WO2016072359A1 - Method for manufacturing polarization plate sheet - Google Patents

Method for manufacturing polarization plate sheet Download PDF

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Publication number
WO2016072359A1
WO2016072359A1 PCT/JP2015/080677 JP2015080677W WO2016072359A1 WO 2016072359 A1 WO2016072359 A1 WO 2016072359A1 JP 2015080677 W JP2015080677 W JP 2015080677W WO 2016072359 A1 WO2016072359 A1 WO 2016072359A1
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WO
WIPO (PCT)
Prior art keywords
polarizing plate
plate sheet
protective film
adhesive layer
film
Prior art date
Application number
PCT/JP2015/080677
Other languages
French (fr)
Japanese (ja)
Inventor
宙孝 石川
泰礼 加藤
Original Assignee
住友化学株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 住友化学株式会社 filed Critical 住友化学株式会社
Priority to KR1020177013678A priority Critical patent/KR102256908B1/en
Priority to CN201580058671.6A priority patent/CN107003459B/en
Publication of WO2016072359A1 publication Critical patent/WO2016072359A1/en

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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
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • 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
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • 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
    • 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
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/045—Slitting
    • 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
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption

Definitions

  • the present invention relates to a method for producing a polarizing plate sheet with reduced undulation defects, which is preferably used in an image display device such as a liquid crystal display device.
  • a polarizing plate used in an image display device such as a liquid crystal display device generally has a laminated structure in which a protective film is bonded to one or both sides of a polarizer via an adhesive layer, and a long polarizer and Using a long protective film, it is produced as a long product (polarizing plate roll) by a roll-to-roll method [for example, JP 2009-134190 A (Patent Document 1)].
  • the obtained long polarizing plate is cut into a sheet of a predetermined size according to the screen size of the image display device, and is laminated to an image display element such as a liquid crystal cell using an adhesive layer or the like. Embedded in an image display device.
  • Patent Document 1 as a method for suppressing a problem called reverse curling and wave curling that occurs in a polarizing plate, a long polarizer and a long protective film are laminated with an adhesive interposed therebetween. It is described that an adhesive is polymerized and cured while the laminate is in close contact with a convex curved surface formed in an arc shape along the longitudinal direction of the laminate.
  • an object of the present invention is to provide a method for producing a polarizing plate sheet having a reduced number or height of undulating defects.
  • a rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof, and having a long side and a short side, wherein at least one of the long sides is 1
  • a method for producing a polarizing plate sheet comprising:
  • the first polarizing plate sheet includes the polarizer, a first protective film laminated on one surface of the polarizer through a first adhesive layer, and a second adhesive on the other surface.
  • the first polarizing plate sheet has the following (a) and (b): (A) a protective film laminated on the protective film; (B) The adhesive layer according to any one of [1] to [7], further comprising at least one of an adhesive layer laminated on the polarizer or the protective film and a separate film laminated on the outer surface thereof. Manufacturing method.
  • the present invention it is possible to provide a polarizing plate sheet having a reduced number or height of undulating defects.
  • the present invention is capable of reducing wavy defects to a sufficient extent even for polarizing plate sheets having four or more or wavy defects whose height exceeds 2 mm. Can provide a method.
  • the manufacturing method of the polarizing plate sheet according to the present invention includes the following steps: (1) A rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof and having a long side and a short side, wherein at least one of the long sides is 1 A step of preparing a first polarizing plate sheet having at least one wavy defect, and (2) slit removing an end portion including the long side having the wavy defect in the first polarizing plate sheet; A step of obtaining a polarizing plate sheet, including.
  • each step will be described.
  • the first polarizing plate sheet has a undulating defect, and is likely to be accompanied by the above-described problem of bubble mixing and accompanying visibility deterioration. Specifically, it is a polarizing plate sheet that has one or more undulation defects on at least one of the long sides. As a result of further occurrence of undulation defects, the first polarizing plate sheet has undulation defects whose height exceeds 2 mm on at least any one long side, or at least four on at least any one long side. It may be a polarizing plate sheet having undulating defects, and the first polarizing plate sheet has four or more undulating defects on at least one of the long sides, and these undulating defects. Any one or more of the above may be a waving defect whose height exceeds 2 mm.
  • the height of the undulating defect is the height from the flat table to the top of the undulating defect when the first polarizing plate sheet is placed on the flat table.
  • the first polarizing plate sheet is displayed as an image.
  • the surface to be bonded to the element (for example, a liquid crystal cell) is placed on a flat table with the surface facing up.
  • the height of the undulation defect is measured at the side (end) of the first polarizing plate sheet.
  • the number of undulating defects is substantially the number of undulating defects. Specifically, when the first polarizing plate sheet is placed on a flat table, the height is 0 from the flat table. It is the number of undulating defects that are 5 mm or more. The number of wavy defects is also measured at the side (edge) of the first polarizing plate sheet.
  • the first polarizing plate sheet has a rectangular shape having a long side and a short side, and is typically a rectangle.
  • the lengths of the long side and the short side are not particularly limited, but the long side of the first polarizing plate sheet is usually 700 mm or more and the short side is 400 mm or more.
  • the size of the first polarizing plate sheet is larger, the waviness defect is more prominent in the height and number of waviness. If the size (long side and / or short side) is too small, the problem of undulation defects itself is less likely to occur.
  • the first polarizing plate sheet is a polarizing plate in which the above-described wavy defects are generated in the process of storing and transporting under some conditions after cutting the polarizing plate manufactured as a long product. it can.
  • the first polarizing plate having a wavy defect whose height exceeds 2 mm or four or more wavy defects on any one long side has the same degree of wavy defect on the long side facing the long side.
  • the first polarizing plate sheet having a wavy defect with a height exceeding 2 mm or four or more wavy defects on any one long side may have a wavy defect also on two short sides.
  • the wavy defects that occur on the two short sides tend to be smaller in height and / or number than the wavy defects that occur on the long sides, and the wavy defects on the short sides are Compared to this, there is a tendency that the problem of air bubbles is less likely to occur. Therefore, in order to suppress the problem of mixing of bubbles and the accompanying deterioration in visibility, it is important to reduce the undulation defect that occurs on the long side.
  • the layer configuration of the first polarizing plate sheet is not particularly limited as long as it includes a polarizer and a protective film laminated and bonded on at least one surface thereof, and the protective film is laminated and bonded on both surfaces of the polarizer. May be.
  • the protective film is usually laminated and bonded onto the polarizer via an adhesive layer.
  • the first polarizing plate sheet may have a layer (or film) other than the polarizer and the protective film.
  • a polarizing plate produced as a long product and a polarizing plate sheet obtained by cutting the polarizing plate have a pressure-sensitive adhesive layer for bonding to an image display element (for example, a liquid crystal cell) on the outer surface of the polarizing plate in advance.
  • an image display element for example, a liquid crystal cell
  • the first polarizing plate sheet can also include such an adhesive layer.
  • a separate film (separator) for protecting the surface (outer surface) is usually laminated on the outer surface of the adhesive layer.
  • a polarizing plate produced as a long product is usually stored or distributed as a polarizing plate roll formed by winding the polarizing plate.
  • the protective film is used.
  • a protective film surface protective film
  • a polarizing plate sheet obtained by cutting the polarizing plate generally has a protective film.
  • the first polarizing plate sheet may include a protective film laminated on the protective film.
  • the protective film of the first polarizing plate sheet has a hard coat layer, an antiglare layer, an antireflection layer, an antistatic layer, an antifouling layer on the outer surface (the surface opposite to the polarizer).
  • a surface treatment layer (coating layer) may be provided.
  • the 1st polarizing plate sheet can contain the layer or film which has optical functions other than a polarizer.
  • One example is a retardation film.
  • a first polarizing plate sheet 1 shown in FIG. 1 includes a polarizer 10; a first protective film 20 that is bonded to one surface of the polarizer 10; a first film that is bonded to the other surface of the polarizer 10. 2 protective film 30; adhesive layer 40 laminated on the outer surface of the second protective film 30; separate film 50 laminated on the outer surface of the adhesive layer 40; a protective film 60 laminated on the outer surface of the first protective film 20 Including.
  • the layer configuration having the pressure-sensitive adhesive layer 40 and the separate film 50, the layer configuration having the protective film 60, or the pressure-sensitive adhesive layer 40 is an example of a preferable layer structure of the first polarizing plate sheet.
  • the pressure-sensitive adhesive layer 40 may be directly laminated on the polarizer 10 by omitting one of the first protective film 20 and the second protective film 30.
  • the polarizer 10 is an optical film having a property of absorbing linearly polarized light having a vibration plane parallel to the optical axis and transmitting linearly polarized light having a vibration plane perpendicular to the optical axis.
  • the polarizer 10 is uniaxially stretched and has two colors. It can be a polyvinyl alcohol-based resin film in which a functional dye is adsorbed and oriented.
  • the dichroic dye iodine or a dichroic organic dye is used.
  • the polyvinyl alcohol-based resin constituting the polarizer 10 includes polyvinyl alcohol, which is a saponified product of polyvinyl acetate, and a copolymer of vinyl acetate and other monomers copolymerizable therewith (for example, ethylene and unsaturated carboxylic acid). It may be a vinyl alcohol copolymer which is a saponified product.
  • the thickness of the polarizer 10 is usually about 5 to 40 ⁇ m.
  • the polarizer 10 includes a step of uniaxially stretching a polyvinyl alcohol-based resin film, a step of dyeing the polyvinyl alcohol-based resin film with a dichroic dye and adsorbing the dichroic dye, and polyvinyl alcohol on which the dichroic dye is adsorbed. It can manufacture by the method of including the process of wash
  • the dichroic dye can be dyed by immersing the film in an aqueous solution containing the dichroic dye, and the treatment with the boric acid aqueous solution can be performed by immersing the film in the boric acid aqueous solution.
  • the uniaxial stretching of the polyvinyl alcohol-based resin film can be performed before, simultaneously with, or after the dyeing of the dichroic dye.
  • this uniaxial stretching may be performed before boric acid treatment or during boric acid treatment. Moreover, you may uniaxially stretch in these several steps.
  • the first and second protective films 20 and 30 can be a thermoplastic resin film having translucency (preferably optically transparent).
  • thermoplastic resins include polyolefin resins such as chain polyolefin resins (polypropylene resins, etc.) and cyclic polyolefin resins (norbornene resins, etc.); polyester resins (polyethylene terephthalate resins, etc.); ) Acrylic resin (methyl methacrylate resin etc.); Cellulosic resin (cellulose acetate resin such as triacetyl cellulose [TAC], diacetyl cellulose etc.); Polycarbonate resin; Polyvinyl alcohol resin; Polyvinyl acetate resin Polyarylate resins; polystyrene resins; polyethersulfone resins; polysulfone resins; polyamide resins; polyimide resins; and mixtures and copolymers thereof.
  • polyolefin resins such as chain polyolefin resins (polypropylene resins,
  • the thickness of the first and second protective films 20 and 30 is, for example, about 5 to 200 ⁇ m, preferably 10 to 150 ⁇ m, and more preferably 15 to 100 ⁇ m.
