WO2016052732A1 - 光学フィルム積層体、その光学フィルム積層体を用いた光学的表示装置、及び透明保護フィルム - Google Patents
光学フィルム積層体、その光学フィルム積層体を用いた光学的表示装置、及び透明保護フィルム Download PDFInfo
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- WO2016052732A1 WO2016052732A1 PCT/JP2015/078056 JP2015078056W WO2016052732A1 WO 2016052732 A1 WO2016052732 A1 WO 2016052732A1 JP 2015078056 W JP2015078056 W JP 2015078056W WO 2016052732 A1 WO2016052732 A1 WO 2016052732A1
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- film
- polarizing film
- protective film
- transparent protective
- optical
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- 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
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
- G02B1/14—Protective coatings, e.g. hard coatings
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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
- 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
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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
-
- 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
-
- 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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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
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- 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
- B32B2307/412—Transparent
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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
-
- 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
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/584—Scratch resistance
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F2201/00—Constructional arrangements not provided for in groups G02F1/00 - G02F7/00
- G02F2201/50—Protective arrangements
Definitions
- the present invention relates to an optical film laminate including a polarizing film and a transparent protective film, an optical display device using the optical film laminate, and a transparent protective film.
- Patent Document 1 a thin polarizing film having a thickness of 10 ⁇ m or less can be produced.
- a polyvinyl alcohol-based resin (hereinafter referred to as “PVA-based resin”) formed into a film is used as a material for the polarizing film including the polarizing film of Patent Document 1.
- PVA-based resin has hydrophilicity and high hygroscopicity, is susceptible to changes in temperature and humidity, and has the disadvantages of being easily stretched and contracted due to changes in the surrounding environment and causing dimensional changes. It is known that the stress resulting from this dimensional change of the polarizing film causes deformation such as warpage in a member such as a display panel disposed adjacent to the polarizing film, thereby reducing display quality.
- a TAC (triacetyl cellulose) film having a thickness of 40 to 80 ⁇ m is usually bonded to both sides of the polarizing film for television as a transparent protective film.
- a thin polarizing film having a thickness of 10 ⁇ m or less has a large stress due to the action of the transparent protective film bonded to the polarizing film, and when the thickness is as small as 10 ⁇ m or less, the stress due to the dimensional change of the polarizing film is thick. Since it will be much smaller than a polarizing film of a type, it has been considered that it is relatively rare to cause problems in members such as adjacent display panels.
- the present invention has been made to solve such problems in the prior art, and the polarizing film itself is not changed. Instead, a transparent protective film is formed in consideration of the dimensional change of the polarizing film.
- An optical film laminate that can reduce stress caused by dimensional change of the polarizing film that may occur at the interface between the polarizing film and the transparent protective film by appropriate selection, and an optical display using the optical film laminate
- An object is to provide a device and a transparent protective film.
- a polarizing film made of a polyvinyl alcohol resin in which a dichroic material is oriented has a thickness of 10 ⁇ m or less, and an adhesive layer on one side of the polarizing film.
- An optical film laminate including a transparent protective film made of a thermoplastic resin disposed between the transparent protective film and the transparent protective film having a thickness of 40 ⁇ m or less, and a 100 mm ⁇ 100 mm test piece in an environment of 85 ° C.
- the optical film laminate in which the dimensional change rate in the direction orthogonal to the absorption axis of the polarizing film after standing for 48 hours is 0.2% or more, it may occur at the interface between the polarizing film and the transparent protective film. It has been found that the stress caused by the dimensional change of the polarizing film can be reduced, and the present invention has been completed.
- the ratio of the dimensional change rate of the transparent protective film to the dimensional change rate of the polarizing film is 0.05. It may be 1 or less.
- the stress resulting from the dimensional change of the polarizing film that can occur at the interface between the polarizing film and the transparent protective film can be effectively reduced.
- an easy adhesion layer may be provided between the adhesive layer and the polarizing film.
- the transparent protective film is any one of an acrylic resin film, a polyethylene terephthalate resin film, and a polyolefin resin film. May be.
- the transparent protective film is an acrylic resin film, and when the glass transition temperature of the film is Tg, The film may be stretched in a direction perpendicular to the absorption axis of the polarizing film at a temperature equal to or higher than Tg.
- the transparent protective film may be formed using an acrylic resin having a glutarimide ring or a lactone ring in the main chain. (7) It is good also as an optical display device using the optical film laminated body in any one of said (1) thru
- a transparent protective film which consists of a thermoplastic resin, Comprising:
- the said transparent protective film is 40 micrometers or less in thickness, and the test piece of 100 mm x 100 mm is 48 in 85 degreeC environment.
- a transparent protective film having a dimensional change rate in the direction orthogonal to the absorption axis of the polarizing film after being allowed to stand for a time of 0.2% or more is provided.
- This transparent protective film is very useful for producing an optical film laminate together with a polarizing film having a thickness of 10 ⁇ m or less.
- the polarizing film having a thickness of 10 ⁇ m or less made of a polyvinyl alcohol-based resin in which a dichroic material is oriented may be disposed via an adhesive layer.
- the transparent protective film according to (8) or (9) may be any of an acrylic resin film, a polyethylene terephthalate resin film, or a polyolefin resin film.
- the transparent protective film is an acrylic resin film, and the polarizing film is at a temperature equal to or higher than the glass transition temperature of the film. It may be stretched in a direction perpendicular to the absorption axis of the film.
- the transparent protective film may be formed using an acrylic resin having a glutarimide ring or a lactone ring in the main chain.
- the stress due to the dimensional change of the polarizing film that may occur at the interface between the polarizing film and the transparent protective film is reduced by appropriately selecting the transparent protective film in consideration of the dimensional change of the polarizing film.
- An optical film laminate, an optical display device using the optical film laminate, and a transparent protective film are provided.
- the stress generated at the interface between the polarizing film and the transparent protective film is mainly caused by the difference between the dimensional change rate in the shrinking direction of the polarizing film accompanying heating and cooling and that of the protective film.
- the dimensional change rate accompanying heating and cooling was measured for polarizing films having various thicknesses.
- TMA manufactured by Seiko Instruments Inc. was used.
- the measuring method of the dimensional change rate of this polarizing film differs from the measuring method of "(3) Dimensional change rate of a protective film" mentioned later, these measuring methods are substantially interchangeable.
- a polarizing film having a thickness of 5 ⁇ m was cut into a strip shape of 4 mm in the absorption axis direction (hereinafter referred to as MD direction) and 25 mm in a direction perpendicular to the absorption axis (hereinafter referred to as TD direction), and then between the chucks.
- MD direction absorption axis direction
- TD direction direction perpendicular to the absorption axis
- the sample was placed at a distance of 20 mm so as to be pulled in the TD direction, the load was controlled so that the tensile load maintained 19.6 mg weight, and the ambient temperature was raised from 25 ° C. to 85 ° C.
- the dimensional change rate in the shrinking direction reached approximately 3.0%. Note that the larger the value of the dimensional change rate, the larger the contraction.
- This dimensional change rate is for a polarizing film having a thickness of 5 ⁇ m produced by “2. Production of polarizing film” described later, and is described in Comparative Examples 1 and 4 described later.
- the dimensional change rate in the TD direction of the 12 ⁇ m polarizing film was also measured by the same method. As a result, a value of 4.0% was obtained for the polarizing film having a thickness of 12 ⁇ m.
- This polarizing film having a thickness of 12 ⁇ m is obtained by, for example, a known production method as disclosed in Japanese Patent No. 4913787, that is, a method of dyeing and stretching a PVA single layer film as it is.
- the dimensional change rate of the polarizing film is not determined only by its thickness, but is considered to change depending on the stretching conditions such as, for example, the draw ratio, but it can have the greatest influence on the dimensional change rate.
- the thickness of the polarizing film can be considered. Because, when the thickness of the polarizing film increases, that is, when the neutral plane is considered in the direction perpendicular to the thickness direction of the polarizing film, the neutral plane extends from the polarizing film to the adhesive boundary surface of the transparent protective film. When the distance increases, the stress at the adhesive interface increases in proportion to the distance from the neutral surface to the adhesive interface, and cracks occur when this stress exceeds the breaking stress of the polarizing film. Because it is considered to be.
- a 12 ⁇ m polarizing film has a larger dimensional change rate than a 5 ⁇ m polarizing film, and accordingly, it can be said that cracks are more likely to occur.
- the dimensional change rate in the TD direction of the polarizing film having a thickness of 10 ⁇ m or less is 3.0% or less similarly to the polarizing film having a thickness of 5 ⁇ m, although there is a slight difference depending on the manufacturing method thereof. It was revealed that the film does not shrink more than the 12 ⁇ m polarizing film.
- the dimensional change rate of a conventional protective film that is, a TAC (triacetyl cellulose-based) film of 40 to 80 ⁇ m is about 0.01 to 0.5% when measured by the same method. It has been clarified that there is a 10-fold difference between the dimensional change rate of the polarizing film.
- the dimensional change rate of the protective film was mainly examined from two viewpoints, and the dimensional change rate of the protective film optimum for the thin polarizing film was obtained.
- One aspect is the presence or absence of cracks after applying a predetermined heat cycle to the optical film laminate, and another aspect is the heat cycle required until a crack of a predetermined depth occurs in the optical film laminate. Is the number of times. Details will be described below.
- the protective film can be produced by a melt extrusion method, that is, a method in which a melt obtained by melting a thermoplastic resin such as polycarbonate at a high temperature is extruded from a T-die lip and wound with a cooling roll.
- the material of the protective film is not particularly limited, and examples thereof include acrylic resins, polyethylene terephthalate resins such as polyethylene terephthalate (PET), and cycloolefin polymers (COP) used for optical film applications. Such polyolefin resin can also be used.
- PET contains the amorphous PET base material described in the following "laminated body preparation process (A)", for example.
- COP is, for example, “trade name: ZEONOR, manufactured by ZEON Corporation”, “ZEONEX, manufactured by ZEON Corporation”, “trade name: ARTON, manufactured by JSR Corporation”, “ Commercial products such as “trade name: Topas, manufactured by TOPAS ADVANCED POLYMERS GmbH”, “trade name: Apel, manufactured by Mitsui Chemicals, Inc.” are included.
- the acrylic resin in the present application, for the purpose of mainly improving heat resistance, a cyclic structure such as a lactone ring or a glutarimide ring is incorporated in the main chain of the acrylic resin. It may be a thing which does not contain them.
- These acrylic resins having a glutarimide ring or a lactone ring in the main chain are produced, for example, by the following method.
- the used extruder is a meshing type co-rotating twin screw extruder having a diameter of 15 mm.
- the set temperature of each temperature control zone of the extruder was 230 to 250 ° C., and the screw rotation speed was 150 rpm.
