtained when glycerin is not added. It was found that as the amount of glycerin increases, the optical properties of the polarizing film are further improved, and when the amount of added glycerin exceeds at least 4.7, the improvement of the optical properties of the polarizing film is saturated.
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Abstract
Description
本発明の積層体は、熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層とを含み、前記熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層が前記熱可塑性樹脂基材と共に延伸された後に行われる後工程であって、ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む後工程によって、該後工程による処理がされたポリビニルアルコール系樹脂層からなる偏光膜を形成するために使用される。
本発明の延伸積層体は、熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層とを含み、ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む後工程によって、該後工程による処理がされたポリビニルアルコール系樹脂層からなる偏光膜を形成するために使用される。熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層は、熱可塑性樹脂基材と共に延伸されたものであり、該延伸は、空中延伸(乾式延伸)とすることができる。
本発明の延伸積層体のロール(原反)は、巻取装置によって、延伸積層体を巻き取ることにより形成されたものである。
本発明の光学フィルム積層体の製造方法は、熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜された、ポリビニルアルコール系樹脂とグリセリンを含むポリビニルアルコール系樹脂層とを含む積層体に対する延伸によって、熱可塑性樹脂基材と延伸されたポリビニルアルコール系樹脂層とを含む延伸積層体を生成する工程と、ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む後工程と、を含み、前記後工程によって処理がされたポリビニルアルコール系樹脂層からなる偏光膜と熱可塑性樹脂基材を含む光学フィルム積層体を生成する。
本発明の空中延伸は、気体中で行われるいわゆる乾式延伸である。その気体は、通常、空気であるが、窒素ガス等の不活性ガスであってもよい。延伸の方法としては、特に限定されず、ロール延伸、又はテンター延伸等の、フィルム延伸に通常用いられている延伸加工法を採用することができる。また、当該延伸は、縦方向又は横方向の一方向の延伸(一軸延伸)でもよく、二軸延伸でも、斜め延伸でもよい。空中延伸の延伸倍率は、1.5倍以上3.5倍以下とすることが好ましく、1.8倍以上3.0倍以下とすることがさらに好ましい。また、空中延伸の延伸温度は、100℃以上150℃以下とすることが好ましい。
本発明における後工程は、ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む。この後工程によって処理がされたポリビニルアルコール系樹脂層からなる偏光膜と熱可塑性樹脂基材を含む光学フィルム積層体が生成される。
本発明における染色工程は、ポリビニルアルコール系樹脂層を二色性物質により染色し、着色積層体を生成する工程である。
本発明のホウ酸水中延伸工程は、染色された延伸積層体(着色積層体)をホウ酸水溶液に浸漬させながら少なくとも長手方向に延伸する工程である。ホウ酸水中延伸工程は、2段延伸法の第2段目の延伸工程とすることができる。このホウ酸水中延伸工程によって、着色積層体に含まれるポリビニルアルコール系樹脂層は、吸着されたポリヨウ素イオンが配向されたビニルアルコール系樹脂層へと変化する。このポリヨウ素イオンが配向されたポリビニルアルコール系樹脂層が光学フィルム積層体の偏光膜を構成する。