  • (meth) acryl means at least one selected from acryl and methacryl.
  • the 1st protective film 20 and the 2nd protective film 30 may be comprised with the same kind of thermoplastic resin, and may be comprised with a different kind of thermoplastic resin, but are comprised with a different kind of thermoplastic resin.
  • the moisture permeability of the protective films bonded to both surfaces is different from each other, such as in the case where the moisture film absorbs moisture, the undulation defect is particularly likely to occur due to the difference in hygroscopicity. Therefore, the present invention is particularly advantageous in such a case.
  • the difference in moisture permeability of the protective films bonded on both sides is 30 g / (m 2 ⁇ 24 hr) or more, further 50 g / (m 2 ⁇ 24 hr) or more, and even more 100 g / (m 2 Even if it is 24 hr) or more, and more particularly 300 g / (m 2 ⁇ 24 hr) or more, it is possible to obtain a polarizing plate sheet that is less likely to cause undulation defects and is less likely to cause problems of air bubbles and associated visibility degradation. it can.
  • the difference in the water vapor transmission rate of the protective film bonded to both surfaces is 900 g / (m 2 ⁇ 24 hr) or less.
  • the moisture permeability is a moisture permeability at a temperature of 40 ° C. and a relative humidity of 90%, and is measured by a cup method defined in JIS Z 0208.
  • Examples of combinations of protective films having a difference in moisture permeability of 30 g / (m 2 ⁇ 24 hr) at a temperature of 40 ° C. and a relative humidity of 90% include, for example, a cellulose resin film (TAC film, etc.) and a cyclic polyolefin resin , A combination of a cellulose resin film (TAC film or the like) and a (meth) acrylic resin film, a combination of a cyclic polyolefin resin and a (meth) acrylic resin film, or the like.
  • the thermoplastic resin which comprises the protective film bonded on both surfaces is the same kind, a difference may arise in a water vapor transmission rate by the presence or absence of a surface treatment layer laminated
  • the polarizer 10, the first protective film 20, and the second protective film 30 can be bonded via an adhesive layer.
  • an adhesive layer a water-based adhesive, that is, an adhesive component dissolved or dispersed in water, or an active energy ray-curable adhesive can be used.
  • the adhesive component of the water-based adhesive can be, for example, a polyvinyl alcohol resin or a urethane resin.
  • the active energy ray-curable adhesive can be, for example, a curable composition containing an active energy ray-curable compound such as an epoxy compound or a (meth) acrylic compound and a polymerization initiator.
  • the active energy ray-curable adhesive can be a solventless adhesive, but can also contain an organic solvent. If a solventless type adhesive is used, a drying process for removing the solvent becomes unnecessary.
  • the active energy ray-curable adhesive When an active energy ray-curable adhesive is used, after bonding a protective film through an adhesive layer, the active energy rays such as visible light, ultraviolet rays, X-rays, electron beams, etc., preferably ultraviolet rays are irradiated and bonded.
  • the agent layer is cured. Therefore, in this case, the adhesive layer in the first polarizing plate sheet is made of a cured product of an active energy ray-curable adhesive.
  • the 1st adhesive layer which bonds 1 protective film 20, and the 2nd adhesive layer which bonds 2nd protective film 30 may be formed from the same kind of adhesives, and are formed from a different kind of adhesives. However, it is preferably formed from the same kind of adhesive from the viewpoint of production efficiency.
  • the present invention is particularly advantageous.
  • an adhesive which comprises the adhesive layer 40 for bonding to an image display element for example, a (meth) acrylic adhesive, a urethane adhesive, a silicone adhesive, a polyester adhesive, Examples thereof include a polyamide-based adhesive, a polyether-based adhesive, a fluorine-based adhesive, and a rubber-based adhesive.
  • a (meth) acrylic pressure-sensitive adhesive is preferably used from the viewpoints of transparency, adhesive strength, reliability, reworkability, and the like.
  • the thickness of the pressure-sensitive adhesive layer 40 is usually 2 to 40 ⁇ m.
  • the separate film 50 and the protect film 60 are provided for the purpose of temporarily protecting the adhesive layer 40 and the first protective film 20 when the polarizing plate is stored, transported, or inspected.
  • the separate film 50 that protects the pressure-sensitive adhesive layer 40 is peeled and removed immediately before the second polarizing plate sheet described below is put to practical use (for example, bonded to an image display element such as a liquid crystal cell).
  • the protective film 60 is usually peeled and removed together with the pressure-sensitive adhesive layer after the second polarizing plate sheet is put into practical use (for example, bonded to an image display element such as a liquid crystal cell).
  • the separate film 50 is usually composed of a thermoplastic resin film having a release treatment on one side, and the release treatment surface is bonded to the pressure-sensitive adhesive layer 40.
  • the protect film 60 is usually configured by providing an adhesive layer on one side of a thermoplastic resin film.
  • the thermoplastic resin constituting the separate film 50 and the protect film 60 may be, for example, a polyethylene resin such as polyethylene, a polypropylene resin such as polypropylene, or a polyester resin such as polyethylene terephthalate or polyethylene naphthalate. it can.
  • the description of the pressure-sensitive adhesive layer 40 described above is cited.
  • the layer configuration of the first polarizing plate sheet is not limited to the example shown in FIG. 1, and may be the following layer configuration, for example.
  • An example of the above [b] is a configuration in which the second protective film 30 is omitted, and a preferred specific example thereof is that the pressure-sensitive adhesive layer 40 is directly laminated on the surface of the polarizer 10 opposite to the first protective film 20.
  • the protective film 60 / first protective film 20 / polarizer 10 / adhesive layer 40 / separate film 50 are layered.
  • a preferred specific example of the above [c] is a protective film 60 / first protective film 20 / polarizer 10 / retardation film (second protective film 30) / adhesive layer 40 / separate film 50 layer structure. It is.
  • a preferred specific example of the above [d] is a protective film 60 / first protective film 20 / polarizer 10 / second protective film 30 / retardation film / adhesive layer 40 / separate film 50 layer structure. is there. In this case, the 2nd protective film 30 and retardation film can be bonded through an adhesive layer, for example.
  • the retardation film is an optical film having optical anisotropy such as uniaxial or biaxial, and can be, for example, a stretched film of a thermoplastic resin.
  • the thermoplastic resin can be the one exemplified above for the first and second protective films 20 and 30, as well as polyvinylidene fluoride / polymethyl methacrylate copolymer, liquid crystal polyester, acetyl cellulose, ethylene-vinyl acetate.
  • a saponified copolymer, polyvinyl chloride, or the like can also be used.
  • the draw ratio is usually about 1.01 to 6 times.
  • Step of obtaining a second polarizing plate sheet This step is a process of obtaining a long side end portion of the first polarizing plate sheet having one or more wavy defects on at least one of the long sides (the wavy defect is removed). This is a step of obtaining a second polarizing plate sheet with reduced waviness defects by slit-removing the end portion including the long side.
  • Conventionally known cutting (cutting) means such as a shear cutter can be used for the slit.
  • the first polarizing plate sheet has a protective film 60 laminated on the protective film, and / or a pressure-sensitive adhesive layer 40 laminated on the polarizer 10 or the protective film, and a separate film 50 laminated on the outer surface thereof.
  • the first polarizing plate sheet having a wavy defect at the end may be accompanied by an appearance defect in which the color of the end becomes dark.
  • This poor appearance is caused by a shift in the interface between the thermoplastic resin film constituting the protective film 60 and the pressure-sensitive adhesive layer or the interface between the separate film 50 and the pressure-sensitive adhesive layer 40 due to the stress at the time when the wavy defect occurs. This is thought to be due to the rough surface of the layer.
  • the surface of the pressure-sensitive adhesive layer 40 is rough, there is a possibility that an appearance defect may remain even after being bonded to an image display element such as a liquid crystal cell.
  • a slit is removed by this step so as to remove the defective appearance portion, a polarizing plate sheet having good appearance quality can be obtained even in terms of color.
  • ⁇ Slit removal is performed on the long side end portion having the undulation defect.
  • the first polarizing plate sheet having a wavy defect with a height exceeding 2 mm or four or more wavy defects on any one long side has the same degree of wavy defect on the long side facing the long side. Therefore, typically, slit removal is performed on both long side end portions.
  • the width W1 at the end of the long side to be slit-removed is reduced in the case of a polarizing plate sheet having a wavy defect having a height exceeding 2 mm or four or more wavy defects in at least one of the long sides. From the viewpoint of effect, it is preferably 65 mm or more per one end. It should be noted that as long as the first polarizing plate sheet is the above-described normal size (long side 700 mm or more and short side 400 mm or more), the long side end portion is preferably 65 mm or more regardless of the size. By removing with the slit width W1, it is possible to obtain a good undulating defect reduction effect.
  • the slit width W1 is more preferably 70 mm or more, more preferably 80 mm or more, still more preferably 100 mm or more, and particularly preferably 140 mm, per one end. That's it.
  • the wavy defects that can occur in the two short sides tend to be smaller in height and / or number than the wavy defects that occur in the long side, and the wavy defects in the short side
  • the undulation defect has occurred.
  • the short side edge part one end part or both end parts
  • the slit width W2 at the short side end can be, for example, 35 mm or more, preferably 40 mm or more, more preferably 45 mm or more, per one end.
  • the second polarizing plate is reduced in size from the first polarizing plate sheet by removing one or both of the short side ends.
  • Leaf bodies may be obtained.
  • the long side edge and the short side edge of the 46-inch size (long side 1031 mm ⁇ short side 585 mm) first polarizing plate sheet are slit to remove a 39 inch size (long side).
  • the slit may be removed to obtain a second polarizing plate sheet having a size of 32 inches (long side 700 mm ⁇ short side 400 mm).
  • the long side end is 65 mm or more per one end.
  • the slit width W1 is removed, only one of the two long side ends may be removed by slit, or both of the long side ends may be removed by slit.
  • only one of the two short side ends may be slit removed, or both short side ends may be slit removed.
  • the polarizing plate sheet is placed on a flat table with the separate film 50 side facing upward, and the number of wavy defects on the two long sides of the polarizing plate sheet (the height is 0 from the flat table as described above). , And the height of the undulating defect from the plane table was measured.
  • Table 1 shows the number and height of undulating defects on the long side having more undulating defects among the two long sides. The height of the undulating defect shown in Table 1 is the highest height of the undulating defect when having a plurality of undulating defects.
  • first polarizing plate sheet A long polarizing plate having the layer structure shown in FIG. 1 was prepared.
  • This polarizing plate is composed of a protective film 60 having a thickness of 53 ⁇ m (consisting of a (meth) acrylic pressure-sensitive adhesive layer and a polyethylene terephthalate film) / first protective film 20 having a thickness of 60 ⁇ m (TAC film) / a polarizer having a thickness of 25 ⁇ m.
  • first protective film 20 and the second protective film 30 are an active energy ray-curable adhesive (a UV curable adhesive containing a curable compound that is a cationic polymerizable epoxy compound and a photocationic polymerization initiator).