- a methyl methacrylate-styrene copolymer (hereinafter also referred to as “MS resin”) was supplied at 2 kg / hr, and the resin was melted and filled with a kneading block, and then 16 parts by weight of monomethyl from the nozzle to the resin. Amine (Mitsubishi Gas Chemical Co., Ltd.) was injected. A reverse flight was placed at the end of the reaction zone to fill the resin.
- the set temperature of each temperature control zone of the extruder was 230 ° C. and the screw rotation speed was 150 rpm.
- the imidized MS resin (1) obtained from the hopper was supplied at 1 kg / hr, and the resin was melted and filled with a kneading block, and then 0.8 parts by weight of dimethyl carbonate and 0.
- a mixed solution of 2 parts by weight of triethylamine was injected to reduce carboxyl groups in the resin.
- a reverse flight was placed at the end of the reaction zone to fill the resin.
- By-products after reaction and excess dimethyl carbonate were removed by reducing the pressure at the vent port to -0.092 MPa.
- the resin coming out as a strand from the die provided at the exit of the extruder was cooled in a water tank and then pelletized with a pelletizer to obtain an imidized MS resin (2) having a reduced acid value.
- the imidized MS resin (2) is applied to a meshing type co-rotating twin screw extruder having a diameter of 15 mm, the set temperature of each temperature control zone of the extruder is 230 ° C., the screw rotation speed is 150 rpm, and the supply amount is 1 kg / hr. It was put in the condition of. The vent port pressure was reduced to -0.095 MPa, and volatile components such as unreacted auxiliary materials were removed again. The devolatilized imide resin that emerged as a strand from the die provided at the exit of the extruder was cooled in a water tank and then pelletized with a pelletizer to obtain an imidized MS resin (3).
- the imidized MS resin (3) includes a glutamylimide unit represented by the general formula (1) described in the above embodiment, and a (meth) acrylic acid ester unit represented by the general formula (2). It corresponds to a glutarimide resin copolymerized with an aromatic vinyl unit represented by the general formula (3).
- the imidization rate, glass transition temperature, and Sp value were measured according to the above-described method.
- the imidation ratio was 70 mol%
- the glass transition temperature was 143 ° C.
- the acid value was 0.2 mmol / g
- the Sp value was 9.38.
- the (meth) acrylic resin pellets having the glutarimide ring unit are dried at 100.5 kPa and 100 ° C. for 12 hours, and extruded from a T die at a die temperature of 270 ° C. with a single-screw extruder, and formed into a film state. did. Further, the film is stretched twice in the conveying direction (MD direction) in an atmosphere 10 ° C. higher than the glass transition temperature (Tg) of the resin, and then in the direction orthogonal to the film conveying direction (TD direction). The film was stretched twice under an atmosphere 7 ° C. higher than Tg to obtain a biaxially stretched film having a thickness of 40 ⁇ m, that is, a protective film. As is well known, the Tg of a (meth) acrylic resin having a glutarimide ring unit is 126 ° C.
- the separately prepared antioxidant / deactivator mixed solution was injected after the second vent at a charging rate of 0.3 kg / hour using a high-pressure pump. Further, after the first vent and after the side feeder, ion exchange water was injected at a charging rate of 0.33 kg / hour using a high-pressure pump.
- AS resin manufactured by Asahi Kasei Chemicals, trade name: Stylac AS783L was added from the side feeder at a supply rate of 2.12 kg / hour.
- melt-kneaded resin was filtered with a leaf disk type polymer filter (manufactured by Nagase Sangyo, filtration accuracy 5 ⁇ m).
- An antioxidant / deactivator mixed solution was prepared by dissolving 50 parts of ADK STAB AO-60 (manufactured by ADEKA) and 40 parts of zinc octylate (manufactured by Nippon Kagaku Sangyo, 3.6% of Nikka octix zinc) in 210 parts of toluene. did.
- the pellet of the thermoplastic acrylic resin composition (A-1) was obtained by the above devolatilization operation.
- the weight average molecular weight of the resin part was 132000, and the glass transition temperature was 125 ° C.
- this (meth) acrylic resin pellet having a lactone ring unit was dried at 100.5 kPa and 100 ° C. for 12 hours in exactly the same manner as the (meth) acrylic resin having a glutarimide ring unit, and a single screw extruder was extruded from a T die at a die temperature of 270 ° C. and formed into a film state. Further, the film is stretched twice in the transport direction (MD direction) in an atmosphere 10 ° C. higher than the resin Tg, and then 12 ° C. higher than the resin Tg in the direction perpendicular to the film transport direction (TD direction).
- MD direction transport direction
- the film was stretched 2.65 times under an atmosphere to obtain a biaxially stretched film having a thickness of 20 ⁇ m, that is, a protective film.
- the Tg of a (meth) acrylic resin having a lactone ring unit is 127 ° C.
- FIG. 2 shows the protective film obtained in “(2) Production of protective film using (meth) acrylic resin having lactone ring unit” when the stretching temperature is constant (Tg + 12 ° C.).
- FIG. 3 shows the relationship between the TD stretch ratio and the dimensional change rate, and FIG. 3 shows that the stretch ratio is constant for the protective film obtained in (2) (twice in the MD direction and in the TD direction). 2.65) shows the relationship between the TD stretching temperature and the dimensional change rate.
- the TD stretch ratio and the dimensional change rate are in a substantially proportional relationship. Although not shown in the graph, it may be considered that the same relationship holds even when the draw ratio is around 2.0 times (used in Example 1 described later). Further, as is apparent from FIG.
- the dimensional change rate decreases as the TD stretching temperature increases, reaches a predetermined value when reaching a predetermined temperature, and does not decrease below that. Therefore, the dimensional change rate can be maintained at, for example, 0.2% or more by setting the TD stretching temperature to a predetermined temperature, for example, Tg or higher, under a predetermined stretching ratio.
- a predetermined temperature for example, Tg or higher
- Tg the temperature
- the degree of molecular orientation is considered to be relatively low even when the draw ratio is increased. It is thought that the degree of molecular orientation of the final film greatly depends on the dimensional change rate. If the degree of orientation is high, the dimensional change rate of shrinkage increases to become isotropic during heating again.
- Thermoplastic resins are largely divided into those in a crystalline state in which the polymer is regularly arranged and those in which the polymer does not have a regular arrangement, or in an amorphous or amorphous state in which only a few have a regular arrangement. Can be separated.
- the former is called a crystalline state, and the latter is called an amorphous or amorphous state.
- a thermoplastic resin that is not in a crystalline state but has a property capable of forming a crystalline state depending on conditions is called a crystalline resin, and a thermoplastic resin that does not have such a property is non-crystalline. Called a crystalline resin.
- a resin that is not in a crystalline state or a resin that does not reach a crystalline state is referred to as an amorphous or amorphous resin.
- amorphous or amorphous is used in distinction from the term “amorphous” which means a property that does not form a crystalline state.
- the crystalline resin examples include olefin resins including polyethylene (PE) and polypropylene (PP), and ester resins including polyethylene terephthalate (PET) and polybutylene terephthalate (PBT).
- olefin resins including polyethylene (PE) and polypropylene (PP)
- ester resins including polyethylene terephthalate (PET) and polybutylene terephthalate (PBT).
- PET polyethylene terephthalate
- PBT polybutylene terephthalate
- One of the characteristics of the crystalline resin is that it generally has a property that crystallization proceeds by polymer alignment by heating and / or stretching orientation. The physical properties of the resin vary depending on the degree of crystallization. On the other hand, for example, even with a crystalline resin such as polypropylene (PP) and polyethylene terephthalate (PET), crystallization can be suppressed by inhibiting the polymer arrangement caused by heat treatment or stretching orientation.
- PP polyprop
- polypropylene (PP) and polyethylene terephthalate (PET) in which crystallization is suppressed are referred to as amorphous polypropylene and amorphous polyethylene terephthalate, respectively, which are collectively referred to as amorphous olefin resin and amorphous terephthalate, respectively. It is called a reactive ester resin.
- amorphous polypropylene (PP) in which crystallization is suppressed can be produced by using an atactic structure without stereoregularity.
- PET polyethylene terephthalate
- a molecule that copolymerizes a modifying group such as isophthalic acid or 1,4-cyclohexanedimethanol as a polymerization monomer that is, a molecule that inhibits crystallization of polyethylene terephthalate (PET).
- PET polyethylene terephthalate
- Amorphous polyethylene terephthalate (PET) in which crystallization is suppressed can be prepared by copolymerizing.
- FIG. 1 is a schematic diagram of a manufacturing process capable of producing a polarizing film of 10 ⁇ m or less, for example, 5 ⁇ m or less.
- a continuous web of polyethylene terephthalate copolymerized with isophthalic acid obtained by copolymerizing 6 mol% of 200 ⁇ m-thick isophthalic acid as a thermoplastic resin substrate serving as a substrate on which a polarizing film is applied.
- amorphous PET polyethylene terephthalate copolymerized with isophthalic acid
- the product name: NOVACLEAR SH046 200 ⁇ m manufactured by Mitsubishi Resin Co., Ltd.
- This thermoplastic resin is amorphous, hardly crystallized even when heat is applied, and the draw ratio is difficult to decrease.
- the continuous web substrate of polyethylene terephthalate has a glass transition temperature of 75 ° C.
- the glass transition temperature of the PVA layer is 80 ° C.
- the film thickness after drying the PVA aqueous solution on the amorphous PET base material 1 is 12 ⁇ m.
- the laminate was coated and dried for 10 minutes by hot air drying in an atmosphere of 60 ° C. to prepare a laminate in which a PVA-based resin was formed on a substrate.
- the laminate thus obtained is referred to as “a laminate in which a PVA layer is formed on an amorphous PET substrate”, “a laminate including a PVA layer”, or “laminate 7”.
- the laminate 7 including the PVA layer 2 is finally manufactured as a polarizing film 3 having a thickness of 5 ⁇ m through the following steps including a two-step stretching process of air-assisted stretching and boric acid solution stretching.
- a polarizing film having a thickness of 10 ⁇ m or more, for example, 12 ⁇ m can also be formed.
- the laminate 7 including the PVA layer 2 having a thickness of 12 ⁇ m is stretched integrally with the amorphous PET base material 1, and the “stretched laminate 8” including the PVA layer 2 is obtained. Generated. Specifically, in the air auxiliary stretching apparatus 30 in which the stretching means 31 is provided in the oven 33, the laminate 7 including the PVA layer 2 is stretched at 120 ° C. higher than the glass transition temperature of the PVA layer and the substrate. It passed through the stretching means 31 in an oven 33 set in the environment, and the free end was uniaxially stretched so that the stretch ratio was 2.0 times, thereby producing a stretched laminate 8 having a thickness of 8 ⁇ m.
