WO2016194433A1 - ポリビニルアルコール系フィルム、ポリビニルアルコール系フィルムの製造方法、及び偏光膜 - Google Patents
ポリビニルアルコール系フィルム、ポリビニルアルコール系フィルムの製造方法、及び偏光膜 Download PDFInfo
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- WO2016194433A1 WO2016194433A1 PCT/JP2016/058215 JP2016058215W WO2016194433A1 WO 2016194433 A1 WO2016194433 A1 WO 2016194433A1 JP 2016058215 W JP2016058215 W JP 2016058215W WO 2016194433 A1 WO2016194433 A1 WO 2016194433A1
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- Prior art keywords
- film
- polyvinyl alcohol
- cast
- polarizing
- cast mold
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Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
- B29C41/26—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on a rotating drum
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L29/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical; Compositions of hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Compositions of derivatives of such polymers
- C08L29/02—Homopolymers or copolymers of unsaturated alcohols
- C08L29/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2329/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal, or ketal radical; Hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Derivatives of such polymer
- C08J2329/02—Homopolymers or copolymers of unsaturated alcohols
- C08J2329/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
Definitions
- the present invention relates to a polyvinyl alcohol film, a method for producing a polyvinyl alcohol film, and a polarizing film. More specifically, the present invention is a polyvinyl alcohol film having linear protrusions of a specific size and excellent in productivity due to the effects of the linear protrusions, and further obtaining a polarizing film excellent in polarization degree and light transmittance. The present invention relates to a polyvinyl alcohol film that can be used.
- a polyvinyl alcohol film is prepared by dissolving a polyvinyl alcohol resin in a solvent such as water to prepare a film-forming stock solution, and then forming the film by a solution casting method (casting method) and using a metal heating roll or the like. And then dried.
- the polyvinyl alcohol film thus obtained is used in many applications as a film excellent in transparency and dyeability, and one of its useful applications is a polarizing film.
- a polarizing film is used as a basic component of a liquid crystal display, and in recent years, its use has been expanded to a large area and high quality liquid crystal television.
- Patent Document 2 proposes a method for producing a polyvinyl alcohol film for a polarizing film under specific film forming conditions using a stock solution (polyvinyl alcohol resin aqueous solution) having a specific composition in order to reduce surface roughness.
- Patent Document 3 as a measure against haze, for example, a polyvinyl alcohol film using two kinds of polyvinyl alcohol resins having different molecular weights has been proposed,
- Patent Document 4 a method for producing a polyvinyl alcohol film using a specific additive has been proposed,
- -In patent document 5 in order to make the thickness of a film uniform, the method of forming into a film on the metal surface (cast type surface) whose surface roughness is 3S (maximum height 3 micrometers) or less is proposed.
- Patent Documents 1 and 2 a specific surfactant is used to reduce the surface roughness of the film.
- the surface of the cast mold is not reduced. If it is rough, a smooth film cannot be obtained.
- Patent Document 4 improves the peelability from a cast mold by adding a specific surfactant to a film-forming raw material (an aqueous solution of a polyvinyl alcohol resin), thereby improving haze and defects (liquid in a film). Drop).
- a specific surfactant to a film-forming raw material (an aqueous solution of a polyvinyl alcohol resin)
- the external haze increases and the surface roughness increases. This phenomenon is because the surface of the cast mold does not allow the surfactant to escape, and the surfactant is deposited on the entire film surface in contact with the cast mold surface.
- An object of the present invention is to provide a manufacturing method and a polarizing film.
- the present inventors have found that the surface of the polyvinyl alcohol film contains a small amount of linear protrusions having a sufficiently narrow width and a sufficiently low height, thereby achieving high polarization performance and It has been found that a smooth and low haze polyvinyl alcohol film for obtaining a polarizing film exhibiting light transmittance can be produced with high productivity, and the present invention has been completed.
- the gist of the present invention is a polyvinyl alcohol film having a thickness of 5 to 60 ⁇ m, a width of 2 m or more, and a length of 2 km or more, and an imaginary line having a length of 1 mm is provided at an arbitrary position on the film surface.
- the present invention relates to a polyvinyl alcohol film characterized in that the number of linear protrusions having a width of 1 to 10 ⁇ m intersecting with the imaginary line and a height of the intersection of 0.01 to 0.1 ⁇ m is 1 to 10. .