所望により実施される工程として、例えば、第1の不溶化工程、架橋工程、第2の不溶化工程、洗浄工程、水滴除去工程、乾燥工程があり、以下順に説明する。
第1の不溶化工程は、染色工程前に、延伸積層体をホウ酸水溶液に浸漬する工程であり、少なくとも後工程の染色工程において延伸積層体に含まれる延伸されたポリビニルアルコール系樹脂層が溶解することを防止するものである。このホウ酸水溶液の濃度、液温、浸漬時間は、好ましくは、水100質量部当たり1質量部~5質量部、10℃以上50℃以下、1秒以上300秒以下である。
架橋工程は、好ましくは、染色工程の後に実施され、(1)後工程のホウ酸水中延伸において着色積層体に含まれる延伸されたポリビニルアルコール系樹脂層を溶解させないようにすること、(2)延伸されたポリビニルアルコール系樹脂層に着色されたヨウ素を溶出させないようにすること、(3)延伸されたポリビニルアルコール系樹脂層の分子同士を架橋することによって結節点を生成することを主な目的として延伸されたビニルアルコール系樹脂層に含まれるポリビニルアルコール分子同士を架橋させる工程であり、必要に応じて、実施することができる。
第2の不溶化工程は、架橋工程後ホウ酸水中延伸工程前に、着色積層体をホウ酸水溶液に浸漬する工程であり、少なくとも後工程のホウ酸水中延伸工程において着色積層体に含まれる延伸されたポリビニルアルコール系樹脂層が溶解することを防止するものである。このホウ酸水溶液の濃度、液温、浸漬時間は、好ましくは、水100質量部当たり1質量部~6質量部、10℃以上60℃以下、1秒以上300秒以下である。
洗浄工程は、ホウ酸水中延伸工程におけるホウ酸水溶液から取り出された光学フィルム積層体に含まれる偏光膜の表面に付着した不要残存物を洗い流す工程であり、必要に応じて、実施することができる。
水滴除去工程は、延伸されたポリビニルアルコール系樹脂層の表面に付着した余分な水滴を除去する工程であり、必要に応じて、実施することができる。
乾燥工程は、光学フィルム積層体を乾燥して、光学フィルム積層体に含まれる偏光膜の水分率を調整する工程であり、必要に応じて、実施することができる。
本発明に用いる熱可塑性樹脂基材は、任意の適切な熱可塑性樹脂が採用され得る。熱可塑性樹脂としては、例えば、ポリエチレンテレフタレート系樹脂等のエステル系樹脂、ノルボルネン系樹脂等のシクロオレフィン系樹脂、ポリプロピレン等のオレフィン系樹脂、ポリアミド系樹脂、ポリカーボネート系樹脂、これらの共重体樹脂等が挙げられる。これらの中でも、好ましくは、ノルボルネン系樹脂、非晶質の(結晶化していない)ポリエチレンテレフタレート系樹脂である。
本発明の積層体に含まれるポリビニルアルコール系樹脂層又は延伸積層体に含まれる延伸されたポリビニルアルコール系樹脂層は、ポリビニルアルコール系樹脂とグリセリンを含む。
上述のように、本発明の偏光膜は、本発明の製造方法によって得られる光学フィルム積層体に含まれる二色性物質を配向させたポリビニルアルコール系樹脂層から構成される。すなわち、偏光膜は、二色性物質を染色工程により含浸及び吸着させたポリビニルアルコール系樹脂フィルムを延伸して、含浸された二色性物質を配向させることにより作成される。
本発明の積層体、延伸積層体、延伸積層体の製造方法、光学フィルム積層体の製造方法、及び偏光膜について、以下の実施例を用いて更に説明する。なお、本発明の積層体、延伸積層体、延伸積層体の製造方法、光学フィルム積層体の製造方法、偏光膜は、これらの実施例のみに限定されるものではない。
熱可塑性樹脂基材として、長尺状で、吸水率0.60%、ガラス転移温度(Tg)80℃の非晶質のイソフタル酸共重合ポリエチレンテレフタレート(以下、「非晶質PET」という)フィルム(厚み:100μm)を用いた。
非晶質PET基材に塗工するポリビニルアルコール水溶液におけるポリビニルアルコール樹脂に対するグリセリンのモル比が4.7である点を除き、実施例1と同様の条件で偏光膜(光学積層体)を製造し、以下のように各種評価を行った。