  • the moisture permeability of the first protective film 20 and the second protective film 30 at 40 ° C. and 90% relative humidity was 560 g / (m 2 ⁇ 24 hr) and 5 g / (m 2 ⁇ 24 hr), respectively.
  • Example 2 The first polarized light of 46 inch size (long side: 1031 mm ⁇ short side: 585 mm) having a long side of 3.5 mm and a number of wavy defects of 4 mm obtained in the same manner as in Experimental Example 1 above. Use a shear cutter to slit the two long side edges of the plate sheet body by 85.5 mm per one end, and slit the two short side edges by 47.5 mm per one end. Thus, a second polarizing plate sheet reduced in size to 39 inches (long side 860 mm ⁇ short side 490 mm) was obtained.
  • first polarizing plate sheet 10 polarizer, 20 first protective film, 30 second protective film, 40 adhesive layer, 50 separate film, 60 protective film.

Abstract

Provided is a method for manufacturing a polarization plate sheet, the polarization plate sheet being of rectangular shape having long sides and short sides, and including a polarization element and a protective film laminated onto at least one surface thereof, the method including a step for preparing a first polarization plate sheet having one or more ruffle defects situated in at least one of the long sides, and a step for slit removal of an end of the first polarization plate sheet, the end including the long side having the ruffle defects, to obtain a second polarization plate sheet.

Description

偏光板枚葉体の製造方法Manufacturing method of polarizing plate sheet
　本発明は、液晶表示装置等の画像表示装置に好適に用いられる、波打ち欠陥が低減された偏光板枚葉体の製造方法に関する。 The present invention relates to a method for producing a polarizing plate sheet with reduced undulation defects, which is preferably used in an image display device such as a liquid crystal display device.
　液晶表示装置等の画像表示装置に用いられる偏光板は一般に、偏光子の片面又は両面に接着剤層を介して保護フィルムを貼合した積層構造を有しており、長尺状の偏光子及び長尺状の保護フィルムを用いて、ロール・トゥ・ロール方式により長尺物（偏光板ロール）として製造される〔例えば特開２００９－１３４１９０号公報（特許文献１）〕。得られた長尺状の偏光板は、画像表示装置の画面サイズに応じて所定サイズの枚葉体に裁断され、粘着剤層等を用いて液晶セル等の画像表示素子に貼合積層されて、画像表示装置に組み込まれる。 A polarizing plate used in an image display device such as a liquid crystal display device generally has a laminated structure in which a protective film is bonded to one or both sides of a polarizer via an adhesive layer, and a long polarizer and Using a long protective film, it is produced as a long product (polarizing plate roll) by a roll-to-roll method [for example, JP 2009-134190 A (Patent Document 1)]. The obtained long polarizing plate is cut into a sheet of a predetermined size according to the screen size of the image display device, and is laminated to an image display element such as a liquid crystal cell using an adhesive layer or the like. Embedded in an image display device.
　特許文献１には、偏光板に生じる逆カール及びウェーブカールと呼ばれる不具合を抑制するための方法として、長尺状の偏光子と長尺状の保護フィルムとを接着剤を介して重ね合わせて積層体を得、ついで、この積層体の長手方向に沿って円弧状に形成された凸曲面に当該積層体を密着させながら接着剤を重合硬化させることが記載されている。 In Patent Document 1, as a method for suppressing a problem called reverse curling and wave curling that occurs in a polarizing plate, a long polarizer and a long protective film are laminated with an adhesive interposed therebetween. It is described that an adhesive is polymerized and cured while the laminate is in close contact with a convex curved surface formed in an arc shape along the longitudinal direction of the laminate.
特開２００９－１３４１９０号公報JP 2009-134190 A
　特許文献１に記載の方法によれば、少なくとも長尺状の偏光板を製造した直後又はこれを枚葉体に裁断した直後において、上記不具合の発生を抑制することが可能である。しかしながら、枚葉体に裁断された偏光板（偏光板枚葉体）は、初期において上記不具合を有していない場合であっても、その保管環境によっては、吸湿に伴って保管中に波打ち欠陥を生じることがある。「波打ち欠陥」とは、偏光板枚葉体の少なくとも１辺及びそれを含む端部領域がウェーブ状に波打つ変形欠陥をいう。偏光板枚葉体に波打ち欠陥が生じていると、例えば液晶表示装置に適用する場合を例に挙げれば、粘着剤層を介して偏光板枚葉体と液晶セルとを貼合するときに、粘着剤層と液晶セルとの貼合界面、特に貼合界面の端部領域及びその近傍に気泡が混入しやすくなる。この気泡が液晶パネルの画像表示領域内に生じると、点灯時に輝点となって液晶表示装置の視認性を低下させ得る。 According to the method described in Patent Document 1, it is possible to suppress the occurrence of the above problems at least immediately after manufacturing a long polarizing plate or immediately after cutting it into a sheet. However, even if the polarizing plate (polarizing plate sheet) cut into a single sheet does not have the above-mentioned problems in the initial stage, depending on the storage environment, the wavy defect may occur during storage due to moisture absorption. May occur. “Wavy defect” refers to a deformation defect in which at least one side of a polarizing plate sheet and an end region including the same are wavy. When a wavy defect occurs in the polarizing plate sheet, for example, when applied to a liquid crystal display device, for example, when the polarizing plate sheet and the liquid crystal cell are bonded via an adhesive layer, Air bubbles are likely to be mixed into the bonding interface between the pressure-sensitive adhesive layer and the liquid crystal cell, particularly the end region of the bonding interface and the vicinity thereof. When the bubbles are generated in the image display area of the liquid crystal panel, the visibility of the liquid crystal display device can be lowered when the bubbles are turned on and become bright spots.
　そこで本発明は、波打ち欠陥の個数又は高さが低減された偏光板枚葉体の製造方法の提供を目的とする。 Therefore, an object of the present invention is to provide a method for producing a polarizing plate sheet having a reduced number or height of undulating defects.
　本発明は、以下に示す偏光板枚葉体の製造方法を提供する。
　［１］偏光子及びその少なくとも一方の面上に積層される保護フィルムを含み、長辺と短辺とを有する方形形状の偏光板枚葉体であって、少なくともいずれか１つの長辺において１個以上の波打ち欠陥を有する第１偏光板枚葉体を用意する工程と、
　前記第１偏光板枚葉体における前記波打ち欠陥を有する長辺を含む端部をスリット除去して、第２偏光板枚葉体を得る工程と、
を含む、偏光板枚葉体の製造方法。 This invention provides the manufacturing method of the polarizing plate sheet shown below.
[1] A rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof, and having a long side and a short side, wherein at least one of the long sides is 1 Preparing a first polarizing plate sheet having one or more wavy defects;
Slit removing the end including the long side having the undulation defect in the first polarizing plate sheet to obtain a second polarizing plate sheet;
A method for producing a polarizing plate sheet comprising:
　［２］前記第１偏光板枚葉体を用意する工程において、前記少なくともいずれか１つの長辺において有する波打ち欠陥が４個以上である、［１］に記載の製造方法。 [2] The manufacturing method according to [1], wherein in the step of preparing the first polarizing plate sheet, there are four or more wavy defects in the at least one long side.
　［３］前記第１偏光板枚葉体を用意する工程において、前記少なくともいずれか１つの長辺において有する波打ち欠陥の高さが２ｍｍを超える、［１］又は［２］に記載の製造方法。 [3] The manufacturing method according to [1] or [2], wherein, in the step of preparing the first polarizing plate sheet, a height of a wavy defect in at least one of the long sides exceeds 2 mm.
　［４］前記第２偏光板枚葉体を得る工程において、前記第１偏光板枚葉体における前記波打ち欠陥を有する長辺を含む端部を６５ｍｍ以上の幅でスリット除去する、［１］～［３］のいずれかに記載の製造方法。 [4] In the step of obtaining the second polarizing plate sheet, slits are removed from the first polarizing plate sheet including the long side having the wavy defect with a width of 65 mm or more. [3] The production method according to any one of [3].
　［５］前記第１偏光板枚葉体は、前記偏光子と、その一方の面上に第１接着剤層を介して積層される第１保護フィルムと、他方の面上に第２接着剤層を介して積層される第２保護フィルムと、を含む、［１］～［４］のいずれかに記載の製造方法。 [5] The first polarizing plate sheet includes the polarizer, a first protective film laminated on one surface of the polarizer through a first adhesive layer, and a second adhesive on the other surface. A production method according to any one of [1] to [4], comprising a second protective film laminated via a layer.
　［６］前記第１保護フィルムと前記第２保護フィルムとは、温度４０℃、相対湿度９０％での透湿度が３０ｇ／（ｍ2・２４ｈｒ）以上異なる、［５］に記載の製造方法。 [6] The manufacturing method according to [5], wherein the first protective film and the second protective film differ in moisture permeability at a temperature of 40 ° C. and a relative humidity of 90% by 30 g / (m 2 · 24 hr) or more.
　［７］前記第１接着剤層及び前記第２接着剤層の少なくともいずれか一方は、活性エネルギー線硬化性接着剤の硬化物からなる、［５］又は［６］に記載の製造方法。 [7] The manufacturing method according to [5] or [6], wherein at least one of the first adhesive layer and the second adhesive layer is made of a cured product of an active energy ray-curable adhesive.
　［８］前記第１偏光板枚葉体は、下記（ａ）及び（ｂ）：
　（ａ）前記保護フィルム上に積層されるプロテクトフィルム、
　（ｂ）前記偏光子上又は前記保護フィルム上に積層される粘着剤層と、その外面に積層されるセパレートフィルム
の少なくともいずれか一方をさらに含む、［１］～［７］のいずれかに記載の製造方法。 [8] The first polarizing plate sheet has the following (a) and (b):
(A) a protective film laminated on the protective film;
(B) The adhesive layer according to any one of [1] to [7], further comprising at least one of an adhesive layer laminated on the polarizer or the protective film and a separate film laminated on the outer surface thereof. Manufacturing method.
　本発明によれば、波打ち欠陥の個数又は高さが低減された偏光板枚葉体を提供することができる。特に本発明は、波打ち欠陥がさらに生じ、４個以上、又はその高さが２ｍｍを超える波打ち欠陥を有する偏光板枚葉体に対しても十分な程度までに波打ち欠陥を低減することができる製造方法を提供できる。 According to the present invention, it is possible to provide a polarizing plate sheet having a reduced number or height of undulating defects. In particular, the present invention is capable of reducing wavy defects to a sufficient extent even for polarizing plate sheets having four or more or wavy defects whose height exceeds 2 mm. Can provide a method.
第１偏光板枚葉体の層構成の一例を示す概略断面図である。It is a schematic sectional drawing which shows an example of the layer structure of a 1st polarizing plate sheet.