- the present invention also provides a polarizing film comprising the polyvinyl alcohol film.
- this invention is the manufacturing method of the polyvinyl alcohol-type film obtained by discharging and flowing the aqueous solution of polyvinyl alcohol-type resin to a cast type
- the present invention relates to a method for producing a polyvinyl alcohol film, wherein the peel strength at the time of forming is 0.001 to 0.1 N / 25 mm.
- the polyvinyl alcohol-based film of the present invention is a smooth and low-haze polyvinyl alcohol-based film, when the polyvinyl alcohol-based film is used, a polarizing film excellent in polarization performance and light transmittance can be produced. Furthermore, the polyvinyl alcohol film of the present invention is excellent in releasability from a cast mold at the time of film formation, and can be produced with high productivity because it is a polyvinyl alcohol film having no defects such as bubbles and precipitates. .
- the polyvinyl alcohol film of the present invention is a polyvinyl alcohol film having a thickness of 5 to 60 ⁇ m, a width of 2 m or more, and a length of 2 km or more.
- a virtual line having a length of 1 mm is provided at an arbitrary position on the film surface
- the film has 1 to 10 linear protrusions having a width of 1 to 10 ⁇ m intersecting with the imaginary line and a height of the intersection of 0.01 to 0.1 ⁇ m.
- the number of such linear protrusions is preferably 2 to 9, particularly preferably 3 to 8. If the number of linear protrusions is less than the lower limit, it is difficult to produce a polyvinyl alcohol-based film with good yield, and if the upper limit is exceeded, the light transmittance of the polarizing film decreases, and the object of the present invention is achieved. I can't. In the present invention, it is defined as linear with an aspect ratio of 10 or more.
- a method for controlling the number of the linear protrusions within a predetermined range a method for adjusting the shape and number of microcracks on the cast mold surface to a predetermined range, a convex linear protrusion by bringing the film surface into contact with a hot roll, A method of crushing, a method of flattening the film surface by bringing it into contact with a solvent such as water or alcohol, a method of polishing or roughening the film surface, and a leveling agent in the film forming raw material.
- the method of adjusting the shape and number of microcracks on the cast mold surface described below within a predetermined range is preferable in that the profile of the film surface can be made constant.
- an unmodified polyvinyl alcohol resin that is, a resin produced by saponifying polyvinyl acetate obtained by polymerizing vinyl acetate is usually used. If necessary, a resin obtained by saponifying a copolymer of vinyl acetate and a small amount (for example, 10 mol% or less, preferably 5 mol% or less) of vinyl acetate and a copolymerizable component may be used. it can.
- components copolymerizable with vinyl acetate include unsaturated carboxylic acids (including salts, esters, amides, nitriles, etc.), and olefins having 2 to 30 carbon atoms (eg, ethylene, propylene, n-butene). , Isobutene, etc.), vinyl ethers, unsaturated sulfonates and the like.
- the modified polyvinyl alcohol-type resin obtained by chemically modifying the hydroxyl group after saponification can also be used.
- a polyvinyl alcohol resin having a 1,2-diol structure in the side chain can be used as the polyvinyl alcohol resin.
- a polyvinyl alcohol resin having a 1,2-diol structure in the side chain includes, for example, (i) a method of saponifying a copolymer of vinyl acetate and 3,4-diacetoxy-1-butene, and (ii) acetic acid.
- the weight average molecular weight of the polyvinyl alcohol resin is preferably 100,000 to 300,000, particularly preferably 110,000 to 280,000, and more preferably 120,000 to 260,000. If the weight average molecular weight is too small, sufficient optical performance tends to be difficult to obtain when the polyvinyl alcohol-based resin is used as an optical film, and if it is too large, it tends to be difficult to stretch the polyvinyl alcohol-based film when manufacturing a polarizing film. There is.
- the weight average molecular weight of the polyvinyl alcohol resin is a weight average molecular weight measured by GPC-MALS method.
- the average saponification degree of the polyvinyl alcohol resin used in the present invention is usually preferably 98 mol% or more, particularly preferably 99 mol% or more, further preferably 99.5 mol% or more, and particularly preferably 99.mol%. It is 8 mol% or more. If the average degree of saponification is too small, there is a tendency that sufficient optical performance cannot be obtained when a polyvinyl alcohol film is used as a polarizing film.