非晶質PET基材に塗工するポリビニルアルコール水溶液におけるポリビニルアルコール樹脂に対するグリセリンのモル比が7.1である点を除き、実施例1と同様の条件で偏光膜(光学積層体)を製造し、以下のように各種評価を行った。
非晶質PET基材に塗工するポリビニルアルコール水溶液におけるポリビニルアルコール樹脂に対するグリセリンのモル比が9.5である点を除き、実施例1と同様の条件でグリセリンが添加されたポリビニルアルコール水溶液を非晶質PET基材に塗工し、乾燥させ、以下のようにフィルムのべたつき性評価を行った。
非晶質PET基材に塗工するポリビニルアルコール水溶液におけるポリビニルアルコール樹脂に対するグリセリンのモル比が11.8である点を除き、実施例1と同様の条件でグリセリンが添加されたポリビニルアルコール水溶液を非晶質PET基材に塗工し、乾燥させ、以下のようにフィルムのべたつき性評価を行った。
非晶質PET基材に塗工するポリビニルアルコール水溶液におけるポリビニルアルコール樹脂に対するグリセリンのモル比が14.2である点を除き、実施例1と同様の条件でグリセリンが添加されたポリビニルアルコール水溶液を非晶質PET基材に塗工し、乾燥させ、以下のようにフィルムのべたつき性評価を行った。
非晶質PET基材に塗工するポリビニルアルコール水溶液におけるポリビニルアルコール樹脂に対するグリセリンのモル比が23.7である点を除き、実施例1と同様の条件でグリセリンが添加されたポリビニルアルコール水溶液を非晶質PET基材に塗工し、乾燥させ、以下のようにフィルムのべたつき性評価を行った。
非晶質PET基材に塗工するポリビニルアルコール水溶液におけるポリビニルアルコール樹脂に対するグリセリンのモル比が33.1である点を除き、実施例1と同様の条件でグリセリンが添加されたポリビニルアルコール水溶液を非晶質PET基材に塗工し、乾燥させ、以下のようにフィルムのべたつき性評価を行った。
非晶質PET基材に塗工するポリビニルアルコール水溶液にグリセリンを添加しない点を除き、実施例1と同様の条件で偏光膜(光学積層体)を製造し、以下のように各種評価を行った。
(厚みの測定方法)
非晶質PET基材及びポリビニルアルコール樹脂層の厚みは、デジタルマイクロメーター(アンリツ社製KC-351C)を用いて測定した。
実施例及び比較例で得られた光学積層体に対して、紫外可視分光光度計(日本分光社製V7100)を用いることによって、偏光膜の単体透過率T、平行透過率Tp、直交透過率Tcを測定した。これらのT、Tp、Tcは、JIS Z 8701の2度視野(C光源)により測定して視感度補正を行なったY値である。
また、偏光度Pを上記の透過率を用い、次式により求めた。
偏光度P(%)={(Tp-Tc)/(Tp+Tc)}1/2×100
なお基材に、反射特性や光散乱性、色相調整など、透過特性に影響する機能が付与されている場合には、ヨウ素等の二色性物質を含むポリビニルアルコール系樹脂層のみを測定する。
図1及び表1を参照すると、非晶質PET基材に塗工するポリビニルアルコール水溶液にグリセリンを、ポリビニルアルコール系樹脂に含まれるポリビニルアルコール系樹脂に対するグリセリンのモル比が1.0以上の量で添加した場合に得られた偏光膜は、グリセリンを添加しなかった場合に得られた偏光膜よりも光学特性(単体透過率Tと偏光度Pとの関係)が向上し、また、添加されるグリセリンの量が多くなるほど、偏光膜の光学特性はより向上し、添加されるグリセリンの量が少なくとも4.7を超えると、偏光膜の光学特性の向上は飽和することが分かった。
上述のとおり、非晶質PET基材に塗工するポリビニルアルコール水溶液に添加するグリセリンの量が大きくなると、フィルム表面がべたつく。そこで、グリセリンが添加されたポリビニルアルコール水溶液の非晶質PET基材上への塗工・乾燥工程後に得られた積層体のべたつき性を触手及び積層体を重ね合わせた場合の接着性により評価した。結果を表1に示す。表1を参照すると、ポリビニルアルコール系樹脂に含まれるポリビニルアルコール系樹脂に対するグリセリンのモル比が、15を超えると、フィルム表面がべたつくことが分かった。
Claims (32)