　本発明に係る偏光板枚葉体の製造方法は、次の工程：
　（１）偏光子及びその少なくとも一方の面上に積層される保護フィルムを含み、長辺と短辺とを有する方形形状の偏光板枚葉体であって、少なくともいずれか１つの長辺において１個以上の波打ち欠陥を有する第１偏光板枚葉体を用意する工程、並びに
　（２）第１偏光板枚葉体における上記波打ち欠陥を有する長辺を含む端部をスリット除去して、第２偏光板枚葉体を得る工程、
を含む。以下、各工程について説明する。 The manufacturing method of the polarizing plate sheet according to the present invention includes the following steps:
(1) A rectangular polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof and having a long side and a short side, wherein at least one of the long sides is 1 A step of preparing a first polarizing plate sheet having at least one wavy defect, and (2) slit removing an end portion including the long side having the wavy defect in the first polarizing plate sheet; A step of obtaining a polarizing plate sheet,
including. Hereinafter, each step will be described.
　（１）第１偏光板枚葉体を用意する工程
　第１偏光板枚葉体は、波打ち欠陥が進行しており、上述したような気泡混入やそれに伴う視認性低下の問題を伴いやすい偏光板枚葉体であり、具体的には、少なくともいずれか１つの長辺において１個以上の波打ち欠陥を有する偏光板枚葉体である。第１偏光板枚葉体は、波打ち欠陥がさらに生じた結果、少なくともいずれか１つの長辺において高さが２ｍｍを超える波打ち欠陥を有するか、又は少なくともいずれか１つの長辺において４個以上の波打ち欠陥を有する偏光板枚葉体であってもよく、第１偏光板枚葉体は、少なくともいずれか１つの長辺において４個以上の波打ち欠陥を有しており、かつ、これらの波打ち欠陥のいずれか１つ以上が、高さが２ｍｍを超える波打ち欠陥であってもよい。 (1) Step of preparing first polarizing plate sheet The first polarizing plate sheet has a undulating defect, and is likely to be accompanied by the above-described problem of bubble mixing and accompanying visibility deterioration. Specifically, it is a polarizing plate sheet that has one or more undulation defects on at least one of the long sides. As a result of further occurrence of undulation defects, the first polarizing plate sheet has undulation defects whose height exceeds 2 mm on at least any one long side, or at least four on at least any one long side. It may be a polarizing plate sheet having undulating defects, and the first polarizing plate sheet has four or more undulating defects on at least one of the long sides, and these undulating defects. Any one or more of the above may be a waving defect whose height exceeds 2 mm.
　波打ち欠陥の高さとは、第１偏光板枚葉体を平面台に載置した場合における平面台から波打ち欠陥頂部までの高さであり、この際、第１偏光板枚葉体は、画像表示素子（例えば液晶セル）に貼合される側の面を上にして平面台に載置される。波打ち欠陥の高さは、第１偏光板枚葉体の辺（端部）において測定される。また、波打ち欠陥の数は、実質的に波打ち欠陥と認められるものの数であり、具体的には、第１偏光板枚葉体を平面台に載置したときに上記高さが平面台から０．５ｍｍ以上である波打ち欠陥の数である。波打ち欠陥の数もまた、第１偏光板枚葉体の辺（端部）において測定される。 The height of the undulating defect is the height from the flat table to the top of the undulating defect when the first polarizing plate sheet is placed on the flat table. At this time, the first polarizing plate sheet is displayed as an image. The surface to be bonded to the element (for example, a liquid crystal cell) is placed on a flat table with the surface facing up. The height of the undulation defect is measured at the side (end) of the first polarizing plate sheet. The number of undulating defects is substantially the number of undulating defects. Specifically, when the first polarizing plate sheet is placed on a flat table, the height is 0 from the flat table. It is the number of undulating defects that are 5 mm or more. The number of wavy defects is also measured at the side (edge) of the first polarizing plate sheet.
　第１偏光板枚葉体は、長辺と短辺とを有する方形形状を有しており、典型的には長方形である。長辺及び短辺の長さは特に制限されないが、通常、第１偏光板枚葉体の長辺は７００ｍｍ以上であり、短辺は４００ｍｍ以上である。波打ち欠陥は、第１偏光板枚葉体のサイズが大きいほど、波打ちの高さや生じる数において顕著になりやすい。サイズ（長辺及び／又は短辺）があまりに小さい場合には、波打ち欠陥の問題それ自体が生じにくい。第１偏光板枚葉体は、長尺物として製造された偏光板を裁断した後、何らかの条件下で保管、運搬する等の過程で上記のような波打ち欠陥が生じた偏光板であることができる。 The first polarizing plate sheet has a rectangular shape having a long side and a short side, and is typically a rectangle. The lengths of the long side and the short side are not particularly limited, but the long side of the first polarizing plate sheet is usually 700 mm or more and the short side is 400 mm or more. As the size of the first polarizing plate sheet is larger, the waviness defect is more prominent in the height and number of waviness. If the size (long side and / or short side) is too small, the problem of undulation defects itself is less likely to occur. The first polarizing plate sheet is a polarizing plate in which the above-described wavy defects are generated in the process of storing and transporting under some conditions after cutting the polarizing plate manufactured as a long product. it can.
　一般に、高さが２ｍｍを超える波打ち欠陥又は４個以上の波打ち欠陥をいずれか１つの長辺に有する第１偏光板枚葉体は、当該長辺に対向する長辺にも同程度の波打ち欠陥を有していることが多い。また、高さが２ｍｍを超える波打ち欠陥又は４個以上の波打ち欠陥をいずれか１つの長辺に有する第１偏光板枚葉体は、２つの短辺にも波打ち欠陥を有していることが多い。ただし、２つの短辺に生じる波打ち欠陥は、その高さ及び／又は数において、長辺に生じる波打ち欠陥に比べて小さい傾向にあり、また、短辺における波打ち欠陥は、長辺の波打ち欠陥に比べて気泡混入の問題を生じにくい傾向にある。従って、気泡混入やそれに伴う視認性低下の問題を抑制するためには、とりわけ長辺に生じている波打ち欠陥を低減することが肝要である。 In general, the first polarizing plate having a wavy defect whose height exceeds 2 mm or four or more wavy defects on any one long side has the same degree of wavy defect on the long side facing the long side. Often has Further, the first polarizing plate sheet having a wavy defect with a height exceeding 2 mm or four or more wavy defects on any one long side may have a wavy defect also on two short sides. Many. However, the wavy defects that occur on the two short sides tend to be smaller in height and / or number than the wavy defects that occur on the long sides, and the wavy defects on the short sides are Compared to this, there is a tendency that the problem of air bubbles is less likely to occur. Therefore, in order to suppress the problem of mixing of bubbles and the accompanying deterioration in visibility, it is important to reduce the undulation defect that occurs on the long side.
　第１偏光板枚葉体の層構成は、偏光子と、その少なくとも一方の面上に積層貼合される保護フィルムとを含む限り特に制限はなく、偏光子の両面に保護フィルムが積層貼合されていてもよい。保護フィルムは通常、接着剤層を介して偏光子上に積層貼合される。 The layer configuration of the first polarizing plate sheet is not particularly limited as long as it includes a polarizer and a protective film laminated and bonded on at least one surface thereof, and the protective film is laminated and bonded on both surfaces of the polarizer. May be. The protective film is usually laminated and bonded onto the polarizer via an adhesive layer.
　第１偏光板枚葉体は、偏光子及び保護フィルム以外の層（又はフィルム）を有することもできる。例えば、一般に、長尺物として製造される偏光板及びこれを裁断してなる偏光板枚葉体は、画像表示素子（例えば液晶セル）に貼合するための粘着剤層を偏光板外面に予め積層した粘着剤層付偏光板として市場流通されることも多いが、第１偏光板枚葉体もまた、このような粘着剤層を含むことができる。粘着剤層を含む場合、通常は、その表面（外面）を保護するためのセパレートフィルム（セパレーター）が粘着剤層外面に積層される。 The first polarizing plate sheet may have a layer (or film) other than the polarizer and the protective film. For example, in general, a polarizing plate produced as a long product and a polarizing plate sheet obtained by cutting the polarizing plate have a pressure-sensitive adhesive layer for bonding to an image display element (for example, a liquid crystal cell) on the outer surface of the polarizing plate in advance. Although often marketed as a laminated polarizing plate with an adhesive layer, the first polarizing plate sheet can also include such an adhesive layer. When an adhesive layer is included, a separate film (separator) for protecting the surface (outer surface) is usually laminated on the outer surface of the adhesive layer.
　また、長尺物として製造される偏光板は通常、これを巻回してなる偏光板ロールとして保管又は流通されるが、巻回の際、外側の保護フィルム表面を保護するために、当該保護フィルム上にプロテクトフィルム（表面保護フィルム）を設けておくことが一般的であり、この場合、当該偏光板を裁断してなる偏光板枚葉体もまた、プロテクトフィルムを有するのが一般的である。かかる場合のように第１偏光板枚葉体は、保護フィルム上に積層されるプロテクトフィルムを含むものであってもよい。 In addition, a polarizing plate produced as a long product is usually stored or distributed as a polarizing plate roll formed by winding the polarizing plate. In order to protect the outer protective film surface during winding, the protective film is used. In general, a protective film (surface protective film) is provided on the polarizing plate, and in this case, a polarizing plate sheet obtained by cutting the polarizing plate generally has a protective film. As in such a case, the first polarizing plate sheet may include a protective film laminated on the protective film.
　さらに、第１偏光板枚葉体が有する保護フィルムは、その外面（偏光子とは反対側の面）に、ハードコート層、防眩層、反射防止層、帯電防止層、防汚層のような表面処理層（コーティング層）を備えるものであってもよい。また、第１偏光板枚葉体は、偏光子以外の他の光学機能を有する層又はフィルムを含むことができる。その一例は位相差フィルムである。 Further, the protective film of the first polarizing plate sheet has a hard coat layer, an antiglare layer, an antireflection layer, an antistatic layer, an antifouling layer on the outer surface (the surface opposite to the polarizer). A surface treatment layer (coating layer) may be provided. Moreover, the 1st polarizing plate sheet can contain the layer or film which has optical functions other than a polarizer. One example is a retardation film.
　第１偏光板枚葉体の層構成の一例を図１に示す。図１に示される第１偏光板枚葉体１は、偏光子１０；偏光子１０の一方の面に貼合される第１保護フィルム２０；偏光子１０の他方の面に貼合される第２保護フィルム３０；第２保護フィルム３０の外面に積層される粘着剤層４０；粘着剤層４０の外面に積層されるセパレートフィルム５０；第１保護フィルム２０の外面に積層されるプロテクトフィルム６０を含む。偏光子１０及び保護フィルム（第１保護フィルム２０、第２保護フィルム３０）に加えて、粘着剤層４０とセパレートフィルム５０を有する層構成、プロテクトフィルム６０を有する層構成、又は粘着剤層４０、セパレートフィルム５０及びプロテクトフィルム６０を有する層構成は、第１偏光板枚葉体の好ましい層構成の例である。粘着剤層４０は、後述するように、第１保護フィルム２０及び第２保護フィルム３０のいずれか一方を省略して、偏光子１０上に直接積層することもできる。 An example of the layer structure of the first polarizing plate sheet is shown in FIG. A first polarizing plate sheet 1 shown in FIG. 1 includes a polarizer 10; a first protective film 20 that is bonded to one surface of the polarizer 10; a first film that is bonded to the other surface of the polarizer 10. 2 protective film 30; adhesive layer 40 laminated on the outer surface of the second protective film 30; separate film 50 laminated on the outer surface of the adhesive layer 40; a protective film 60 laminated on the outer surface of the first protective film 20 Including. In addition to the polarizer 10 and the protective film (the first protective film 20 and the second protective film 30), the layer configuration having the pressure-sensitive adhesive layer 40 and the separate film 50, the layer configuration having the protective film 60, or the pressure-sensitive adhesive layer 40, The layer structure having the separate film 50 and the protect film 60 is an example of a preferable layer structure of the first polarizing plate sheet. As will be described later, the pressure-sensitive adhesive layer 40 may be directly laminated on the polarizer 10 by omitting one of the first protective film 20 and the second protective film 30.