- the average saponification degree in the present invention is measured according to JIS K 6726.
- polyvinyl alcohol resin used in the present invention two or more kinds having different modified species, weight average molecular weight, average saponification degree and the like may be used in combination.
- the polyvinyl alcohol-based film of the present invention is prepared by preparing a polyvinyl alcohol-based resin aqueous solution using the above-mentioned polyvinyl alcohol-based resin, discharging and casting the aqueous solution into a cast mold, and forming and drying the film by a casting method.
- a casting method For example, it can be manufactured by the following steps.
- B) The process of heating and drying the formed film.
- C A step of winding the dried film on a roll after slitting.
- examples of the cast mold include a cast drum (drum mold roll), an endless belt, and the like.
- the cast mold is preferably performed from the viewpoint of widening, lengthening, and film thickness uniformity.
- the cast mold is a cast drum will be described as an example.
- the number of micro cracks on the cast drum surface under specific conditions, the surface roughness Rz of the cast drum surface, and the setting of each specific range of the peel strength when peeling the film from the cast drum are The present invention is also applicable to cast dies other than cast drums (drum-type rolls) such as endless belts.
- step (A) will be described.
- the polyvinyl alcohol resin described above is first washed with a solvent such as water, dehydrated with a centrifuge, etc., and wet with a polyvinyl alcohol resin having a water content of 50% by weight or less.
- a solvent such as water, dehydrated with a centrifuge, etc.
- a cake is preferred.
- Such a polyvinyl alcohol resin wet cake is dissolved in warm water or hot water to prepare an aqueous polyvinyl alcohol resin solution.
- the method for preparing the polyvinyl alcohol-based resin aqueous solution is not particularly limited.
- the polyvinyl alcohol-based resin aqueous solution may be prepared by using a heated multi-screw extruder.
- the polyvinyl alcohol-based resin wet cake thus prepared is charged and water vapor is blown into the can to prepare an aqueous solution having a desired concentration and dissolution.
- polyvinyl alcohol-based resin aqueous solutions include plastics commonly used such as glycerin, diglycerin, triglycerin, ethylene glycol, triethylene glycol, polyethylene glycol, and trimethylol propane as necessary. It is preferable from the point of film forming property to contain an agent and at least one surfactant of nonionic property, anionic property, and cationic property.
- the resin concentration of the aqueous polyvinyl alcohol resin solution thus obtained is preferably 15 to 60% by weight, particularly preferably 17 to 55% by weight, and further preferably 20 to 50% by weight. If the resin concentration is too low, the drying load increases, so the production capacity tends to decrease. If the resin concentration is too high, the viscosity becomes too high and uniform dissolution tends to be difficult.
- the obtained polyvinyl alcohol resin aqueous solution is defoamed.
- the defoaming method include stationary defoaming and defoaming with a multi-screw extruder.
- the multi-screw extruder is not particularly limited as long as it is a multi-screw extruder having a vent. Usually, a twin-screw extruder having a vent is used.
- the polyvinyl alcohol-based resin aqueous solution is introduced into a T-shaped slit die by a certain amount, discharged and cast on a rotating cast drum, and formed into a film by a casting method.
- the temperature of the polyvinyl alcohol resin aqueous solution at the exit of the T-type slit die is preferably 80 to 100 ° C., and particularly preferably 85 to 98 ° C. If the temperature of the aqueous polyvinyl alcohol resin solution is too low, it tends to cause poor flow, and if it is too high, it tends to foam.
- the viscosity of the aqueous polyvinyl alcohol resin solution is preferably 50 to 200 Pa ⁇ s, particularly preferably 70 to 150 Pa ⁇ s, at the time of discharge. If the viscosity of such an aqueous solution is too low, it tends to be poor in flow, and if it is too high, it tends to be difficult to flow.
- the discharge speed of the aqueous polyvinyl alcohol resin solution discharged from the T-type slit die onto the cast drum is preferably 0.5 to 5 m / min, particularly preferably 0.6 to 4 m / min, and more preferably 0.8. 7-3 m / min. If the discharge speed is too slow, the productivity tends to decrease, and if it is too fast, the fluency tends to be difficult.