- 熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層とを含み、前記熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層が前記熱可塑性樹脂基材と共に延伸された後に行われる後工程であって、ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む後工程によって、該後工程による処理がされたポリビニルアルコール系樹脂層からなる偏光膜を形成するために使用される積層体であって、
前記ポリビニルアルコール系樹脂層は、ポリビニルアルコール系樹脂とグリセリンを含む積層体。 - 前記後工程は、ポリビニルアルコール系樹脂層を延伸する最終延伸工程を更に含む請求項1に記載の積層体。
- 前記ポリビニルアルコール系樹脂に対する前記グリセリンのモル比が、1.0以上15以下である請求項1又は2に記載の積層体。
- 熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層とを含み、ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む後工程によって、該後工程による処理がされたポリビニルアルコール系樹脂層からなる偏光膜を形成するために使用される延伸積層体であって、
前記ポリビニルアルコール系樹脂層は、ポリビニルアルコール系樹脂とグリセリンを含み、
前記熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層は、熱可塑性樹脂基材と共に延伸されたものである、
延伸積層体。 - 前記後工程は、ポリビニルアルコール系樹脂層を延伸する最終延伸工程を更に含む請求項8に記載の延伸積層体。
- 前記ポリビニルアルコール系樹脂に対する前記グリセリンのモル比が、1.0以上15以下である請求項4又は5に記載の延伸積層体。
- 前記熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層は、熱可塑性樹脂基材と共に空中延伸されたものである請求項4~6のいずれか1項に記載の延伸積層体。
- 前記空中延伸の延伸倍率は、1.5倍以上3.5倍以下である請求項7に記載の延伸積層体。
- 前記空中延伸の延伸温度は、100℃以上150℃以下である請求項8に記載の延伸積層体。
- 前記後工程は、
ポリビニルアルコール系樹脂層を二色性物質により染色し、着色積層体を生成する染色工程と、
着色積層体を、ホウ酸水溶液中において延伸するホウ酸水中延伸工程と、
を少なくとも含む請求項4~9のいずれか1項に記載の延伸積層体。 - 前記偏光膜の厚みが、10μm以下である請求項4~10のいずれか1項に記載の延伸積層体。
- 前記偏光膜の厚みが、7μm以下である請求項4~10のいずれか1項に記載の延伸積層体。
- 前記偏光膜の厚みが、5μm以下である請求項4~10のいずれか1項に記載の延伸積層体。
- 請求項4~13のいずれか1項に記載の延伸積層体をロール状に巻き取ることにより形成された延伸積層体のロール。
- 熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜されたポリビニルアルコール系樹脂層とを含み、ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む後工程によって、該後工程による処理がされたポリビニルアルコール系樹脂層からなる偏光膜を形成するために使用される延伸積層体の製造方法であって、
熱可塑性樹脂基材上に、グリセリンを含むポリビニルアルコール系樹脂塗工液を塗布して、前記熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜された、ポリビニルアルコール系樹脂とグリセリンを含むポリビニルアルコール系樹脂層とを含む積層体を生成する工程と、
前記積層体に対する延伸によって、延伸積層体を生成する工程と、
を含む延伸積層体の製造方法。 - 前記後工程は、ポリビニルアルコール系樹脂層を延伸する最終延伸工程を更に含む請求項15に記載の延伸積層体の製造方法。
- 前記積層体に含まれる前記ポリビニルアルコール系樹脂に含まれる前記ポリビニルアルコール系樹脂に対する前記グリセリンのモル比が、1.0以上15以下である請求項15又は16に記載の延伸積層体の製造方法。
- 前記積層体に対する延伸は、空中延伸である請求項15~17のいずれか1項に記載の延伸積層体の製造方法。