　偏光子１０は、光学軸に平行な振動面をもつ直線偏光を吸収し、光学軸に直交する振動面をもつ直線偏光を透過する性質を有する光学フィルムであり、例えば、一軸延伸され、二色性色素が吸着配向されたポリビニルアルコール系樹脂フィルムであることができる。二色性色素としては、ヨウ素や二色性有機染料が用いられる。偏光子１０を構成するポリビニルアルコール系樹脂は、ポリ酢酸ビニルのケン化物であるポリビニルアルコールのほか、酢酸ビニルとそれに共重合可能な他のモノマー（例えばエチレンや不飽和カルボン酸等）との共重合体のケン化物であるビニルアルコール系共重合体であってもよい。偏光子１０の厚みは通常、５～４０μｍ程度である。 The polarizer 10 is an optical film having a property of absorbing linearly polarized light having a vibration plane parallel to the optical axis and transmitting linearly polarized light having a vibration plane perpendicular to the optical axis. For example, the polarizer 10 is uniaxially stretched and has two colors. It can be a polyvinyl alcohol-based resin film in which a functional dye is adsorbed and oriented. As the dichroic dye, iodine or a dichroic organic dye is used. The polyvinyl alcohol-based resin constituting the polarizer 10 includes polyvinyl alcohol, which is a saponified product of polyvinyl acetate, and a copolymer of vinyl acetate and other monomers copolymerizable therewith (for example, ethylene and unsaturated carboxylic acid). It may be a vinyl alcohol copolymer which is a saponified product. The thickness of the polarizer 10 is usually about 5 to 40 μm.
　偏光子１０は、ポリビニルアルコール系樹脂フィルムを一軸延伸する工程、ポリビニルアルコール系樹脂フィルムを二色性色素で染色してその二色性色素を吸着させる工程、二色性色素が吸着されたポリビニルアルコール系樹脂フィルムをホウ酸水溶液で処理する工程、及びホウ酸水溶液による処理後に水洗する工程を含む方法によって製造することができる。二色性色素の染色は二色性色素を含有する水溶液にフィルムを浸漬することにより、ホウ酸水溶液による処理はホウ酸水溶液にフィルムを浸漬することにより行うことができる。 The polarizer 10 includes a step of uniaxially stretching a polyvinyl alcohol-based resin film, a step of dyeing the polyvinyl alcohol-based resin film with a dichroic dye and adsorbing the dichroic dye, and polyvinyl alcohol on which the dichroic dye is adsorbed. It can manufacture by the method of including the process of wash | cleaning a system resin film with the boric-acid aqueous solution, and the process of washing with water after the process by boric-acid aqueous solution. The dichroic dye can be dyed by immersing the film in an aqueous solution containing the dichroic dye, and the treatment with the boric acid aqueous solution can be performed by immersing the film in the boric acid aqueous solution.
　ポリビニルアルコール系樹脂フィルムの一軸延伸は、二色性色素の染色前、染色と同時、又は染色の後に行うことができる。一軸延伸を染色の後で行う場合、この一軸延伸は、ホウ酸処理の前又はホウ酸処理中に行ってもよい。また、これらの複数の段階で一軸延伸を行ってもよい。 The uniaxial stretching of the polyvinyl alcohol-based resin film can be performed before, simultaneously with, or after the dyeing of the dichroic dye. When uniaxial stretching is performed after dyeing, this uniaxial stretching may be performed before boric acid treatment or during boric acid treatment. Moreover, you may uniaxially stretch in these several steps.
　第１及び第２保護フィルム２０，３０は、透光性を有する（好ましくは光学的に透明な）熱可塑性樹脂フィルムであることができる。熱可塑性樹脂の具体例は、鎖状ポリオレフィン系樹脂（ポリプロピレン系樹脂等）、環状ポリオレフィン系樹脂（ノルボルネン系樹脂など）のようなポリオレフィン系樹脂；ポリエステル系樹脂（ポリエチレンテレフタレート系樹脂等）；（メタ）アクリル系樹脂（メタクリル酸メチル系樹脂等）；セルロース系樹脂（トリアセチルセルロース〔ＴＡＣ〕、ジアセチルセルロースのような酢酸セルロース系樹脂等）；ポリカーボネート系樹脂；ポリビニルアルコール系樹脂；ポリ酢酸ビニル系樹脂；ポリアリレート系樹脂；ポリスチレン系樹脂；ポリエーテルスルホン系樹脂；ポリスルホン系樹脂；ポリアミド系樹脂；ポリイミド系樹脂；及びこれらの混合物、共重合物を含む。第１及び第２保護フィルム２０，３０の厚みは、例えば５～２００μｍ程度であり、好ましくは１０～１５０μｍ、より好ましくは１５～１００μｍである。本明細書において「（メタ）アクリル」とは、アクリル及びメタクリルから選択される少なくとも一方を意味する。 The first and second protective films 20 and 30 can be a thermoplastic resin film having translucency (preferably optically transparent). Specific examples of thermoplastic resins include polyolefin resins such as chain polyolefin resins (polypropylene resins, etc.) and cyclic polyolefin resins (norbornene resins, etc.); polyester resins (polyethylene terephthalate resins, etc.); ) Acrylic resin (methyl methacrylate resin etc.); Cellulosic resin (cellulose acetate resin such as triacetyl cellulose [TAC], diacetyl cellulose etc.); Polycarbonate resin; Polyvinyl alcohol resin; Polyvinyl acetate resin Polyarylate resins; polystyrene resins; polyethersulfone resins; polysulfone resins; polyamide resins; polyimide resins; and mixtures and copolymers thereof. The thickness of the first and second protective films 20 and 30 is, for example, about 5 to 200 μm, preferably 10 to 150 μm, and more preferably 15 to 100 μm. In the present specification, “(meth) acryl” means at least one selected from acryl and methacryl.
　図１に示される第１偏光板枚葉体１のように、偏光子１０の一方の面上に第１保護フィルム２０を備え、他方の面上に第２保護フィルム３０を備える場合において、第１保護フィルム２０と第２保護フィルム３０とは、同種の熱可塑性樹脂で構成されていてもよいし、異種の熱可塑性樹脂で構成されていてもよいが、異種の熱可塑性樹脂で構成されている場合など、両面に貼合される保護フィルムの透湿度が互いに異なる場合には、吸湿性の違いによって波打ち欠陥がとりわけ発生しやすいため、このような場合に本発明はとりわけ有利である。本発明によれば、両面に貼合される保護フィルムの透湿度の差が３０ｇ／（ｍ2・２４ｈｒ）以上、さらには５０ｇ／（ｍ2・２４ｈｒ）以上、なおさらには１００ｇ／（ｍ2・２４ｈｒ）以上、特にさらには３００ｇ／（ｍ2・２４ｈｒ）以上であっても、波打ち欠陥が低減され、気泡混入やそれに伴う視認性低下の問題を生じにくい偏光板枚葉体を得ることができる。通常、両面に貼合される保護フィルムの透湿度の差は、９００ｇ／（ｍ2・２４ｈｒ）以下である。 In the case where the first protective film 20 is provided on one surface of the polarizer 10 and the second protective film 30 is provided on the other surface like the first polarizing plate sheet 1 shown in FIG. The 1st protective film 20 and the 2nd protective film 30 may be comprised with the same kind of thermoplastic resin, and may be comprised with a different kind of thermoplastic resin, but are comprised with a different kind of thermoplastic resin. When the moisture permeability of the protective films bonded to both surfaces is different from each other, such as in the case where the moisture film absorbs moisture, the undulation defect is particularly likely to occur due to the difference in hygroscopicity. Therefore, the present invention is particularly advantageous in such a case. According to the present invention, the difference in moisture permeability of the protective films bonded on both sides is 30 g / (m 2 · 24 hr) or more, further 50 g / (m 2 · 24 hr) or more, and even more 100 g / (m 2 Even if it is 24 hr) or more, and more particularly 300 g / (m 2 · 24 hr) or more, it is possible to obtain a polarizing plate sheet that is less likely to cause undulation defects and is less likely to cause problems of air bubbles and associated visibility degradation. it can. Usually, the difference in the water vapor transmission rate of the protective film bonded to both surfaces is 900 g / (m 2 · 24 hr) or less.
　上記透湿度は、温度４０℃、相対湿度９０％での透湿度であり、ＪＩＳ　Ｚ　０２０８に規定されるカップ法により測定される。温度４０℃、相対湿度９０％での透湿度の差が３０ｇ／（ｍ2・２４ｈｒ）以上である保護フィルムの組み合わせとしては、例えば、セルロース系樹脂フィルム（ＴＡＣフィルム等）と環状ポリオレフィン系樹脂との組み合わせ、セルロース系樹脂フィルム（ＴＡＣフィルム等）と（メタ）アクリル系樹脂フィルムとの組み合わせ、環状ポリオレフィン系樹脂と（メタ）アクリル系樹脂フィルムとの組み合わせ等を挙げることができる。なお、両面に貼合される保護フィルムを構成する熱可塑性樹脂が同種であっても、その上に積層される表面処理層の有無や種類の相違により、透湿度に差が生じることがある。 The moisture permeability is a moisture permeability at a temperature of 40 ° C. and a relative humidity of 90%, and is measured by a cup method defined in JIS Z 0208. Examples of combinations of protective films having a difference in moisture permeability of 30 g / (m 2 · 24 hr) at a temperature of 40 ° C. and a relative humidity of 90% include, for example, a cellulose resin film (TAC film, etc.) and a cyclic polyolefin resin , A combination of a cellulose resin film (TAC film or the like) and a (meth) acrylic resin film, a combination of a cyclic polyolefin resin and a (meth) acrylic resin film, or the like. In addition, even if the thermoplastic resin which comprises the protective film bonded on both surfaces is the same kind, a difference may arise in a water vapor transmission rate by the presence or absence of a surface treatment layer laminated | stacked on it, or a kind difference.
　偏光子１０と、第１保護フィルム２０及び第２保護フィルム３０とは、接着剤層を介して貼合することができる。接着剤層を形成する接着剤としては、水系接着剤、すなわち、接着剤成分を水に溶解したもの又は水に分散させたものや、活性エネルギー線硬化性接着剤を用いることができる。 The polarizer 10, the first protective film 20, and the second protective film 30 can be bonded via an adhesive layer. As the adhesive forming the adhesive layer, a water-based adhesive, that is, an adhesive component dissolved or dispersed in water, or an active energy ray-curable adhesive can be used.