- the roll 8 ′ of the stretched laminated body 8 can be manufactured by being wound around the winding device 32 provided in the oven 33.
- the stretching ratio of the air-assisted stretching is 2.0 times, but the stretching ratio can be increased up to 3.5 times that of this step depending on the target thickness and degree of polarization.
- free-end stretching refers to a method of stretching without suppressing this shrinkage.
- longitudinal uniaxial stretching is a stretching method in which stretching is performed only in the longitudinal direction. Free-end uniaxial stretching is contrasted with fixed-end uniaxial stretching that stretches while suppressing shrinkage that generally occurs in a direction perpendicular to the stretching direction.
- stretching laminated body 8 is immersed in the 1st boric acid insolubilizing aqueous solution 41 of 30 degreeC of liquid temperature for 30 second.
- the first boric acid insolubilized aqueous solution 41 used in this step contains 3 parts by weight of boric acid with respect to 100 parts by weight of water (hereinafter referred to as “first boric acid insolubilized aqueous solution”).
- the purpose of this step is to perform an insolubilization treatment so as not to dissolve the PVA layer contained in the stretched laminate 8 at least in the immediately subsequent dyeing step (D).
- the dye solution 51 is set so that the iodine concentration is within the range of 0.08 to 0.25% by weight and the potassium iodide concentration is 0 so that the PVA layer 2 contained in the stretched laminate 8 is not dissolved.
- the concentration ratio between iodine and potassium iodide was 1 to 7 within the range of .56 to 1.75% by weight. It is considered that the iodine concentration, potassium iodide concentration, and immersion time in this step greatly affect the concentration of iodine element contained in the PVA layer. Therefore, the single transmittance of the final polarizing film can be adjusted by adjusting the iodine concentration and potassium iodide concentration in this step and the immersion time.
- the polarizing film 3 that is finally produced by adjusting the concentration of iodine and potassium iodide and adjusting the immersion time within the above ranges of iodine concentration and potassium iodide concentration. It is possible to adsorb iodine to the oriented PVA layer 2 of the stretched laminate 8 so that the single transmittance of the PVA layer constituting the material becomes 45.0%.
- the single transmittance is not limited to 45.0%, but can be adjusted to 44.0%, 44.3%, 44.5%, or 45.5%.
- the second insolubilization step (E) described below is performed for the following purpose.
- the PVA layer 2 contained in the colored laminate 10 is not dissolved, and secondly, the PVA layer 2 is colored.
- the purpose of this is to stabilize the coloring so as not to elute the iodine, and thirdly, to generate nodules that generate nodules by cross-linking the PVA molecules of the PVA layer 2,
- the first and second objectives are particularly achieved.
- the second insolubilization step (E) is performed as a pre-step of the boric acid underwater drawing step (F).
- an insolubilized colored laminate 11 is produced.
- the insolubilized colored laminate 11 includes the insolubilized PVA layer 2.
- the second insolubilization treatment apparatus 60 that accommodates an aqueous solution (hereinafter referred to as “second boric acid insolubilized aqueous solution”) 61 composed of boric acid and potassium iodide, the colored laminate 10 is subjected to a second treatment at 40 ° C.
- the insolubilized colored laminate 11 is generated by immersing in the boric acid insolubilized aqueous solution 61 for 60 seconds and crosslinking the PVA molecules of the PVA layer on which iodine is adsorbed.
- the second boric acid insolubilized aqueous solution used in this step contains 3 parts by weight of boric acid with respect to 100 parts by weight of water and 3 parts by weight of potassium iodide with respect to 100 parts by weight of water.
- the laminated body 12 was produced
- the total draw ratio of the present embodiment is 5.5 times, but by adjusting the draw ratio of the air-assisted auxiliary drawing process and the draw ratio of the boric acid water drawing process, it is 5.0 times or more and 6.5 times or less. Also good.
- the boric acid aqueous solution 71 was adjusted so as to contain 6.5 parts by weight of boric acid with respect to 100 parts by weight of water and 5 parts by weight of potassium iodide with respect to 100 parts by weight of water. Since the polarizing film of the present invention has a high transmittance and the amount of cross-linking points where polyiodine ions are adsorbed to PVA is small, polyiodine ions and iodine ions are likely to be eluted in this step and the subsequent washing step.
- the insolubilized colored laminate 11 having an adjusted iodine adsorption amount was first immersed in the boric acid aqueous solution 71 for 5 to 10 seconds.
- the insolubilized colored laminate 11 is passed as it is between a plurality of sets of rolls having different peripheral speeds, which are the stretching means 73 of the boric acid underwater treatment apparatus 70, and the stretching ratio becomes 2.7 times over 30 to 90 seconds.
- the free end was uniaxially stretched.
- the PVA layer contained in the crosslinked colored laminate 11 has a thickness of 5 ⁇ m in which polyiodine ions (I 3 ⁇ and I 5 ⁇ ) are oriented in one direction as a PVA-iodine complex in which PVA is adsorbed.
- This PVA layer constitutes the polarizing film 3 of the laminate 12.
- the insolubilized colored laminate 11 is drawn in the boric acid underwater drawing step (F) and taken out from the boric acid aqueous solution 71.
- the laminated body 12 including the extracted polarizing film 3 is sent to the cleaning step (G).
- the purpose of the cleaning step (G) is to wash away unnecessary residues adhering to the surface of the thin high-performance polarizing film 3.
- the laminate 12 is sent to the cleaning device 80 and immersed in a cleaning solution 81 containing potassium iodide at a liquid temperature of 30 ° C. for 1 to 10 seconds so that the PVA of the thin high-performance polarizing film 3 is not dissolved.
- the concentration of potassium iodide in the cleaning liquid 81 is 4 parts by weight with respect to 100 parts by weight of water.
- the washed laminate 12 is sent to the drying step (H) where it is dried.
- the dried laminate 12 is wound up as a continuous web laminate 12 by a winding device 91 provided in the drying device 90, and a roll of the laminate 12 including the thin high-performance polarizing film 3 is generated.
- the Arbitrary appropriate methods for example, natural drying, ventilation drying, and heat drying, are employable as a drying process (H).
- the drying is performed in the oven drying apparatus 90 with warm air of 60 ° C. for 240 seconds.
- the polarizing film 3 having a thickness of 5 ⁇ m is manufactured.
- the optical film laminate of the present invention comprises a combination of the protective film obtained in “1. Production of protective film” and the polarizing film obtained in “2. Production of polarizing film”.
- an optical film laminate can be produced by the step (I) in FIG. 1, that is, the [Lamination / transfer step (I)].
- the polarizing film 3 is left as it is on the thermoplastic substrate on which the polarizing film 3 is formed, for example, the amorphous PET substrate 1, and includes the protective film 4 (including other optical films). Can be rolled up while bonding. In this winding process, the optical film laminate 13 is generated by peeling the amorphous PET base material 1 while transferring the polarizing film 3 to the protective film 4.
- the laminate 12 is fed out from the roll by the feeding / bonding device 101 included in the laminating / transferring device 100, and the polarizing film 3 of the fed laminated body 12 is protected by the winding / transferring device 102.
- the polarizing film 3 is peeled from the base material 1 in the process, and the optical film laminate 13 is generated.
- an adhesive layer is provided between the polarizing film 3 and the protective film 4. This adhesive layer was prepared by mixing 40 parts by weight of N-hydroxyethylacrylamide (HEAA), 60 parts by weight of acryloylmorpholine (ACMO) and 3 parts by weight of a photoinitiator “IRGACURE 819” (manufactured by BASF).
- Consists of a photo-curable adhesive The adjusted adhesive is applied on the polarizing film 3 so that the thickness of the adhesive layer after curing is 0.5 ⁇ m, and this application side is bonded to the easy adhesion layer side of the protective film 14 as an active energy ray.
- the adhesive was cured by irradiating with ultraviolet rays.
- ultraviolet irradiation a gallium-filled metal halide lamp, irradiation device: Fusion UV Systems, Inc.
- the protective film provided separately from the amorphous PET substrate 1 is not used, but the amorphous PET substrate 1 is protected. It may be used as a film.
- the amorphous PET substrate 1 may be once peeled from the polarizing film 3 and stretched to a desired thickness, and then bonded to the polarizing film 3 as a protective film.
- the polarizing film 3 and the amorphous PET base material 1 can be stretched to a desired thickness as they are without peeling off to produce the optical film laminate 13.
- Evaluation method of optical film laminate The following evaluations were performed on the protective film, the polarizing film, and the optical film laminate.
- (1) Measurement of thickness of protective film The thickness of the produced protective film was measured at 5 points in the width direction using a dial gauge (manufactured by Ozaki Seisakusho) in a state before being bonded to the polarizing film.
- the pressure-sensitive adhesive side was attached to the center of a non-alkali glass plate having a length of 250 mm, a width of 170 mm, and a thickness of 1 mm, and a pressure defoaming device (manufactured by Kurihara Seisakusho) was used. A pressure defoaming process was performed at 15 ° C. for 15 minutes. Thereafter, the sample was put in an environmental test machine while being attached to the glass, a thermal shock from ⁇ 40 ° C. to 85 ° C. was applied for 10 cycles, and the lengths of cracks generated in the “a” part in FIG. 4 were compared. The thermal shock test was given up to a total of 100 cycles, and the number of cycles required for the crack to reach side “b” was counted.
- a pressure defoaming device manufactured by Kurihara Seisakusho
- Ratio of dimensional change rate of protective film and dimensional change rate of polarizing film From the viewpoint of reducing stress generated at the interface between the polarizing film and the protective film, the dimensional change rate of the protective film ( ⁇ f) and the dimensional change rate of the polarizing film ( ⁇ p ) ( ⁇ f / ⁇ p). As is apparent, the difference between these dimensional change rates is preferably as small as possible, that is, the ratio value is preferably close to 1. In Table 1 described later, the ratio of the dimensional change rate of the protective film to the dimensional change rate of the polarizing film actually used in the experiment was obtained.
- Example 1 A protective film having a thickness of 40 ⁇ m was obtained by the method described in “(1) Production of protective film using (meth) acrylic resin having glutarimide ring unit”. A polarizing film having a thickness of 5 ⁇ m was obtained by the method described in “2. Production of polarizing film”. The optical film laminate composed of the protective film and the polarizing film was evaluated. As a result, the dimensional change rate in the TD direction of the protective film is +0.21, there is no occurrence of cracks, and the heat cycle required to reach a crack of a predetermined depth is 70 times, which is a good result. Obtained. The ratio with the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.07.
- Example 2 Basically the same as in Example 1, but the protective film having a thickness of 20 ⁇ m was obtained by increasing the draw ratio in the TD direction by 30% to 2.65 times during the production of the protective film. This protective film was adhered to a polarizing film having a thickness of 5 ⁇ m obtained by the method described in “2. Production of polarizing film”, and the obtained optical film laminate was evaluated.