- the diameter of the cast drum is preferably 2 to 5 m, particularly preferably 2.4 to 4.5 m, and more preferably 2.8 to 4 m. If the diameter is too small, the drying length is insufficient and the speed tends not to be obtained, and if it is too large, the transportability tends to decrease.
- the width of the cast drum is preferably 2 m or more, particularly preferably 3 m or more, more preferably 4 m or more, and particularly preferably 5 to 6 m. If the width of the cast drum is too small, the productivity tends to decrease.
- the rotational speed of such a cast drum is preferably 3 to 50 m / min, particularly preferably 4 to 40 m / min, and further preferably 5 to 35 m / min. If the rotational speed is too slow, the productivity tends to decrease, and if it is too fast, the drying tends to be insufficient.
- the surface temperature of such a cast drum is preferably 40 to 99 ° C., particularly preferably 60 to 95 ° C. If the surface temperature is too low, drying tends to be poor, and if it is too high, foaming tends to occur.
- a surface of stainless steel (SUS) containing iron as a main component is subjected to metal plating for preventing scratches, that is, a metal plating layer is formed.
- the metal plating include chrome plating, nickel plating, and zinc plating, and these are used alone or in a laminate of two or more layers.
- the outermost surface is a chromium plating layer in terms of easy smoothing of the drum surface and excellent durability.
- the width intersecting with the virtual line is 1 to 10 ⁇ m and the depth of the intersection is 0.01 to
- the number of 0.2 ⁇ m microcracks is preferably 5 to 30, particularly preferably 6 to 25, and further preferably 7 to 20. If the number of such microcracks is too small, the peelability of the film tends to decrease and the productivity of the polyvinyl alcohol film tends to decrease. If the number is too large, the surface roughness of the polyvinyl alcohol film increases and the polarization of the polarizing film increases. There is a tendency for performance to decrease.
- the metal plating layer on the cast drum surface has more or less microcracks.
- microcracks are caused by stress of the metal plating layer, and the shape and number can be controlled by the thickness of the metal plating layer, plating conditions, heat treatment, chemical treatment, multilayering, and the like.
- microcracks in the above-described range can be formed by heat treatment at 100 ° C. to 150 ° C.
- Such micro cracks can impart water repellency to the cast drum surface by the lotus effect (lotus leaf effect), and this water repellency effect is the peelability of a film containing a relatively large amount of moisture from the cast drum.
- a surfactant is added to an aqueous polyvinyl alcohol resin solution, which is a film-forming stock solution, to improve peelability.
- a surfactant increases the surface roughness of the polyvinyl alcohol film, and as a result, the polarizing performance of the polarizing film tends to decrease.
- the above-mentioned microcrack is not a chemical action but a physical action that enhances the peelability of the film, and therefore does not cause a problem that occurs when a surfactant is used.
- the surface roughness Rz of the surface of the cast drum used in the present invention is preferably 0.1 to 0.3 ⁇ m, particularly preferably 0.13 to 0.27 ⁇ m, and further preferably 0.15 to 0. 25 ⁇ m. If the surface roughness Rz is too small, it tends to be difficult to produce a polyvinyl alcohol film with high productivity. If the surface roughness Rz is too large, the surface roughness of the polyvinyl alcohol film increases, and the polarization degree of the polarizing film increases. There is a tendency to decrease.
- a method for controlling the surface roughness within a predetermined range a method for adjusting the shape and number of microcracks on the cast drum surface to a predetermined range, a method for adjusting point defects on the cast drum surface, and polishing the cast drum surface
- a method of adjusting the shape and number of microcracks on the cast drum surface within a predetermined range is preferable in that the profile of the film surface can be made constant.
- the peel strength when peeling the film from the cast drum is preferably 0.001 to 0.1 N / 25 mm, particularly preferably 0.002 to 0.05 N / 25 mm, and more preferably 0. 0.003 to 0.01 N / 25 mm. If the peel strength is too large, the peelability of the film from the cast drum will decrease, the film will break, or the retardation of the polyvinyl alcohol film will tend to increase. Since the film tends to peel off and the smoothness of the film tends to decrease, in any case, it becomes difficult to produce a polyvinyl alcohol film with high productivity.
- a method for controlling the peel strength there are a method for adjusting the shape and number of microcracks on the cast drum surface within a predetermined range, a method for polishing and roughening the cast drum surface, and a surfactant as a film forming raw material.