　水系接着剤の接着剤成分は、例えばポリビニルアルコール系樹脂又はウレタン樹脂であることができる。活性エネルギー線硬化性接着剤は、例えば、エポキシ系化合物や（メタ）アクリル系化合物等の活性エネルギー線硬化性化合物と、重合開始剤とを含む硬化性組成物であることができる。活性エネルギー線硬化性接着剤は、無溶剤型の接着剤であることができるが、有機溶剤を含むこともできる。無溶剤型の接着剤を用いれば、溶剤を除去するための乾燥処理が不要となる。活性エネルギー線硬化性接着剤を使用する場合、接着剤層を介して保護フィルムを貼合した後、可視光線、紫外線、Ｘ線、電子線等の活性エネルギー線、好ましくは紫外線を照射して接着剤層を硬化させる。従って、この場合、第１偏光板枚葉体における接着剤層は、活性エネルギー線硬化性接着剤の硬化物からなる。 The adhesive component of the water-based adhesive can be, for example, a polyvinyl alcohol resin or a urethane resin. The active energy ray-curable adhesive can be, for example, a curable composition containing an active energy ray-curable compound such as an epoxy compound or a (meth) acrylic compound and a polymerization initiator. The active energy ray-curable adhesive can be a solventless adhesive, but can also contain an organic solvent. If a solventless type adhesive is used, a drying process for removing the solvent becomes unnecessary. When an active energy ray-curable adhesive is used, after bonding a protective film through an adhesive layer, the active energy rays such as visible light, ultraviolet rays, X-rays, electron beams, etc., preferably ultraviolet rays are irradiated and bonded. The agent layer is cured. Therefore, in this case, the adhesive layer in the first polarizing plate sheet is made of a cured product of an active energy ray-curable adhesive.
　図１に示される第１偏光板枚葉体１のように、偏光子１０の一方の面上に第１保護フィルム２０を備え、他方の面上に第２保護フィルム３０を備える場合において、第１保護フィルム２０を貼合する第１接着剤層と第２保護フィルム３０を貼合する第２接着剤層とは、同種の接着剤から形成されていてもよいし、異種の接着剤から形成されていてもよいが、製造効率の観点から、好ましくは同種の接着剤から形成される。 In the case where the first protective film 20 is provided on one surface of the polarizer 10 and the second protective film 30 is provided on the other surface like the first polarizing plate sheet 1 shown in FIG. The 1st adhesive layer which bonds 1 protective film 20, and the 2nd adhesive layer which bonds 2nd protective film 30 may be formed from the same kind of adhesives, and are formed from a different kind of adhesives. However, it is preferably formed from the same kind of adhesive from the viewpoint of production efficiency.
　第１接着剤層及び第２接着剤層の少なくともいずれか一方（好ましくは双方）が活性エネルギー線硬化性接着剤の硬化物からなる場合には、吸湿に起因する波打ち欠陥がとりわけ発生しやすいため、このような場合に本発明はとりわけ有利である。 When at least one (preferably both) of the first adhesive layer and the second adhesive layer is made of a cured product of an active energy ray-curable adhesive, undulation defects due to moisture absorption are particularly likely to occur. In such a case, the present invention is particularly advantageous.
　画像表示素子（例えば液晶セル）に貼合するための粘着剤層４０を構成する粘着剤としては、例えば（メタ）アクリル系粘着剤、ウレタン系粘着剤、シリコーン系粘着剤、ポリエステル系粘着剤、ポリアミド系粘着剤、ポリエーテル系粘着剤、フッ素系粘着剤、ゴム系粘着剤等が挙げられる。中でも、透明性、粘着力、信頼性、リワーク性等の観点から、（メタ）アクリル系粘着剤が好ましく用いられる。粘着剤層４０の厚みは通常、２～４０μｍである。 As an adhesive which comprises the adhesive layer 40 for bonding to an image display element (for example, liquid crystal cell), for example, a (meth) acrylic adhesive, a urethane adhesive, a silicone adhesive, a polyester adhesive, Examples thereof include a polyamide-based adhesive, a polyether-based adhesive, a fluorine-based adhesive, and a rubber-based adhesive. Among these, a (meth) acrylic pressure-sensitive adhesive is preferably used from the viewpoints of transparency, adhesive strength, reliability, reworkability, and the like. The thickness of the pressure-sensitive adhesive layer 40 is usually 2 to 40 μm.
　セパレートフィルム５０及びプロテクトフィルム６０はそれぞれ、偏光板を保管・運搬したり、検査したりするときに、粘着剤層４０、第１保護フィルム２０を仮保護する目的で設けられる。粘着剤層４０を保護するセパレートフィルム５０は、後述する第２偏光板枚葉体が実用に供される（例えば液晶セルのような画像表示素子に貼合される）直前に剥離除去される。また、プロテクトフィルム６０は通常、第２偏光板枚葉体が実用に供された（例えば液晶セルのような画像表示素子に貼合された）後に、その粘着剤層ごと剥離除去される。 The separate film 50 and the protect film 60 are provided for the purpose of temporarily protecting the adhesive layer 40 and the first protective film 20 when the polarizing plate is stored, transported, or inspected. The separate film 50 that protects the pressure-sensitive adhesive layer 40 is peeled and removed immediately before the second polarizing plate sheet described below is put to practical use (for example, bonded to an image display element such as a liquid crystal cell). The protective film 60 is usually peeled and removed together with the pressure-sensitive adhesive layer after the second polarizing plate sheet is put into practical use (for example, bonded to an image display element such as a liquid crystal cell).
　セパレートフィルム５０は通常、片面に離型処理が施された熱可塑性樹脂フィルムで構成され、その離型処理面が粘着剤層４０に貼り合わされる。また、プロテクトフィルム６０は通常、熱可塑性樹脂フィルムの片面に粘着剤層を設けて構成される。セパレートフィルム５０及びプロテクトフィルム６０を構成する熱可塑性樹脂は、例えば、ポリエチレンのようなポリエチレン系樹脂、ポリプロピレンのようなポリプロピレン系樹脂、ポリエチレンテレフタレートやポリエチレンナフタレートのようなポリエステル系樹脂等であることができる。プロテクトフィルム６０が有する粘着剤層については、前述した粘着剤層４０についての記述が引用される。 The separate film 50 is usually composed of a thermoplastic resin film having a release treatment on one side, and the release treatment surface is bonded to the pressure-sensitive adhesive layer 40. The protect film 60 is usually configured by providing an adhesive layer on one side of a thermoplastic resin film. The thermoplastic resin constituting the separate film 50 and the protect film 60 may be, for example, a polyethylene resin such as polyethylene, a polypropylene resin such as polypropylene, or a polyester resin such as polyethylene terephthalate or polyethylene naphthalate. it can. Regarding the pressure-sensitive adhesive layer that the protective film 60 has, the description of the pressure-sensitive adhesive layer 40 described above is cited.
　第１偏光板枚葉体の層構成は図１に示される例に限定されるものではなく、例えば次のような層構成であることもできる。 The layer configuration of the first polarizing plate sheet is not limited to the example shown in FIG. 1, and may be the following layer configuration, for example.
　〔ａ〕粘着剤層４０、セパレートフィルム５０及びプロテクトフィルム６０のいずれか１以上を省略した構成、
　〔ｂ〕第１保護フィルム２０及び第２保護フィルム３０のいずれか一方を省略した構成、
　〔ｃ〕第２保護フィルム３０として位相差フィルムのような光学補償フィルムを用いる構成、
　〔ｄ〕第１保護フィルム２０及び第２保護フィルム３０に加えて、位相差フィルムのような光学補償フィルムを有する構成。 [A] Configuration in which any one or more of the pressure-sensitive adhesive layer 40, the separate film 50, and the protect film 60 are omitted;
[B] a configuration in which one of the first protective film 20 and the second protective film 30 is omitted;
[C] a configuration using an optical compensation film such as a retardation film as the second protective film 30;
[D] A configuration having an optical compensation film such as a retardation film in addition to the first protective film 20 and the second protective film 30.
　上記〔ｂ〕の一例は第２保護フィルム３０を省略した構成であり、その好適な具体例は、偏光子１０における第１保護フィルム２０とは反対側の面に粘着剤層４０を直接積層して、プロテクトフィルム６０／第１保護フィルム２０／偏光子１０／粘着剤層４０／セパレートフィルム５０の層構成としたものである。 An example of the above [b] is a configuration in which the second protective film 30 is omitted, and a preferred specific example thereof is that the pressure-sensitive adhesive layer 40 is directly laminated on the surface of the polarizer 10 opposite to the first protective film 20. Thus, the protective film 60 / first protective film 20 / polarizer 10 / adhesive layer 40 / separate film 50 are layered.
　上記〔ｃ〕の好適な具体例は、プロテクトフィルム６０／第１保護フィルム２０／偏光子１０／位相差フィルム（第２保護フィルム３０）／粘着剤層４０／セパレートフィルム５０の層構成としたものである。上記〔ｄ〕の好適な具体例は、プロテクトフィルム６０／第１保護フィルム２０／偏光子１０／第２保護フィルム３０／位相差フィルム／粘着剤層４０／セパレートフィルム５０の層構成としたものである。この場合、第２保護フィルム３０と位相差フィルムとは、例えば粘着剤層を介して貼合することができる。 A preferred specific example of the above [c] is a protective film 60 / first protective film 20 / polarizer 10 / retardation film (second protective film 30) / adhesive layer 40 / separate film 50 layer structure. It is. A preferred specific example of the above [d] is a protective film 60 / first protective film 20 / polarizer 10 / second protective film 30 / retardation film / adhesive layer 40 / separate film 50 layer structure. is there. In this case, the 2nd protective film 30 and retardation film can be bonded through an adhesive layer, for example.
　位相差フィルムは、一軸又は二軸等の光学異方性を有する光学フィルムであり、例えば熱可塑性樹脂の延伸フィルムであることができる。熱可塑性樹脂は、第１及び第２保護フィルム２０，３０について上で例示したものであることができるほか、ポリビニリデンフルオライド／ポリメチルメタクリレート共重合体、液晶ポリエステル、アセチルセルロース、エチレン－酢酸ビニル共重合体のケン化物、ポリ塩化ビニル等を用いることもできる。延伸倍率は通常、１．０１～６倍程度である。 The retardation film is an optical film having optical anisotropy such as uniaxial or biaxial, and can be, for example, a stretched film of a thermoplastic resin. The thermoplastic resin can be the one exemplified above for the first and second protective films 20 and 30, as well as polyvinylidene fluoride / polymethyl methacrylate copolymer, liquid crystal polyester, acetyl cellulose, ethylene-vinyl acetate. A saponified copolymer, polyvinyl chloride, or the like can also be used. The draw ratio is usually about 1.01 to 6 times.