- the dimensional change rate of the protective film is +0.42, there is no occurrence of cracks, and even if the heat cycle is repeated 100 times or more, cracks do not reach the predetermined depth, and a better result than Example 1 is obtained. Obtained. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.14.
- Example 2 is the same as Example 2 except that the stretching temperature in the TD direction during production of the protective film is 3 ° C. higher than Example 1. In this case, the dimensional change rate of the protective film was +0.3. Further, no crack was generated, and the heat cycle required to reach a crack of a predetermined depth was 90 times. At this time, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.1.
- Example 4 Example 2 is the same as Example 2 except that the stretching temperature in the TD direction during the production of the protective film is 6 ° C. higher than Example 1. In this case, the dimensional change rate of the protective film was +0.22. Moreover, there was no crack generation, and the heat cycle required to reach a crack of a predetermined depth was 70 times. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.073.
- Example 5 Basically the same as in Example 1, but when the protective film was produced, it was stretched by increasing the stretching ratio in the TD direction by 30%, and the thickness of the protective film was adjusted to 40 ⁇ m by adjusting the stretching ratio in the MD direction accordingly. It was. A polarizing film having a thickness of 5 ⁇ m was obtained by the method described in “2. Production of polarizing film”. The optical film laminate composed of these protective film and polarizing film was evaluated. As a result, the dimensional change rate of the protective film was +0.53, no crack was generated, and the heat cycle required to reach a crack of a predetermined depth was 80 times, which is better than Example 1. Results were obtained. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.177.
- Example 6 A protective film having a thickness of 20 ⁇ m was obtained by the method described in “(2) Production of protective film using (meth) acrylic resin having lactone ring unit”. In this case, the stretching temperature (139 ° C.) and the stretching ratio (2.65 times) in the TD direction are the same as those in Example 4.
- a polarizing film having a thickness of 5 ⁇ m was obtained by the method described in “2. Production of polarizing film”. The optical film laminate composed of these protective film and polarizing film was evaluated. As a result, the dimensional change rate in the TD direction of the protective film was +0.36, no crack was generated, and the heat cycle required to reach a crack of a predetermined depth was 70 times, and good results was gotten. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.12.
- Example 7 The amorphous PET base material described in the above “laminated body preparation step (A)” was peeled from the polarizing film, and then stretched to a thickness of 20 ⁇ m.
- the stretching temperature in the TD direction was 100 ° C.
- the stretching ratio was 2.0 times.
- the dimensional change rate of the protective film was 1.78
- the heat cycle required to reach a crack of a predetermined depth was 80 times, and good results were obtained.
- the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.59.
- Example 8 A ZEONOR film (thickness 50 ⁇ m) manufactured by Nippon Zeon Co., Ltd. was used, and the film was stretched at a stretching temperature in the TD direction of 130 ° C. and a stretching ratio of 2.0 times.
- the dimensional change rate of the protective film was ⁇ 0.24, and the heat cycle required to reach a crack of a predetermined depth was 70 times, and good results were obtained.
- the ratio with the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.08.
- Example 1 Basically the same as Example 6, except that the thickness of the polarizing film is 12 ⁇ m.
- the polarizing film having a thickness of 12 ⁇ m is obtained by a method of dyeing and stretching a PVA single layer film as it is, as described above.
- the dimensional change rate of the protective film was +0.36, and a good result was obtained, but the heat cycle required to reach a crack of a predetermined depth was 10 times, which is not practical. It turned out to be. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 12 ⁇ m was 0.09.
- Example 6 is the same as Example 6 except that the stretching temperature in the TD direction during preparation of the protective film is 12 ° C. higher than Example 6.
- the dimensional change rate of the protective film was +0.18, cracks were generated, and the heat cycle required to reach a crack of a predetermined depth was also deteriorated by 10 times. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.06.
- Example 3 This is the same as Example 5 except that the stretching temperature in the TD direction during the production of the protective film is 12 ° C. higher than that of Example 5 and the stretching ratio is 2.05 times.
- the dimensional change rate of the protective film was +0.1, but cracks occurred, and the heat cycle required to reach a crack of a predetermined depth was also deteriorated to 30 times.
- the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.033.
- Example 4 Except that the stretching temperature in the TD direction during preparation of the protective film was 11 ° C. higher than that of Example 6 and the thickness of the polarizing film was 12 ⁇ m, it was the same as Example 6. A polarizing film having a thickness of 12 ⁇ m was obtained in the same manner as in Comparative Example 1. In this case, the dimensional change rate of the protective film was +0.18, but cracks occurred, and the heat cycle required to reach a crack of a predetermined depth was also deteriorated by 10 times. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.06.
- Example 7 is the same as Example 7 except that the stretching ratio in the TD direction at the time of preparation of the protective film is 1.0.
- the dimensional change rate of the protective film was +0.88, which resulted in expansion, and the heat cycle required to reach a crack of a predetermined depth was also deteriorated by 10 times.
- the ratio with the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m is 0.29, it does not make sense because it is expanded.
- Example 8 is the same as Example 8 except that the stretching temperature in the TD direction during the production of the protective film is 140 ° C.
- the dimensional change rate of the protective film was ⁇ 0.12, and the heat cycle required to reach a crack of a predetermined depth was also deteriorated by 10 times. Further, the ratio to the dimensional change rate of the polarizing film having a thickness of 5 ⁇ m was 0.04.
- Table 1 shows the test results of Examples 1 to 8 and Comparative Examples 1 to 6.
- the acrylic resin for example, even if it contains a glutarimide ring, it contains a lactone ring, and the thickness of the polarizing film is 10 ⁇ m or less, for example, 5 ⁇ m.
- the thickness of the protective film is 40 ⁇ m or less, for example, 40 ⁇ m or 20 ⁇ m, and the dimensional change rate is 0.2% or more, when a predetermined heat cycle is given to the optical film laminate
- cracks did not occur, and the number of heat cycles required until a crack with a predetermined depth was generated in the optical film laminate was 70 times or more, and good results were obtained.
- the ratio between the dimensional change rate of the transparent protective film and the dimensional change rate of the polarizing film when good results are obtained with respect to the occurrence of cracks and the heat cycle is 0.07 (0.05 or more in consideration of errors). That's it.
- the example of the lactone ring is only Example 6.
- the Tg of the lactone ring (126 ° C.) and the Tg of the glutarimide ring (127 ° C.) are substantially the same, the dimensional change From the viewpoint of rate, in other words, from the viewpoint of molecular orientation, both can be considered substantially the same.
- the acrylic resin containing a lactone ring can be considered basically the same as that containing a glutarimide ring. Furthermore, it will be apparent to those skilled in the art that similar results can be obtained when a glutaric anhydride structure is introduced or when N-substituted maleimides such as phenylmaleimide, cyclohexylmaleimide, and methylmaleimide are copolymerized.
- the polarizing film has a thickness of 10 ⁇ m or less, for example, 5 ⁇ m
- the protective film has a thickness of 40 ⁇ m or less, for example, 20 ⁇ m
- the draw ratio is 2.0 (or more).
- PET is exemplified as the polyethylene terephthalate resin.
- polyethylene terephthalate resin since it is a polyester resin, the same applies to, for example, polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, etc. other than PET. It will be apparent to those skilled in the art that the following results are obtained.
- the polarizing film has a thickness of 10 ⁇ m or less, for example, 5 ⁇ m
- the protective film has a thickness of 40 ⁇ m or less, for example, 25 ⁇ m
- the stretching temperature is Tg + 30 (or less).
- the number of heat cycles required until a crack having a predetermined depth was generated in the optical film laminate was 70 times or more, and good results were obtained.
- the ratio of the dimensional change rate of the transparent protective film and the dimensional change rate of the polarizing film was 0.08 or more.
- FIGS. 5 and 6 show an embodiment of an optical display device (layer configuration) using the optical film laminate according to the present invention.
- FIG. 5A is a cross-sectional view showing the most basic configuration of an optical display device using the optical film laminate of the present invention.
- the optical display device 200 is, for example, a liquid crystal display panel or an organic EL display.
- An optical display panel 201 that can be a panel is provided, and a polarizing film 203 is bonded to one surface of the display panel 201 via an optically transparent adhesive layer 202.
- a protective film (hereinafter referred to as “protective layer”) 204 made of an optically transparent resin material is bonded to the outer surface of the polarizing film 203 via an adhesive layer (not shown).
- a transparent window 205 can be disposed outside the protective layer 204 on the viewing side of the optical display device, as indicated by a broken line.
- materials for bonding or adhering layers and films include the above-mentioned photo-curable adhesives, for example, acrylic polymers, silicone polymers, polyesters, polyurethanes, polyamides, polyethers, fluorine-based and rubber-based, isocyanates.
- a polymer having a base polymer such as a polymer, polyvinyl alcohol, gelatin, vinyl latex, or water-based polyester can be appropriately selected and used.
- a material having a diffusion function may be used as the pressure-sensitive adhesive layer 202, or a two-layer structure of a pressure-sensitive adhesive layer and a diffusion agent layer may be used.
- an anchor layer (not shown) as described in JP-A No. 2002-258269, JP-A No. 2004-078143, JP-A No. 2007-171892 ) can also be provided.
- the binder resin is not particularly limited as long as it can improve the anchoring force of the pressure-sensitive adhesive.
- Resins (polymers) having organic reactive groups such as polymers containing, urethane ester resins, and various acrylic resins containing oxazoline groups can be used.
- an antistatic agent can be added to the anchor layer as described in, for example, JP-A-2004-338379 in order to impart antistatic properties.
- Antistatic agents for imparting antistatic properties include ionic surfactant systems, conductive polymer systems such as polyaniline, polythiophene, polypyrrole, and polyquinoxaline, metal oxide systems such as tin oxide, antimony oxide, and indium oxide.
- a conductive polymer system is preferably used.
- water-soluble conductive polymers such as polyaniline and polythiophene or water-dispersible conductive polymers are particularly preferably used.
- the surface of the protective layer 204 where the polarizing film 203 is not adhered may be subjected to a treatment for the purpose of hard coat layer, antireflection treatment, anti-sticking, diffusion or anti-glare as a surface treatment layer.
- the surface treatment layer may contain an ultraviolet absorber.
- the surface treatment layer is preferably a layer having a low moisture permeability for the purpose of improving the humidification durability of the polarizing film.
- Hard coat treatment is performed for the purpose of preventing scratches on the surface of the polarizing plate.
- the antireflection treatment is performed for the purpose of preventing the reflection of external light on the surface of the polarizing plate. Reflection by the interference action of light as described in Japanese Patent Application Laid-Open No. 2005-248173, for example, according to the prior art. Low layer types such as a thin layer type that prevents reflection using the light cancellation effect, and a structure type that exhibits low reflectivity by imparting a fine structure to the surface as described in Japanese Patent Application Laid-Open No. 2011-2759. This can be achieved by forming a reflective layer.