- the method of blending, the method of forming a release film on the surface of the cast drum, and the like can be mentioned. It is preferable at the point which can be made.
- a process (B) is a process of heating and drying the formed film.
- the film formed on the cast drum is dried by alternately contacting the front and back surfaces of the film with a plurality of hot rolls.
- the surface temperature of the hot roll is usually 40 to 150 ° C, preferably 50 to 140 ° C. If the surface temperature is too low, drying tends to be poor. If the surface temperature is too high, drying tends to be excessive, and appearance defects such as undulation tend to be caused.
- the hot roll is, for example, a roll having a diameter of 0.2 to 2 m, the surface of which is hard chrome plated or mirror-finished. Usually, 2 to 30 rolls, preferably 10 to 25 rolls are used for drying. preferable.
- the heat treatment temperature is preferably 60 to 150 ° C, particularly preferably 70 to 140 ° C. If the heat treatment temperature is too low, the water resistance of the polyvinyl alcohol-based film tends to decrease or causes a retardation shift. If it is too high, the stretchability during the production of the polarizing film tends to decrease. Examples of such a heat treatment method include a method of contacting with a high-temperature hot roll, a method of using a floating dryer, and the like.
- Step (C) is a step in which both ends of the film are slit and wound on a roll.
- drum-type roll rotating cast drum
- the polyvinyl alcohol film of the present invention is obtained.
- the polyvinyl alcohol film obtained by the production method of the present invention is required to have a thickness of 5 to 60 ⁇ m, and is preferably 5 to 50 ⁇ m in thickness from the viewpoint of thinning, particularly preferably retardation.
- the thickness is 5 to 40 ⁇ m from the viewpoint of reduction, and more preferably 5 to 30 ⁇ m from the viewpoint of avoiding breakage.
- the polyvinyl alcohol film of the present invention needs to have a width of 2 m or more, particularly preferably 3 m or more, particularly preferably 4 m or more from the viewpoint of increasing the area, and more preferably 4 to 6 m from the viewpoint of avoiding breakage. It is.
- the polyvinyl alcohol film of the present invention is required to have a length of 2 km or more, particularly preferably 3 km or more from the viewpoint of increasing the area, and more preferably 3 to 50 km from the viewpoint of transport weight.
- the haze of the polyvinyl alcohol film of the present invention is preferably 0.3% or less, particularly preferably 0.2% or less, and further preferably 0.1% or less. If the haze is too high, the light transmittance when the polarizing film is formed tends to be lowered.
- the polyvinyl alcohol film of the present invention is excellent in productivity, is suitably used as an optical polyvinyl alcohol film, and is particularly preferably used as a raw material for a polarizing film.
- the polarizing film of the present invention is produced through steps such as swelling, dyeing, boric acid crosslinking, stretching, washing, and drying by unwinding the polyvinyl alcohol film from a roll and transferring it in the horizontal direction.
- the swelling process is performed before the dyeing process.
- water is usually used as the treatment liquid.
- the treatment solution may contain a small amount of an iodide compound, an additive such as a surfactant, alcohol, or the like.
- the temperature of the swelling bath is usually about 10 to 45 ° C., and the immersion time in the swelling bath is usually about 0.1 to 10 minutes.
- the dyeing step is performed by bringing the film into contact with a liquid containing iodine or a dichroic dye.
- a liquid containing iodine or a dichroic dye usually, an iodine-potassium iodide aqueous solution is used.
- the iodine concentration is suitably 0.1-2 g / L, and the potassium iodide concentration is 1-100 g / L.
- the dyeing time is practically about 30 to 500 seconds.
- the temperature of the treatment bath is preferably 5 to 50 ° C.
- the aqueous solution may contain a small amount of an organic solvent compatible with water in addition to the aqueous solvent.
- the boric acid crosslinking step is performed using a boron compound such as boric acid or borax.
- the boron compound is used in the form of an aqueous solution or a water-organic solvent mixture at a concentration of about 10 to 100 g / L, and it is preferable that potassium iodide coexists in the solution from the viewpoint of stabilizing the polarization performance.
- the temperature during the treatment is preferably about 30 to 70 ° C., and the treatment time is preferably about 0.1 to 20 minutes. If necessary, the stretching operation may be performed during the treatment.