　（２）第２偏光板枚葉体を得る工程
　本工程は、少なくともいずれか１つの長辺において１個以上の波打ち欠陥を有する第１偏光板枚葉体の長辺端部（当該波打ち欠陥を有する長辺を含む端部）をスリット除去して、当該波打ち欠陥が低減された第２偏光板枚葉体を得る工程である。スリットには、シアーカッター等の従来公知の裁断（切断）手段を用いることができる。 (2) Step of obtaining a second polarizing plate sheet This step is a process of obtaining a long side end portion of the first polarizing plate sheet having one or more wavy defects on at least one of the long sides (the wavy defect is removed). This is a step of obtaining a second polarizing plate sheet with reduced waviness defects by slit-removing the end portion including the long side. Conventionally known cutting (cutting) means such as a shear cutter can be used for the slit.
　第１偏光板枚葉体が保護フィルム上に積層されるプロテクトフィルム６０を有するか、及び／又は偏光子１０若しくは保護フィルム上に積層される粘着剤層４０とその外面に積層されるセパレートフィルム５０を含む場合において、端部（とりわけ上記長辺端部）に波打ち欠陥を生じている第１偏光板枚葉体は、当該端部の色目が黒っぽくなる外観不良を伴っていることがある。この外観不良は、波打ち欠陥が生じる際の応力によってプロテクトフィルム６０を構成する熱可塑性樹脂フィルムと粘着剤層との界面、あるいはセパレートフィルム５０と粘着剤層４０との界面にずれが生じて粘着剤層表面が荒れることが原因であると考えられる。特に粘着剤層４０の表面に荒れが生じた場合には、液晶セルのような画像表示素子に貼合した後においても外観不良が残るおそれがある。 The first polarizing plate sheet has a protective film 60 laminated on the protective film, and / or a pressure-sensitive adhesive layer 40 laminated on the polarizer 10 or the protective film, and a separate film 50 laminated on the outer surface thereof. In some cases, the first polarizing plate sheet having a wavy defect at the end (particularly, the long side end) may be accompanied by an appearance defect in which the color of the end becomes dark. This poor appearance is caused by a shift in the interface between the thermoplastic resin film constituting the protective film 60 and the pressure-sensitive adhesive layer or the interface between the separate film 50 and the pressure-sensitive adhesive layer 40 due to the stress at the time when the wavy defect occurs. This is thought to be due to the rough surface of the layer. In particular, when the surface of the pressure-sensitive adhesive layer 40 is rough, there is a possibility that an appearance defect may remain even after being bonded to an image display element such as a liquid crystal cell.
　本工程によって、上記外観不良部分が除かれるようにスリット除去を行えば、色目の面でも外観品質の良好な偏光板枚葉体を得ることができる。 If a slit is removed by this step so as to remove the defective appearance portion, a polarizing plate sheet having good appearance quality can be obtained even in terms of color.
　スリット除去は、上記波打ち欠陥を有する長辺端部について行う。特に、高さが２ｍｍを超える波打ち欠陥又は４個以上の波打ち欠陥をいずれか１つの長辺に有する第１偏光板枚葉体は、当該長辺に対向する長辺にも同程度の波打ち欠陥を有していることが多いことから、典型的には、両方の長辺端部についてスリット除去が行われる。 ¡Slit removal is performed on the long side end portion having the undulation defect. In particular, the first polarizing plate sheet having a wavy defect with a height exceeding 2 mm or four or more wavy defects on any one long side has the same degree of wavy defect on the long side facing the long side. Therefore, typically, slit removal is performed on both long side end portions.
　スリット除去される長辺端部の幅Ｗ１は、少なくともいずれか１つの長辺において高さが２ｍｍを超える波打ち欠陥又は４個以上の波打ち欠陥を有する偏光板枚葉体の場合、波打ち欠陥の低減効果の観点から、片端部あたり６５ｍｍ以上であることが好ましい。注目すべきは、第１偏光板枚葉体が上述した通常のサイズ（長辺７００ｍｍ以上、かつ短辺４００ｍｍ以上）である限り、そのサイズに関わらず、長辺端部を好ましくは６５ｍｍ以上のスリット幅Ｗ１で除去することによって、良好な波打ち欠陥低減効果が得られるということである。波打ち欠陥をより効果的に低減させる観点から、スリット幅Ｗ１は、片端部あたり、より好ましくは７０ｍｍ以上であり、さらに好ましくは８０ｍｍ以上であり、なおさらに好ましくは１００ｍｍ以上であり、特に好ましくは１４０ｍｍ以上である。 The width W1 at the end of the long side to be slit-removed is reduced in the case of a polarizing plate sheet having a wavy defect having a height exceeding 2 mm or four or more wavy defects in at least one of the long sides. From the viewpoint of effect, it is preferably 65 mm or more per one end. It should be noted that as long as the first polarizing plate sheet is the above-described normal size (long side 700 mm or more and short side 400 mm or more), the long side end portion is preferably 65 mm or more regardless of the size. By removing with the slit width W1, it is possible to obtain a good undulating defect reduction effect. From the viewpoint of more effectively reducing undulation defects, the slit width W1 is more preferably 70 mm or more, more preferably 80 mm or more, still more preferably 100 mm or more, and particularly preferably 140 mm, per one end. That's it.
　上述のように、２つの短辺に生じ得る波打ち欠陥は、その高さ及び／又は数において、長辺に生じる波打ち欠陥に比べて小さい傾向にあり、また、短辺における波打ち欠陥は、長辺の波打ち欠陥に比べて気泡混入の問題を生じにくい傾向にあるため、短辺端部をスリット除去する必要は必ずしもないが、短辺における波打ち欠陥を低減させるために、波打ち欠陥が生じている長辺端部に加えて、波打ち欠陥が生じている短辺端部（片端部又は両端部）をスリット除去してもよい。短辺端部のスリット幅Ｗ２は、片端部あたり、例えば３５ｍｍ以上であることができ、好ましくは４０ｍｍ以上、より好ましくは４５ｍｍ以上である。 As described above, the wavy defects that can occur in the two short sides tend to be smaller in height and / or number than the wavy defects that occur in the long side, and the wavy defects in the short side However, it is not always necessary to remove the slits at the end of the short side. However, in order to reduce the undulation defect on the short side, the undulation defect has occurred. In addition to the side edge part, the short side edge part (one end part or both end parts) where the undulation defect has occurred may be slit removed. The slit width W2 at the short side end can be, for example, 35 mm or more, preferably 40 mm or more, more preferably 45 mm or more, per one end.
　また、短辺端部に波打ち欠陥が生じているか否かに関わらず、短辺端部の一方又は両方をスリット除去して、第１偏光板枚葉体からサイズダウンされた第２偏光板枚葉体を得てもよい。サイズダウンの具体例としては、４６インチサイズ（長辺１０３１ｍｍ×短辺５８５ｍｍ）の第１偏光板枚葉体の長辺端部及び短辺端部をスリット除去して、３９インチサイズ（長辺８６０ｍｍ×短辺４９０ｍｍ）の第２偏光板枚葉体を得る場合や、３９インチサイズ（長辺８６０ｍｍ×短辺４９０ｍｍ）の第１偏光板枚葉体の長辺端部及び短辺端部をスリット除去して、３２インチサイズ（長辺７００ｍｍ×短辺４００ｍｍ）の第２偏光板枚葉体を得る場合等を挙げることができる。 In addition, regardless of whether or not a wavy defect occurs at the short side end, the second polarizing plate is reduced in size from the first polarizing plate sheet by removing one or both of the short side ends. Leaf bodies may be obtained. As a specific example of the size reduction, the long side edge and the short side edge of the 46-inch size (long side 1031 mm × short side 585 mm) first polarizing plate sheet are slit to remove a 39 inch size (long side). 860 mm × short side 490 mm) to obtain a second polarizing plate sheet, or 39 inch size (long side 860 mm × short side 490 mm) first polarizing plate sheet For example, the slit may be removed to obtain a second polarizing plate sheet having a size of 32 inches (long side 700 mm × short side 400 mm).
　サイズダウンのためのスリット除去においては、高さが２ｍｍを超える波打ち欠陥を有するか、又は４個以上の波打ち欠陥を有する偏光板枚葉体の場合、長辺端部を、片端部あたり６５ｍｍ以上のスリット幅Ｗ１で除去する限り、２つの長辺端部の一方のみをスリット除去してもよいし、双方の長辺端部をスリット除去してもよい。同様に、２つの短辺端部の一方のみをスリット除去してもよいし、双方の短辺端部をスリット除去してもよい。 In slit removal for size reduction, in the case of a polarizing plate sheet having a wavy defect with a height exceeding 2 mm or having four or more wavy defects, the long side end is 65 mm or more per one end. As long as the slit width W1 is removed, only one of the two long side ends may be removed by slit, or both of the long side ends may be removed by slit. Similarly, only one of the two short side ends may be slit removed, or both short side ends may be slit removed.
　以下、実施例を示して本発明をさらに具体的に説明するが、本発明はこれらの例によって限定されるものではない。以下の例において、波打ち欠陥の数及び高さは、次の測定方法に従った。 Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples. In the following examples, the number and height of undulating defects were in accordance with the following measuring method.
　（波打ち欠陥の数及び高さ）
　セパレートフィルム５０側を上向きにして、偏光板枚葉体を平面台に載置し、偏光板枚葉体の２つの長辺における波打ち欠陥の数（上述のように、高さが平面台から０．５ｍｍ以上である波打ち欠陥に限る。）、及び波打ち欠陥の平面台からの高さをそれぞれ測定した。表１には、２つの長辺のうち、より多くの波打ち欠陥を有する長辺における波打ち欠陥の数及び高さを記載している。表１に記載の波打ち欠陥の高さは、複数の波打ち欠陥を有する場合には、最も高い波打ち欠陥の高さである。 (Number and height of undulating defects)
The polarizing plate sheet is placed on a flat table with the separate film 50 side facing upward, and the number of wavy defects on the two long sides of the polarizing plate sheet (the height is 0 from the flat table as described above). , And the height of the undulating defect from the plane table was measured. Table 1 shows the number and height of undulating defects on the long side having more undulating defects among the two long sides. The height of the undulating defect shown in Table 1 is the highest height of the undulating defect when having a plurality of undulating defects.