- the anti-sticking treatment is performed for the purpose of preventing adhesion with an adjacent layer (for example, a diffusion plate on the backlight side).
- Anti-glare treatment is performed for the purpose of preventing external light from being reflected on the surface of the polarizing plate and obstructing visual recognition of the light transmitted through the polarizing plate.
- a roughening method using a sandblasting method or an embossing method It can be formed by imparting a fine concavo-convex structure to the surface of the protective film by an appropriate method such as a method of blending transparent fine particles.
- the antiglare layer may also serve as a diffusion layer (viewing angle expanding function or the like) for diffusing the light transmitted through the polarizing plate to expand the viewing angle.
- the hard coat layer is preferably a hard coat layer having a pencil hardness of 2H or higher.
- the configuration of the optical display device shown in FIG. 5B is almost the same as that shown in FIG. 5A, but a diffusion layer 206 is disposed between the polarizing film 203 and the protective layer 204. It has a configuration. In the configuration shown in FIG. 5C, the diffusion layer 206 is disposed between the adhesive layer 202 and the polarizing film 203.
- the optical display device shown in FIG. 5D is basically the same as that shown in FIG. 5A, but the polarizing film 203 has a protective layer 204 via an easy-adhesion layer 207 that facilitates adhesion. Glued to.
- As the easy adhesion layer for example, a material disclosed in JP 2010-55062 A can be used.
- the optical display device shown in FIG. 5E is different from the optical display device shown in FIG. 5D only in that an antistatic layer 208 is provided on the outer surface of the protective layer 204.
- a 1 ⁇ 4 wavelength retardation film 209 is provided between the protective layer 204 and the antistatic layer 208. Is placed.
- the quarter-wave retardation film can be disposed on the viewer side with respect to the antistatic layer. According to this configuration, since the quarter-wave retardation film is disposed on the viewing side with respect to the polarizing film 203, the light emitted from the display panel 201 through the polarizing film 203 is transmitted through the quarter-wave retardation film. When exiting, it is converted to circularly polarized light.
- the optical display device having this configuration provides an advantage that, for example, even when a viewer wears polarized sunglasses, there is no hindrance to visual recognition.
- FIG. 6A shows an embodiment of an optical display device 300 including a transmissive liquid crystal display panel 301 as an optical display panel.
- the panel configuration on the viewing side from the liquid crystal display panel 301 is almost the same as the configuration in the optical display device 200 shown in FIG. That is, the first polarizing film 303 is bonded to the surface on the viewing side of the liquid crystal display panel 301 via the pressure-sensitive adhesive layer 302, and the protective layer 304 is bonded to the first polarizing film 303 via the easy adhesion layer 307. Is done.
- a quarter-wave retardation layer 309 is bonded to the protective layer 304.
- An antistatic layer 308 is formed on the quarter-wave retardation layer 309, although it is optional.
- a window 305 is disposed outside the quarter-wave retardation layer 309, although this is also optional.
- the second polarizing film 303a is disposed on the other surface of the liquid crystal display panel 301 via the second pressure-sensitive adhesive layer 302a.
- a backlight 310 is disposed on the back side of the second polarizing film 303a.
- FIG. 6B shows an embodiment of an optical display device 400 including a reflective liquid crystal display panel 401 as a display panel.
- the panel configuration on the viewing side from the liquid crystal display panel 401 is substantially the same as the configuration in the optical display device 300 shown in FIG. That is, the first polarizing film 403 is bonded to the surface on the viewing side of the liquid crystal display panel 401 via the adhesive layer 402, and the protective layer 404 is bonded to the first polarizing film 403 via the easy-adhesion layer 407.
- the A quarter-wave retardation layer 409 is bonded to the protective layer 404.
- An antistatic layer 408 is formed on the quarter-wave retardation layer 409, although it is optional.
- a window 405 is disposed outside the quarter-wave retardation layer 409, although this is also optional.
- a second polarizing film 403a is bonded to the other surface of the liquid crystal display panel 401 via a second adhesive layer 402a, and the second polarizing film 403a is bonded to the second polarizing film 403a.
- the second protective layer 404a is bonded through the easy adhesion layer 407a.
- An optional antistatic layer 408a is formed on the second protective layer 404a.
- a mirror 411 for reflecting the light transmitted through the liquid crystal display panel 401 toward the liquid crystal display panel 401 is disposed on the back side of the second protective layer 404a. In this configuration, external light incident from the viewing side is reflected by the mirror 411, passes through the liquid crystal display panel 401, and goes outside, so that the display can be viewed from the viewing side.
- the mirror 411 can be a half mirror that transmits part of incident light.
- a backlight 410 is disposed behind the mirror 411 as indicated by an imaginary line in FIG. According to this configuration, it is possible to perform display by turning on the backlight 410 when the outside light is dark.
- FIG. 6 (c) shows another embodiment. This embodiment is different from the embodiment shown in FIG. 6B in that a quarter-wave retardation layer 409a is arranged between the first polarizing film 403 and the liquid crystal display panel 401, and the second polarizing film.
- a quarter-wave retardation layer 409b is disposed between 403a and the liquid crystal display panel 401. More specifically, a quarter-wave retardation layer 409a is bonded to the first polarizing film 403, and the quarter-wave retardation layer 409a is connected to the viewing side of the liquid crystal display panel 401 via the adhesive layer 402. It is joined to the surface.
- a quarter wavelength retardation layer 409b is joined to the second polarizing film 403a, and the quarter wavelength retardation layer 409b is joined to the back side surface of the liquid crystal display panel 401 through the adhesive layer 402a.
- the quarter-wave retardation layer 409a and the quarter-wave retardation layer 409b are “SID Digest of Tech. Papers, 2000, pp 902 to 905," Improvement of Transmitted Light Efficiency in SH- ". As described in LCDs “Using Quarter-Wave Retardation Films”, Y. Iwamoto et al., It has a function of improving the display brightness of the display device.
- each protective layer can be formed of the above-described material.
- FIG. 6D shows an example of an optical display device 500 using an optical display panel 501 configured as an organic EL display panel or a reflective liquid crystal display panel.
- a retardation film 512 is bonded to the surface on the viewing side of the display panel 501 through an adhesive layer 502, and a polarizing film 503 is bonded to the retardation film 512.
- the polarizing film 503 is bonded to the protective layer 504 through the easy-adhesion layer 507, and the quarter-wave retardation layer 509 is bonded to the protective layer 504.
- an antistatic layer 508 can be formed on the quarter-wave retardation layer 509.
- a window 505 can be disposed outside the quarter-wave retardation layer 509, although it is optional.
- the retardation film 512 is used to prevent light incident on the inside from the viewing side of the polarizing film 503 from being internally reflected and emitted to the viewing side.
- the retardation film 512 disposed between the polarizing film 503 and the display panel 501 can be a quarter wavelength retardation layer.
- the refractive index in the slow axis direction is nx
- the refractive index in the in-plane direction perpendicular thereto is ny
- the refractive index in the thickness direction is nz
- these refractive indexes are in a relationship of nx> nz> ny.
- a biaxial retardation film having In this configuration, the retardation film 512 is disposed so that the slow axis direction is 45 ° with respect to the absorption axis of the polarizing film 503. According to this configuration, an antireflection function in an oblique direction can also be obtained.
- a mirror is usually disposed on the back side of the display panel 501.
- FIG. 6E shows an optical display device 600 according to still another embodiment of the present invention.
- the optical display panel is configured by a transmissive IPS liquid crystal display panel 601, and a retardation film 612 is bonded to a surface on the viewing side of the display panel 601 via an adhesive layer 602.
- a polarizing film 603 is bonded to the retardation film 612.
- the polarizing film 603 is bonded to the protective layer 604 through the easy adhesion layer 607, and the pattern retardation layer 613 is bonded to the protective layer 604.
- This pattern retardation layer 613 is formed by “EKISHO” Vol. 14, no.
- the pattern retardation layer has a function of changing the right-eye image and the left-eye image output from the display panel to different polarization states, respectively, in order to enable 3D display.
- a window 605 can be disposed outside the pattern retardation layer 613, although it is optional.
- the IPS mode includes a super-in-plane switching (S-IPS) mode and an advanced super-in-plane switching (AS-IPS) mode using a V-shaped electrode or a zigzag electrode.
- a retardation film 612a is bonded to the back surface of the liquid crystal display panel 601 via a second adhesive layer 602a, and a second polarizing film 603a is bonded to the retardation film 612a.
- a second protective layer 604a is bonded to the second polarizing film 603a through an easy adhesion layer 607a.
- An optional antistatic layer 608a is formed on the second protective layer 604a.
- each or one of these retardation films 612 and 612a has a refractive index in the slow axis direction as nx, a refractive index in the in-plane direction perpendicular thereto, ny, and a refractive index in the thickness direction as nz.
- a biaxial retardation film having a refractive index of nx> nz> ny can be obtained.
- the retardation film 612a has a two-layer structure of a biaxial retardation film having a refractive index of nx> nz> ny and a biaxial retardation film having a relation of nx> ny> nz. it can.
- the retardation film is disposed so that the direction of the slow axis is 0 ° or 90 ° with respect to the direction of the absorption axis of the polarizing film.
- This arrangement is effective for correcting the polarizing film crossing angle when viewed from an oblique direction.
- the panel configuration of FIG. 6 (e) can be applied even when the liquid crystal display panel 601 is a transmissive VA liquid crystal.
- the retardation films 612 and 612a are biaxial retardation films having a refractive index relationship of nx> nz> ny, or biaxial retardation films having a relationship of nx> ny> nz.
- the retardation films 612 and 612a are retardation films having a refractive index relationship of nx> ny ⁇ nz or a retardation film having a relationship of nx ⁇ ny> nz.
- the retardation film is arranged so that the direction of the slow axis is 0 ° or 90 ° with respect to the direction of the absorption axis of the polarizing film. This arrangement is effective in compensating for the retardation in the thickness direction of the liquid crystal, in addition to correcting the crossing angle of the polarizing films when viewed from an oblique direction.
- the optical film laminate of the present invention can be widely used for televisions, mobile phones, portable information terminals and other optical display devices.