- 前記空中延伸の延伸倍率は、1.5倍以上3.5倍以下である請求項18に記載の延伸積層体の製造方法。
- 前記空中延伸の延伸温度は、100℃以上150℃以下である請求項19に記載の延伸積層体の製造方法。
- 請求項15~20のいずれか1項に記載の延伸積層体の製造方法によって製造された延伸積層体をロール状に巻き取ることにより延伸積層体のロールを形成する工程を含む延伸積層体のロールの製造方法。
- 熱可塑性樹脂基材と、該熱可塑性樹脂基材上に製膜された、ポリビニルアルコール系樹脂とグリセリンを含むポリビニルアルコール系樹脂層とを含む積層体に対する延伸によって、熱可塑性樹脂基材と延伸されたポリビニルアルコール系樹脂層とを含む延伸積層体を生成する工程と、
ポリビニルアルコール系樹脂層を二色性物質により染色する染色工程を少なくとも含む後工程と、
を含み、
前記後工程によって処理がされたポリビニルアルコール系樹脂層からなる偏光膜と熱可塑性樹脂基材を含む光学フィルム積層体を生成する光学フィルム積層体の製造方法。 - 前記後工程は、ポリビニルアルコール系樹脂層を延伸する最終延伸工程を更に含む請求項22に記載の光学フィルム積層体の製造方法。
- 前記積層体に含まれる前記ポリビニルアルコール系樹脂に含まれる前記ポリビニルアルコール系樹脂に対する前記グリセリンのモル比が、1.0以上15以下である請求項22又は23に記載の光学フィルム積層体の製造方法。
- 前記積層体に対する延伸は、空中延伸である請求項22~24のいずれか1項に記載の延伸積層体の製造方法。
- 前記空中補助延伸の延伸倍率は、1.5倍以上3.5倍以下である請求項25に記載の光学フィルム積層体の製造方法。
- 前記空中補助延伸の延伸温度は、100℃以上150℃以下である請求項26に記載の光学フィルム積層体の製造方法。
- 前記後工程は、
ポリビニルアルコール系樹脂層を二色性物質により染色し、着色積層体を生成する染色工程と、
着色積層体を、ホウ酸水溶液中において延伸するホウ酸水中延伸工程と、
を少なくとも含む請求項22~27のいずれか1項に記載の光学フィルム積層体の製造方法。 - 前記偏光膜の厚みが、10μm以下である請求項22~28のいずれか1項に記載の光学フィルム積層体の製造方法。
- 前記偏光膜の厚みが、7μm以下である請求項22~28のいずれか1項に記載の光学フィルム積層体の製造方法。
- 前記偏光膜の厚みが、5μm以下である請求項22~28のいずれか1項に記載の光学フィルム積層体の製造方法。
- 請求項22~31のいずれか1項に記載の光学フィルム積層体の製造方法により製造された偏光膜。
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JPWO2020184083A1 (ja) * | 2019-03-08 | 2021-11-25 | 日東電工株式会社 | 偏光膜、偏光板、および該偏光膜の製造方法 |
JP7267396B2 (ja) | 2019-03-08 | 2023-05-01 | 日東電工株式会社 | 偏光膜、偏光板、および該偏光膜の製造方法 |
JPWO2021095527A1 (ja) * | 2019-11-11 | 2021-05-20 | ||
JPWO2021095526A1 (ja) * | 2019-11-11 | 2021-05-20 |
Also Published As
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KR101890221B1 (ko) | 2018-08-22 |
JP6216442B2 (ja) | 2017-10-18 |
TW201534993A (zh) | 2015-09-16 |
JPWO2015137515A1 (ja) | 2017-04-06 |
US20160377774A1 (en) | 2016-12-29 |
CN106104326B (zh) | 2018-10-12 |
KR20160129877A (ko) | 2016-11-09 |
CN106104326A (zh) | 2016-11-09 |
TWI548899B (zh) | 2016-09-11 |
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