　＜実験例１＞
　〔１〕第１偏光板枚葉体の作製
　図１に示される層構成を有する長尺状の偏光板を用意した。この偏光板の層構成は、厚み５３μｍのプロテクトフィルム６０（（メタ）アクリル系粘着剤層とポリエチレンテレフタレートフィルムとからなる）／厚み６０μｍの第１保護フィルム２０（ＴＡＣフィルム）／厚み２５μｍの偏光子１０（ヨウ素が吸着配向している一軸延伸ポリビニルアルコールフィルム）／厚み５２μｍの第２保護フィルム３０（環状ポリオレフィン系樹脂からなる位相差フィルム）／厚み２０μｍの粘着剤層４０（（メタ）アクリル系粘着剤層）／厚み３８μｍのセパレートフィルム５０（片面に離型処理が施されたポリエチレンテレフタレートフィルム）である。第１保護フィルム２０及び第２保護フィルム３０はともに、活性エネルギー線硬化性接着剤（カチオン重合性のエポキシ系化合物である硬化性化合物と光カチオン重合開始剤とを含む紫外線硬化性接着剤である（株）ＡＤＥＫＡ製の「ＫＲ－７０Ｔ」）の硬化物からなる接着剤層を介して偏光子１０に貼合されている。また、第１保護フィルム２０及び第２保護フィルム３０の４０℃、相対湿度９０％における透湿度は、それぞれ、５６０ｇ／（ｍ2・２４ｈｒ）、５ｇ／（ｍ2・２４ｈｒ）であった。 <Experimental example 1>
[1] Production of first polarizing plate sheet A long polarizing plate having the layer structure shown in FIG. 1 was prepared. This polarizing plate is composed of a protective film 60 having a thickness of 53 μm (consisting of a (meth) acrylic pressure-sensitive adhesive layer and a polyethylene terephthalate film) / first protective film 20 having a thickness of 60 μm (TAC film) / a polarizer having a thickness of 25 μm. 10 (uniaxially stretched polyvinyl alcohol film in which iodine is adsorbed and oriented) / 52 μm thick second protective film 30 (retardation film made of cyclic polyolefin resin) / 20 μm thick adhesive layer 40 ((meth) acrylic adhesive) Agent layer) / separate film 50 having a thickness of 38 μm (polyethylene terephthalate film having a release treatment on one surface). Both the first protective film 20 and the second protective film 30 are an active energy ray-curable adhesive (a UV curable adhesive containing a curable compound that is a cationic polymerizable epoxy compound and a photocationic polymerization initiator). It is bonded to the polarizer 10 through an adhesive layer made of a cured product of “KR-70T” manufactured by ADEKA Corporation. Further, the moisture permeability of the first protective film 20 and the second protective film 30 at 40 ° C. and 90% relative humidity was 560 g / (m 2 · 24 hr) and 5 g / (m 2 · 24 hr), respectively.
　上記長尺状の偏光板から、４６インチサイズ（長辺１０３１ｍｍ×短辺５８５ｍｍ）の長方形の偏光板枚葉体を切り出した後、３０℃相対湿度８０％の環境下で３日間保管して、上記測定方法に従う波打ち高さが３．５ｍｍであり、波打ち欠陥の数が５個である長辺を有する第１偏光板枚葉体を得た。 After cutting out a rectangular polarizing plate sheet having a size of 46 inches (long side: 1031 mm × short side: 585 mm) from the long polarizing plate, it was stored for 3 days in an environment of 30 ° C. and 80% relative humidity, A first polarizing plate sheet having a long side with a corrugated height of 3.5 mm and a number of corrugated defects of 5 according to the measurement method was obtained.
　〔２〕第２偏光板枚葉体の作製（長辺端部のスリット除去）
　上で得られた第１偏光板枚葉体における、波打ち高さが３．５ｍｍであり、波打ち欠陥の数が５個である長辺端部を、シアーカッターを用いて１０ｍｍの幅でスリット除去し、スリット後の第２偏光板枚葉体の長辺における波打ち欠陥の高さ及び数を測定した。この操作をトータルのスリット幅（スリット幅Ｗ１）が１７０ｍｍになるまで繰り返し、スリット幅Ｗ１と波打ち欠陥低減効果との関係について調べた。結果を表１に示す。 [2] Fabrication of second polarizing plate sheet (removal of slits at end of long side)
In the first polarizing plate sheet obtained above, the long edge of the corrugated height of 3.5 mm and the number of corrugated defects of 5 is removed with a shear cutter to a width of 10 mm. Then, the height and number of undulation defects on the long side of the second polarizing plate sheet after the slit were measured. This operation was repeated until the total slit width (slit width W1) reached 170 mm, and the relationship between the slit width W1 and the wavy defect reduction effect was examined. The results are shown in Table 1.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　＜実験例２＞
　上記実験例１と同様にして得られた波打ち高さが３．５ｍｍであり、波打ち欠陥の数が４個である長辺を有する４６インチサイズ（長辺１０３１ｍｍ×短辺５８５ｍｍ）の第１偏光板枚葉体における２つの長辺端部を、シアーカッターを用いて、片端部あたり８５．５ｍｍずつスリット除去するとともに、２つの短辺端部を、片端部あたり４７．５ｍｍずつスリット除去することによって、３９インチサイズ（長辺８６０ｍｍ×短辺４９０ｍｍ）にサイズダウンされた第２偏光板枚葉体を得た。この第２偏光板枚葉体について、波打ち高さが３．５ｍｍであり、波打ち欠陥の数が４個である第１偏光板枚葉体の長辺に相当する長辺における波打ち欠陥の高さ及び数を測定した。結果を表２に示す。 <Experimental example 2>
The first polarized light of 46 inch size (long side: 1031 mm × short side: 585 mm) having a long side of 3.5 mm and a number of wavy defects of 4 mm obtained in the same manner as in Experimental Example 1 above. Use a shear cutter to slit the two long side edges of the plate sheet body by 85.5 mm per one end, and slit the two short side edges by 47.5 mm per one end. Thus, a second polarizing plate sheet reduced in size to 39 inches (long side 860 mm × short side 490 mm) was obtained. About this 2nd polarizing plate sheet, the height of the undulation defect in the long side corresponding to the long side of the 1st polarizing plate sheet whose wave height is 3.5mm and the number of undulation defects is four. And the number was measured. The results are shown in Table 2.
　次に、上で得られた３９インチサイズの第２偏光板枚葉体における２つの長辺端部を、シアーカッターを用いて、片端部あたり８０．０ｍｍずつスリット除去するとともに、２つの短辺端部を、片端部あたり４５．０ｍｍずつスリット除去することによって、３２インチサイズ（長辺７００ｍｍ×短辺４００ｍｍ）にサイズダウンされた第２偏光板枚葉体を得た。この第２偏光板枚葉体について、上で波打ち欠陥の高さ及び数を測定した３９インチサイズの第２偏光板枚葉体の長辺に相当する長辺における波打ち欠陥の高さ及び数を測定した。結果を表２に示す。 Next, the two long side ends of the 39-inch size second polarizing plate obtained above were slit by 80.0 mm per one end using a shear cutter, and two short sides A second polarizing plate sheet having a size reduced to 32 inches (long side: 700 mm × short side: 400 mm) was obtained by slitting the end part by 45.0 mm per one end part. For the second polarizing plate sheet, the height and number of wavy defects on the long side corresponding to the long side of the 39-inch size second polarizing plate sheet, the height and number of which were measured above, were measured. It was measured. The results are shown in Table 2.
Figure JPOXMLDOC01-appb-T000002
Figure JPOXMLDOC01-appb-T000002
　１　第１偏光板枚葉体、１０　偏光子、２０　第１保護フィルム、３０　第２保護フィルム、４０　粘着剤層、５０　セパレートフィルム、６０　プロテクトフィルム。 1 first polarizing plate sheet, 10 polarizer, 20 first protective film, 30 second protective film, 40 adhesive layer, 50 separate film, 60 protective film.

Claims (8)

  1. 　偏光子及びその少なくとも一方の面上に積層される保護フィルムを含み、長辺と短辺とを有する方形形状の偏光板枚葉体であって、少なくともいずれか１つの長辺において１個以上の波打ち欠陥を有する第１偏光板枚葉体を用意する工程と、
    　前記第１偏光板枚葉体における前記波打ち欠陥を有する長辺を含む端部をスリット除去して、第２偏光板枚葉体を得る工程と、
    を含む、偏光板枚葉体の製造方法。     A polarizing plate sheet including a polarizer and a protective film laminated on at least one surface thereof and having a long side and a short side, wherein at least one of the long sides has at least one Preparing a first polarizing plate sheet having undulation defects;
    Slit removing the end including the long side having the undulation defect in the first polarizing plate sheet to obtain a second polarizing plate sheet;
    A method for producing a polarizing plate sheet comprising:
  2. 　前記第１偏光板枚葉体を用意する工程において、前記少なくともいずれか１つの長辺において有する波打ち欠陥が４個以上である、請求項１に記載の製造方法。 The manufacturing method according to claim 1, wherein, in the step of preparing the first polarizing plate sheet, there are four or more undulating defects on at least one of the long sides.
  3. 　前記第１偏光板枚葉体を用意する工程において、前記少なくともいずれか１つの長辺において有する波打ち欠陥の高さが２ｍｍを超える、請求項１又は２に記載の製造方法。 The manufacturing method according to claim 1 or 2, wherein, in the step of preparing the first polarizing plate sheet, a height of a wavy defect on at least one of the long sides exceeds 2 mm.
  4. 　前記第２偏光板枚葉体を得る工程において、前記第１偏光板枚葉体における前記波打ち欠陥を有する長辺を含む端部を６５ｍｍ以上の幅でスリット除去する、請求項１～３のいずれか１項に記載の製造方法。 4. The step of obtaining the second polarizing plate sheet includes slit-removing an end including a long side having the wavy defect in the first polarizing plate sheet with a width of 65 mm or more. The production method according to claim 1.
  5. 　前記第１偏光板枚葉体は、前記偏光子と、その一方の面上に第１接着剤層を介して積層される第１保護フィルムと、他方の面上に第２接着剤層を介して積層される第２保護フィルムと、を含む、請求項１～４のいずれか１項に記載の製造方法。 The first polarizing plate sheet includes the polarizer, a first protective film laminated on one surface of the polarizer through a first adhesive layer, and a second adhesive layer on the other surface. The manufacturing method according to any one of claims 1 to 4, further comprising a second protective film laminated in a stacked manner.
  6. 　前記第１保護フィルムと前記第２保護フィルムとは、温度４０℃、相対湿度９０％での透湿度が３０ｇ／（ｍ2・２４ｈｒ）以上異なる、請求項５に記載の製造方法。 The manufacturing method according to claim 5, wherein the first protective film and the second protective film differ in moisture permeability at a temperature of 40 ° C. and a relative humidity of 90% by 30 g / (m 2 · 24 hr) or more.
  7. 　前記第１接着剤層及び前記第２接着剤層の少なくともいずれか一方は、活性エネルギー線硬化性接着剤の硬化物からなる、請求項５又は６に記載の製造方法。 The manufacturing method according to claim 5 or 6, wherein at least one of the first adhesive layer and the second adhesive layer is made of a cured product of an active energy ray-curable adhesive.
  8. 　前記第１偏光板枚葉体は、下記（ａ）及び（ｂ）：
    　（ａ）前記保護フィルム上に積層されるプロテクトフィルム、
    　（ｂ）前記偏光子上又は前記保護フィルム上に積層される粘着剤層と、その外面に積層されるセパレートフィルム
    の少なくともいずれか一方をさらに含む、請求項１～７のいずれか１項に記載の製造方法。     The first polarizing plate sheet has the following (a) and (b):
    (A) a protective film laminated on the protective film;
    (B) The adhesive layer according to any one of claims 1 to 7, further comprising at least one of an adhesive layer laminated on the polarizer or the protective film and a separate film laminated on an outer surface thereof. Manufacturing method.
PCT/JP2015/080677 2014-11-05 2015-10-30 Method for manufacturing polarization plate sheet WO2016072359A1 (en)

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