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Abstract
Description
(2) 上記(1)に記載の光学フィルム積層体において、前記偏光膜の吸収軸に直交する方向において、前記透明保護フィルムの寸法変化率と前記偏光膜の寸法変化率の比が0.05以上1以下であってもよい。この場合、偏光膜と透明保護フィルムとの界面に生じ得る偏光膜の寸法変化に起因する応力を効果的に軽減させることができる。
(3) 上記(1)又は(2)に記載の光学フィルム積層体において、前記接着層と前記偏光膜との間に易接着層が設けられていてもよい。
(4) 上記(1)乃至(3)のいずれかに記載の光学フィルム積層体において、前記透明保護フィルムは、アクリル系樹脂フィルム、ポリエチレンテレフタレート系樹脂フィルム、又はポリオレフィン系樹脂フィルムのいずれかであってもよい。
(5) 上記(1)乃至(4)のいずれかに記載の光学フィルム積層体において、前記透明保護フィルムは、アクリル系樹脂フィルムであって、該フィルムのガラス転移温度をTgとしたときに、Tg以上の温度にて、前記偏光膜の吸収軸に直交する方向に延伸されたものであってもよい。
(6) 上記(5)に記載の光学フィルム積層体において、前記透明保護フィルムは、主鎖にグルタルイミド環又はラクトン環を有するアクリル系樹脂を利用して形成されていてもよい。
(7) 上記(1)乃至(6)のいずれかに記載の光学フィルム積層体を用いた光学的表示装置としてもよい。
(8) また、本発明によれば、熱可塑性樹脂から成る透明保護フィルムであって、前記透明保護フィルムは、厚みが40μm以下であり、100mm×100mmの試験片を85℃の環境下に48時間放置した後の、前記偏光膜の吸収軸に直交する方向における寸法変化率が0.2%以上である、透明保護フィルムが提供される。この透明保護フィルムは、厚みが10μm以下の偏光膜とともに光学フィルム積層体を製造するのに非常に有用なものである。
(9) 上記(8)に記載の透明保護フィルムにおいて、二色性物質を配向させたポリビニルアルコール系樹脂から成る厚みが10μm以下の偏光膜の片面に接着層を介して配置されてもよい。
(10) 上記(8)又は(9)に記載の透明保護フィルムは、アクリル系樹脂フィルム、ポリエチレンテレフタレート系樹脂フィルム、又はポリオレフィン系樹脂フィルムのいずれかであってもよい。
(11) 上記(8)乃至(10)のいずれかに記載の透明保護フィルムにおいて、前記透明保護フィルムは、アクリル系樹脂フィルムであって、該フィルムのガラス転移温度以上の温度にて、前記偏光膜の吸収軸に直交する方向に延伸されたものであってもよい。
(12) 上記(11)に記載の透明保護フィルムにおいて、前記透明保護フィルムは、主鎖にグルタルイミド環又はラクトン環を有するアクリル系樹脂を利用して形成されていてもよい。
偏光膜と透明な保護フィルムとの界面に生じる応力は、主に、加熱、冷却に伴う偏光膜の収縮方向における寸法変化率と保護フィルムのそれとの差によって生じるものと考えられる。この知見に基づき、先ず、様々な厚みの偏光膜について、加熱、冷却に伴う寸法変化率を測定した。この測定には、セイコーインスツル社製TMAを用いた。なお、この偏光膜の寸法変化率の測定方法は、後述する「(3)保護フィルムの寸法変化率」の測定方法とは異なるが、これらの測定方法は、実質的に互換できるものである。偏光膜を、後述の「(3)保護フィルムの寸法変化率」の方法で測定するのは困難なため、代替手法として用いただけのものである。
先ず、厚み5μmの偏光膜を、その吸収軸方向(以下、MD方向とする)に4mm、吸収軸と直交する方向(以下、TD方向とする)に25mmの短冊状に切り出した後、チャック間距離20mmとして試料をTD方向に引っ張るように設置し、引張荷重が19.6mg重を維持するように荷重制御し、雰囲気温度を25℃から85℃に10℃/分の速さで昇温させ、10分間85℃のまま保持した。その後、10℃/分の速さで降温させ、これを繰り返し48時間行った後、TMAによってその寸法の変化率を測定した。この結果、収縮方向における寸法変化率はおよそ3.0%に達した。尚、寸法変化率の値は、大きい程より大きく収縮していることを意味する。
本発明の光学フィルム積層体に用いることができる保護フィルムの作製方法の一例を説明する。尚、この作製方法は、単なる一例にすぎず、その他の作製方法を用いてもよいことは勿論である。上に説明したように、保護フィルムに求められる条件は、偏光膜の寸法変化率を許容するような寸法変化率を有することであって、それ以外の条件は、ここでは問題としない。
例えば、保護フィルムは、溶融押出法、即ち、高温でポリカーボネートのような熱可塑性樹脂を溶融した溶融物を、Tダイリップから押出し、冷却ロールで巻き取る方法によって作製することができる。
また、保護フィルムの材料も特に限定されるものではなく、例えば、アクリル系樹脂、ポリエチレンテレフタレート(PET)のようなポリエチレンテレフタレート系樹脂、光学フィルム用途として用いられているシクロオレフィン系ポリマー(COP)のようなポリオレフィン系樹脂などを用いることもできる。PETは、例えば、下記「積層体作成工程(A)」に記載された非晶性PET基材を含む。COPは、例えば、「商品名:ゼオノア(ZEONOR)、日本ゼオン(株)製」、「ゼオネックス(ZEONEX)、日本ゼオン(株)製」、「商品名:アートン、JSR(株)製」、「商品名:Topas、TOPAS ADVANCED POLYMERS GmbH社製」、「商品名:アペル、三井化学(株)製」などの市販品を含む。
更に、アクリル系樹脂に関して、本願では、主に耐熱性の向上を目的として、ラクトン環やグルタルイミド環などの環状構造をこのアクリル系樹脂の主鎖中に組み込むこととしているが、これらは任意のものであり、それらを含まないものであってもよい。主鎖にグルタルイミド環又はラクトン環を有するこれらのアクリル系樹脂は、例えば、以下の方法で作製される。
この製法は、特許文献2に開示された製法に準拠する。先ず、原料の樹脂としてメタクリル酸メチル-スチレン共重合体(スチレン量11モル%)、イミド化剤としてモノメチルアミンを用いて、イミド化樹脂を製造した。
この製法は、特許文献3に開示された製法に準拠する。攪拌装置、温度計、冷却器、窒素導入管を備えた1000L反応釜に、メタクリル酸メチル40部、2-(ヒドロキシメチル)アクリル酸メチル10部、トルエン50部、アデカスタブ2112(ADEKA製)0.025部を仕込み、これに窒素を通じつつ、105℃まで昇温させ、還流したところで、開始剤とt-アミルパーオキシイソノナノエート(アトフィナ吉富製、商品名:ルパゾール570)を0.05部添加すると同時に、0.10部のt-アミルパーオキシイソノナノエートを2時間かけて滴下しながら、還流下(約105~110℃)で溶液重合を行い、さらに4時間かけて熟成を行った。
図2から明らかなように、TD延伸倍率と寸法変化率は略比例関係にある。尚、グラフには示されていないが、延伸倍率が2.0倍付近(後述する実施例1で用いた)においても同様の関係が成り立つと考えてよい。
また、図3から明らかなように、寸法変化率は、TD延伸温度の上昇とともに小さくなり、所定の温度に達した時点で最小値となり、それ以下には下がらない。従って、所定の延伸倍率の下において、TD延伸温度を、所定の温度、例えば、Tg以上に設定することによって、寸法変化率を、例えば、0.2%以上に維持することができる。
原理的には、高温であるほど高分子の熱運動によって分子配向が等方的になるため、延伸倍率を上げても分子配向度は比較的低いと考えられる。寸法変化率には最終的に出来上がったフィルムの分子配向度が大きく依存していると考えられ、配向度が高ければ再度加熱時に等方的になろうとして収縮の寸法変化率が大きくなり、配向度が低ければ再度加熱してもさほど大きく収縮しようとしない。この結果、例えば、図2に示すように、TD延伸温度は一定でTD延伸倍率を変えた場合、延伸倍率が大きい方が寸法変化率は大きくなり、一方、図3に示すように、TD延伸倍率は一定でTD延伸温度を変えた場合、延伸温度が低い方が寸法変化率大きくなると考えられる。
次に、本発明の光学フィルム積層体に用いることができる偏光膜の作製方法の一例を、その偏光膜を作製する際に用いられる熱可塑性樹脂の一般的材料特性とともに説明する。但し、この作製方法は、単なる一例にすぎず、その他の作製方法を用いても勿論よい。
偏光膜を塗工する基材となる熱可塑性樹脂基材として、厚み200μmのイソフタル酸を6mol%共重合させたイソフタル酸共重合ポリエチレンテレフタレート(以下「非晶性PET)と記載する)の連続ウェブの基材(三菱樹脂(株)製 商品名:ノバクリア SH046 200μm)を用いた。この熱可塑性樹脂は、非晶性であり、熱を加えても結晶化しにくく、延伸倍率が低下しにくい。また、このポリエチレンテレフタレートの連続ウェブの基材は、ガラス転移温度が75℃である。なお、PVA層のガラス転移温度は、80℃である。
第1段の空中補助延伸工程(B)によって、12μm厚のPVA層2を含む積層体7を非晶性PET基材1と一体に延伸し、PVA層2を含む「延伸積層体8」を生成した。具体的には、オーブン33内に延伸手段31が配備された空中補助延伸処理装置30において、PVA層2を含む積層体7を、PVA層及び基材のガラス転移温度より高い120℃の延伸温度環境に設定されたオーブン33内で延伸手段31に通し、延伸倍率が2.0倍になるように、自由端一軸延伸し、厚み8μmの延伸積層体8を生成した。この段階で、オーブン33に併設させた巻取装置32に巻き取って延伸積層体8のロール8’を製造することができる。本実施形態では、空中補助延伸の延伸倍率を2.0倍としているが、目的の厚みや偏光度に応じて、本工程の3.5倍まで延伸倍率を上げることが可能である。
次に、第1不溶化工程(C)において、ロール8’を装着した繰出装置43から繰り出される延伸積層体8に不溶化処理を施し、不溶化された延伸積層体9を生成した。当然のことながら、この工程で不溶化された延伸積層体9は、不溶化されたPVA層2を含む。以下、これを「不溶化延伸積層体9」という。
次に、染色工程(D)によって、PVA分子が配向された8μm厚のPVA層2に二色性物質のヨウ素を吸着させた着色積層体10を生成した。具体的には、染色液51の染色浴52を備えた染色装置50において、第1不溶化処理装置40から繰り出される不溶化延伸積層体9を液温30℃のヨウ素及びヨウ化カリウムを含む染色液51に、不溶化延伸積層体9の配向されたPVA層2にヨウ素を吸着させた着色積層体10を生成した。
以下に説明する第2不溶化工程(E)は、以下の目的によりなされる。本工程は、第1に、後工程のホウ酸水中延伸工程(F)において、着色積層体10に含まれるPVA層2を溶解させないようにする不溶化と、第2に、PVA層2に着色されたヨウ素を溶出させないようにする着色安定化と、第3に、PVA層2のPVA分子同士を架橋することによって結節点を生成する結節点の生成とを目的とし、第2不溶化工程は、この第1と第2の目的を特に達成するものである。
第2不溶化工程(E)は、ホウ酸水中延伸工程(F)の前工程として行われる。染色工程(D)において生成された着色積層体10に不溶化処理を施すことによって、不溶化された着色積層体11が生成される。以下、これを「不溶化着色積層体11」という。不溶化着色積層体11は、不溶化されたPVA層2を含む。具体的には、ホウ酸とヨウ化カリウムとからなる水溶液(以下、「第2ホウ酸不溶化水溶液」という)61を収容する第2不溶化処理装置60において、着色積層体10を40℃の第2ホウ酸不溶化水溶液61に60秒間浸漬し、ヨウ素を吸着させたPVA層のPVA分子同士を架橋することによって、不溶化着色積層体11が生成される。この工程で使用される第2ホウ酸不溶化水溶液は、水100重量部に対してホウ酸を3重量部含み、水100重量部に対してヨウ化カリウムを3重量部含む。
[ホウ酸水中延伸工程(F)]
第2段のホウ酸水中延伸工程によって、ヨウ素を配向させたPVA層2を含む、不溶化着色積層体11をさらに延伸し、5μm厚の偏光膜3を構成するヨウ素を配向させたPVA層を含む積層体12を生成した。具体的には、ホウ酸水溶液71のホウ酸浴72と延伸手段73を備えたホウ酸水中延伸処理装置70において、第2不溶化処理装置60から連続的に繰り出された、不溶化着色積層体11をホウ酸とヨウ化カリウムを含む液温70℃の延伸温度環境に設定されたホウ酸水溶液71に浸漬し、次にホウ酸水中処理装置70に配備された延伸手段73に通し、延伸倍率が2.7倍になるように自由端一軸に延伸することによって、積層体12を生成した。本実施形態の総延伸倍率は、5.5倍であるが、空中補助延伸工程の延伸倍率及びホウ酸水中延伸工程の延伸倍率を調整することによって、5.0倍以上6.5倍以下としてもよい。
不溶化着色積層体11は、ホウ酸水中延伸工程(F)において延伸処理され、ホウ酸水溶液71から取り出される。取り出された偏光膜3を含む積層体12は、洗浄工程(G)に送られる。洗浄工程(G)は、薄型高性能偏光膜3の表面に付着した不要残存物を洗い流すことを目的とする。具体的には、積層体12を洗浄装置80に送り込み、薄型高性能偏光膜3のPVAが溶解しないように、液温30℃のヨウ化カリウムを含む洗浄液81に1~10秒間浸漬する。洗浄液81中のヨウ化カリウム濃度は、水100重量部に対して、4重量部である。
洗浄された積層体12は、乾燥工程(H)に送られ、ここで乾燥される。次いで、乾燥された積層体12は、乾燥装置90に併設された巻取装置91によって、連続ウェブの積層体12として巻き取られ、薄型高性能偏光膜3を含む積層体12のロールが生成される。乾燥工程(H)として、任意の適切な方法、例えば、自然乾燥、送風乾燥、加熱乾燥を採用することができる。本実施形態においては、オーブンの乾燥装置90において、60℃の温風で、240秒間、乾燥を行った。
以上の工程により、5μm厚の偏光膜3が作製される。
本発明の光学フィルム積層体は、「1.保護フィルムの作製」で得られた保護フィルムと、「2.偏光膜の作製」で得られた偏光膜の組み合わせから成る。例えば、図1の工程(I)、即ち、[貼合せ/転写工程(I)]によって、光学フィルム積層体を作ることができる。この場合、偏光膜3は、該偏光膜3が製膜された熱可塑性基材、例えば非晶性PET基材1上にそのまま残された状態で、保護フィルム4(その他の光学フィルムを含んでいてもよい)を貼合せながら巻き取られる。この巻き取り工程において、偏光膜3を保護フィルム4に転写しながら非晶性PET基材1を剥離することにより、光学フィルム積層体13が生成されることになる。具体的には、貼合せ/転写装置100に含まれる繰出/貼合せ装置101によって積層体12がロールから繰り出され、繰り出された積層体12の偏光膜3が、巻取/転写装置102によって保護フィルム4に転写され、その過程で、偏光膜3が基材1から剥離されて、光学フィルム積層体13が生成される。特に図示していないが、偏光膜3と保護フィルム4との間には接着層が設けられる。この接着層は、N-ヒドロキシエチルアクリルアミド(HEAA)40重量部とアクリロイルモルホリン(ACMO)60重量部と光開始剤「IRGACURE 819」(BASF社製)3重量部を混合することによって調整された、光硬化性の接着剤によって構成される。調整した接着剤は、硬化後の接着層の厚みが0.5μmとなるように偏光膜3の上に塗布され、この塗布側を保護フィルム14の易接着層側に貼り合わせ、活性エネルギー線として紫外線を照射し、接着剤を硬化させた。紫外線照射は、ガリウム封入メタルハライドランプ、照射装置:Fusion UV Systems,Inc社製のLight HAMMER10、バルブ:Vバルブ、ピーク照度:1600mW/cm2、積算照射量1000/mJ/cm2(波長380~440nm)を使用し、紫外線の照度は、Solatell社製のSola-Checkシステムを使用して測定した。
また、上記「積層体作成工程(A)」に記載されているように非晶性PET基材1とは別個に設けた保護フィルムを用いるのではなく、この非晶性PET基材1を保護フィルムとして利用してもよい。例えば、非晶性PET基材1を偏光膜3から一旦剥離し、所望の厚みに延伸した後に、保護フィルムとして偏光膜3と貼り合わせてもよい。また、偏光膜3と非晶性PET基材1を剥離せずに、そのまま所望の厚みに延伸して、光学フィルム積層体13を生成することもできる。
保護フィルムや、偏光膜、及び光学フィルム積層体について、以下の各評価を行った。
(1)保護フィルムの厚みの測定
作製した保護フィルムの厚みを、偏光膜と貼り合わせる前の状態において、ダイヤルゲージ(尾崎製作所製)を用いて幅方向5点で測定した。
作製した偏光膜を、保護フィルムと貼り合わせる直前の状態、即ち、図1の繰出/貼合せ装置101によって、積層体12がロールから繰り出されたときにサンプリングし、熱可塑性樹脂から剥離した後、(1)に記載のダイヤルゲージを用いて偏光膜の厚みを測定した。
偏光膜と貼り合わせる前の保護フィルム、即ち、図1の繰出/貼合せ装置101において、偏光膜3を転写するために繰り出された保護フィルム4について、以下の寸法変化率測定を行った。
作製された保護フィルムサンプルから、試験片を、保護フィルムの搬送方向(MD方向)について100mm、保護フィルムの搬送方向に対して垂直な方向(TD方向)について100mmの正方形形状に切り出し、4辺の中点近傍に標点を設け、25℃50%RHの室温環境下にて、向かい合う辺同士の標点間距離「a」を測定した。次に85℃の乾燥オーブン(espec社製)に48時間投入し、85℃の環境試験機内から測定前と同じ25℃50%RHの室温環境下に取り出した後、30分後に、平面二軸寸法測定機(ミツトヨ製QV606)にて、同様に向かい合う辺同士の評点間距離「a’」を測定した。このとき、(a’-a)/a×100(%)をそれぞれMD方向の寸法変化率とした。
得られた光学フィルム積層体について、以下のクラック評価を行った。
(4-1)所定のヒートサイクルを与えた後のクラックの有無に関する評価
作製した光学フィルム積層体のサンプルを、MD方向に200mm、TD方向に150mmの長方形型に切り出し、粘着剤側を長さ250mm、幅170mm、厚み1mmの無アルカリガラス板の中央部に貼り付けた。次に加圧脱泡装置(栗原製作所製)を用いて、0.5MPaの圧力下で、50℃で15分間の加圧脱泡装置を施した。その後、ガラスに貼りつけたままサンプルを環境試験機に投入し、-40℃から85℃までの冷熱衝撃を100サイクル与え、MD方向にクラックが発生するかどうかを確認した。
(4-2)所定深さのクラックが生じるまでに要したヒートサイクルの回数に関する評価
作製した光学フィルム積層体のサンプルを、積層方向を紙面に対して垂直に見た時に、TD方向を長辺として図4に示す形状に切り出した。尚、偏光膜と保護フィルムは紙面に対して垂直方向に積層されている。切り出し加工にはレーザー加工機を用いた。次に粘着剤側を長さ250mm、幅170mm、厚み1mmの無アルカリガラス板の中央部に貼り付け、加圧脱泡装置(栗原製作所製)を用いて、0.5MPaの圧力下で、50℃で15分間の加圧脱泡処理を施した。その後、ガラスに貼りつけたままサンプルを環境試験機に投入し、-40℃から85℃までの冷熱衝撃を10サイクル与え、図4中「a」部に発生するクラックの長さを比較した。冷熱衝撃試験は合計で最大100サイクルまで与え、クラックが辺「b」まで達するのに必要なサイクル数をカウントした。
偏光膜と保護フィルムとの界面に生じる応力を軽減させる観点から、保護フィルムの寸法変化率(εf)と偏光膜の寸法変化率(εp)との比(εf/εp)を求めた。明らかなように、これらの寸法変化率の差は小さければ小さい程よい、つまり、比の値は1に近い程、好ましい。後述する表1では、実際に実験に用いた偏光膜の寸法変化率に対する保護フィルムの寸法変化率の比を求めた。
上記「(1)グルタルイミド環単位を有する(メタ)アクリル系樹脂を利用した保護フィルムの作製」に記載された方法で、厚み40μmの保護フィルムを得た。また、上記「2.偏光膜の作製」に記載された方法で、厚み5μmの偏光膜を得た。これら保護フィルムと偏光膜とから構成される光学フィルム積層体について評価を行った。
この結果、保護フィルムのTD方向における寸法変化率は、+0.21となり、また、クラックの発生は無く、所定深さのクラックに達するまでに要したヒートサイクルは、70回と、良好な結果が得られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.07となった。
基本的に実施例1と同じであるが、保護フィルムの作製時にTD方向の延伸倍率を30%上げて2.65倍とし、厚み20μmの保護フィルムを得た。この保護フィルムを、上記「2.偏光膜の作製」に記載された方法で得た厚み5μmの偏光膜と接着し、得られた光学フィルム積層体について評価を行った。
この場合、保護フィルムの寸法変化率は、+0.42となり、また、クラックの発生は無く、ヒートサイクルを100回以上繰り返しても所定深さまでクラックは達せず、実施例1よりも良好な結果が得られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.14となった。
保護フィルムの作製時におけるTD方向の延伸温度が実施例1より3℃高いこと以外は、実施例2と同様である。
この場合の保護フィルムの寸法変化率は、+0.3であった。また、クラックの発生は無く、所定深さのクラックに達するまでに要したヒートサイクルは、90回であった。また、このとき厚み5μmの偏光膜の寸法変化率との比は、0.1となった。
保護フィルムの作製時におけるTD方向の延伸温度が実施例1より6℃高いこと以外は、実施例2と同様である。
この場合の保護フィルムの寸法変化率は、+0.22であった。また、クラックの発生は無く、所定深さのクラックに達するまでに要したヒートサイクルは、70回であった。また、厚み5μmの偏光膜の寸法変化率との比は、0.073となった。
基本的に実施例1と同じであるが、保護フィルムの作製時にTD方向の延伸倍率を30%上げて延伸し、これに伴ってMD方向の延伸倍率を調整することにより保護フィルムの厚みを40μmとした。また、上記「2.偏光膜の作製」に記載された方法で、厚み5μmの偏光膜を得た。これら保護フィルムと偏光膜とから構成される光学フィルム積層体について、評価を行った。
この結果、保護フィルムの寸法変化率は、+0.53となり、また、クラックの発生は無く、所定深さのクラックに達するまでに要したヒートサイクルは、80回となり、実施例1よりも良好な結果が得られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.177となった。
上記「(2)ラクトン環単位を有する(メタ)アクリル系樹脂を利用した保護フィルムの作製」に記載された方法で、厚み20μmの保護フィルムを得た。この場合のTD方向における延伸温度(139℃)と延伸倍率(2.65倍)は、実施例4と同じである。また、上記「2.偏光膜の作製」に記載された方法で、厚み5μmの偏光膜を得た。これら保護フィルムと偏光膜とから構成される光学フィルム積層体について、評価を行った。
この結果、保護フィルムのTD方向における寸法変化率は、+0.36となり、また、クラックの発生は無く、所定深さのクラックに達するまでに要したヒートサイクルは、70回であり、良好な結果が得られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.12となった。
上記「積層体作成工程(A)」に記載された非晶性PET基材を、偏光膜から剥離した後、厚みが20μmになるよう延伸した。この場合のTD方向における延伸温度は100℃であり、延伸倍率は2.0倍であった。
この場合の保護フィルムの寸法変化率-1.78となり、また、所定深さのクラックに達するまでに要したヒートサイクルは80回であり、良好な結果が得られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.59となった。尚、クラックの有無については、所定深さのクラックに達するまでに要したヒートサイクルの回数や実施例1乃至6等の結果から明らかであるため、つまり、クラックが生じないことは明らかであるため、特に実験を行っていない(実施例8についても同様)。
日本ゼオン(株)製ゼオノアフィルム(厚み50μm)を使用し、TD方向の延伸温度を130℃、延伸倍率を2.0倍で延伸した。
この場合の保護フィルムの寸法変化率は-0.24となり、また、所定深さのクラックに達するまでに要したヒートサイクルは、70回であり、良好な結果が得られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.08となった。
基本的に実施例6と同じであるが、偏光膜の厚みを12μmとした点で相違する。この12μm厚みの偏光膜は、上記の通り、PVA単層のフィルムをそのまま染色及び延伸する方法で得られたものである。この場合、保護フィルムの寸法変化率は、+0.36と良好な結果が得られたが、所定深さのクラックに達するまでに要したヒートサイクルは、10回であり、実用に耐えないものであることが判明した。また、厚み12μmの偏光膜の寸法変化率との比は、0.09となった。尚、クラックの有無については、所定深さのクラックに達するまでに要したヒートサイクルの回数や比較例2、3等の結果から明らかであるため、つまり、クラックが生じることは明らかであるため、特に実験を行っていない(比較例4乃至6についても同様)。
保護フィルムの作製時におけるTD方向の延伸温度が実施例6より12℃高いこと以外は、実施例6と同様である。この場合、保護フィルムの寸法変化率は、+0.18であり、クラックが発生し、所定深さのクラックに達するまでに要したヒートサイクルも、10回と悪化が見られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.06となった。
保護フィルムの作製時におけるTD方向の延伸温度が実施例5より12℃高く、延伸倍率が2.05倍であること以外は、実施例5と同様である。
この場合、保護フィルムの寸法変化率は、+0.1であったが、クラックが発生し、所定深さのクラックに達するまでに要したヒートサイクルも、30回と悪化が見られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.033となった。
保護フィルムの作製時におけるTD方向の延伸温度が実施例6より11℃高く、偏光膜の厚みを12μmとしたこと以外は、実施例6と同様である。尚、厚み12μmの偏光膜は、比較例1と同様の方法で得た。この場合、保護フィルムの寸法変化率は、+0.18であったが、クラックが発生し、所定深さのクラックに達するまでに要したヒートサイクルも、10回と悪化が見られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.06となった。
保護フィルムの作成時におけるTD方向の延伸倍率が1.0倍である以外は、実施例7と同様である。
この場合、保護フィルムの寸法変化率は+0.88であり、膨張する結果となり、所定深さのクラックに達するまでに要したヒートサイクルも、10回と悪化が見られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.29となったが、膨張であるため、意味をなさない。
保護フィルムの作成時におけるTD方向の延伸温度が140℃である以外は、実施例8と同様である。
この場合、保護フィルムの寸法変化率は-0.12であり、所定深さのクラックに達するまでに要したヒートサイクルも、10回と悪化が見られた。また、厚み5μmの偏光膜の寸法変化率との比は、0.04となった。
尚、本実施例では、ラクトン環についての実施例は実施例6のみであるが、ラクトン環のTg(126℃)とグルタルイミド環のTg(127℃)は略同じであることから、寸法変化率の観点、言いかえれば、分子配向性の観点からみれば、両者は実質的に同じものと考えることができる。よって、たとえ実施例が存在しなくとも、ラクトン環を含有したアクリル系樹脂については、基本的に、グルタルイミド環を含有したそれと同様に考えることができる。更に、グルタル酸無水物構造を導入した場合や、フェニルマレイミド、シクロヘキシルマレイミド、メチルマレイミドなどのN-置換マレイミドを共重合した場合も、同様の結果が得られることは当業者には明らかであろう。
また、ポリエチレンテレフタレート系樹脂については、偏光膜の厚みが10μm以下、例えば、5μmであって、保護フィルムの厚みが40μm以下、例えば、20μmであり、且つ、その延伸倍率が2.0(以上)の場合には、光学フィルム積層体に所定深さのクラックが生じるまでに要するヒートサイクルの回数は80回以上と良好な結果が得られた。また、ヒートサイクルについて良好な結果が得られたときの、透明保護フィルムの寸法変化率と偏光膜の寸法変化率の比は、0.59以上となった。尚、本実施例では、ポリエチレンテレフタレート系樹脂としてPETを例示しているが、ポリエステル系樹脂であるから、PET以外の、例えば、ポリブチレンテレフタレート、ポリエチレンナフタレート、ポリブチレンナフタレート等についても、同様の結果が得られることは当業者には明らかであろう。
更に、ポリオレフィン系樹脂については、偏光膜の厚みが10μm以下、例えば、5μmであって、保護フィルムの厚みが40μm以下、例えば、25μmであり、且つ、その延伸温度がTg+30(以下)の場合には、光学フィルム積層体に所定深さのクラックが生じるまでに要するヒートサイクルの回数は70回以上と良好な結果が得られた。また、ヒートサイクルについて良好な結果が得られたときの、透明保護フィルムの寸法変化率と偏光膜の寸法変化率の比は、0.08以上となった。
図5及び図6に、本発明による光学フィルム積層体を用いた光学的表示装置(層構成)の実施形態を示す。
4 保護フィルム
13 光フィルム積層体
Claims (12)
- 二色性物質を配向させたポリビニルアルコール系樹脂から成る厚みが10μm以下の偏光膜と、前記偏光膜の片面に接着層を介して配置された熱可塑性樹脂から成る透明保護フィルムとを含む光学フィルム積層体であって、
前記透明保護フィルムは、厚みが40μm以下であり、100mm×100mmの試験片を85℃の環境下に48時間放置した後の、前記偏光膜の吸収軸に直交する方向における寸法変化率が0.2%以上である、光学フィルム積層体。 - 前記偏光膜の吸収軸に直交する方向において、前記透明保護フィルムの寸法変化率と前記偏光膜の寸法変化率の比が0.05以上1以下である、請求項1に記載の光学フィルム積層体。
- 前記接着層と前記偏光膜との間に易接着層が設けられている、請求項1又は2に記載の光学フィルム積層体。
- 前記透明保護フィルムは、アクリル系樹脂フィルム、ポリエチレンテレフタレート系樹脂フィルム、又はポリオレフィン系樹脂フィルムのいずれかである、請求項1乃至3のいずれかに記載の光学フィルム積層体。
- 前記透明保護フィルムは、アクリル系樹脂フィルムであって、該アクリル系樹脂フィルムのガラス転移温度以上の温度にて、前記偏光膜の吸収軸に直交する方向に延伸されたものである、請求項1乃至4のいずれかに記載の光学フィルム積層体。
- 前記透明保護フィルムは、主鎖にグルタルイミド環又はラクトン環を有するアクリル系樹脂を利用して形成されている請求項5に記載の光学フィルム積層体。
- 請求項1乃至6のいずれかに記載の光学フィルム積層体を用いた光学的表示装置。
- 熱可塑性樹脂から成る透明保護フィルムであって、
前記透明保護フィルムは、厚みが40μm以下であり、100mm×100mmの試験片を85℃の環境下に48時間放置した後の、偏光膜の吸収軸に直交する方向における寸法変化率が0.2%以上である、透明保護フィルム。 - 二色性物質を配向させたポリビニルアルコール系樹脂から成る厚みが10μm以下の偏光膜の片面に接着層を介して配置される、請求項8に記載の透明保護フィルム。
- アクリル系樹脂フィルム、ポリエチレンテレフタレート系樹脂フィルム、又はポリオレフィン系樹脂フィルムのいずれかである、請求項8又は9に記載の透明保護フィルム。
- 前記透明保護フィルムは、アクリル系樹脂フィルムであって、該アクリル系樹脂フィルムのガラス転移温度以上の温度にて、前記偏光膜の吸収軸に直交する方向に延伸されたものである、請求項8乃至10のいずれかに記載の透明保護フィルム。
- 前記透明保護フィルムは、主鎖にグルタルイミド環又はラクトン環を有するアクリル系樹脂を利用して形成されている請求項11に記載の透明保護フィルム。
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CN202211208050.XA CN115576046B (zh) | 2014-10-02 | 2015-10-02 | 光学膜层叠体、使用光学膜层叠体的光学显示装置、和透明保护膜 |
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