- the stretching step it is preferable to stretch 3 to 10 times, preferably 3.5 to 6 times in a uniaxial direction.
- a slight stretching may be performed in a direction perpendicular to the stretching direction.
- the temperature during stretching is preferably 40 to 170 ° C.
- the draw ratio may be finally set within the above range, and the drawing operation may be performed not only in one stage but also in any stage of the manufacturing process.
- the washing step is performed, for example, by immersing a polyvinyl alcohol film in an aqueous solution of iodide such as water or potassium iodide, thereby removing deposits generated on the surface of the film.
- iodide such as water or potassium iodide
- the concentration of potassium iodide may be about 1 to 80 g / L.
- the temperature during the washing treatment is usually 5 to 50 ° C., preferably 10 to 45 ° C.
- the treatment time is usually 1 to 300 seconds, preferably 10 to 240 seconds.
- the drying process may be performed in the atmosphere at 40 to 80 ° C. for 1 to 10 minutes.
- the polarization degree of the polarizing film is preferably 99.5% or more, more preferably 99.8% or more. If the degree of polarization is too low, there is a tendency that the contrast in the liquid crystal display cannot be secured.
- the degree of polarization is generally the light transmittance (H 11 ) measured at the wavelength ⁇ in the state where two polarizing films are overlapped so that their orientation directions are the same direction, and the two polarizing films. It is calculated according to the following equation from the light transmittance (H 1 ) measured at the wavelength ⁇ in a state where the films are superposed so that the orientation directions are orthogonal to each other. [(H 11 ⁇ H 1 ) / (H 11 + H 1 )] 1/2
- the single transmittance of the polarizing film of the present invention is preferably 42% or more. If the single transmittance is too low, it tends to be impossible to achieve high brightness of the liquid crystal display.
- the single transmittance is a value obtained by measuring the light transmittance of a single polarizing film using a spectrophotometer.
- the polarizing film of the present invention is suitable for producing a polarizing plate having excellent polarization performance and little polarization unevenness.
- the manufacturing method of the polarizing plate of this invention is demonstrated.
- the polarizing film of the present invention is bonded to one side or both sides of an optically isotropic resin film as a protective film via an adhesive to form a polarizing plate.
- protective films include films of cellulose triacetate, cellulose diacetate, polycarbonate, polymethyl methacrylate, cycloolefin polymer, cycloolefin copolymer, polystyrene, polyethersulfone, polyarylene ester, poly-4-methylpentene, polyphenylene oxide, and the like. Or a sheet.
- the bonding method is performed by a known method. For example, after a liquid adhesive composition is uniformly applied to a polarizing film, a protective film, or both, the two are bonded and pressure-bonded, and heated or activated. This is done by irradiating energy rays.
- a curable resin such as urethane resin, acrylic resin, urea resin or the like is applied to one side or both sides of the protective film and cured to obtain a polarizing plate.
- the polarizing film and polarizing plate obtained by the present invention are free from display defects and uneven color, and have excellent in-plane uniformity of polarization performance, such as portable information terminals, personal computers, TVs, projectors, signage, electronic desk calculators, electronic Watches, word processors, electronic paper, game consoles, videos, cameras, photo albums, thermometers, audio, liquid crystal display devices such as cars and machinery instruments, sunglasses, anti-glare glasses, stereoscopic glasses, wearable displays, display elements ( CRT, LCD, organic EL, electronic paper, etc.) are preferably used for reflection reducing layers, optical communication equipment, medical equipment, building materials, toys and the like.
- portable information terminals personal computers, TVs, projectors, signage, electronic desk calculators, electronic Watches, word processors, electronic paper, game consoles, videos, cameras, photo albums, thermometers, audio, liquid crystal display devices such as cars and machinery instruments, sunglasses, anti-glare glasses, stereoscopic glasses, wearable displays, display elements ( CRT, LCD, organic
- ⁇ Measurement conditions (1) Number of microcracks (lines / mm) When a virtual line having a length of 1 mm is provided at 10 locations on the surface of the cast drum in the differential interference processing mode using a laser focus microscope VK-9700 (objective lens: 50 times) manufactured by Keyence Corporation, The number of microcracks having an intersecting width of 1 to 10 ⁇ m and an intersection depth of 0.01 to 0.2 ⁇ m was counted, and the average value at 10 locations was defined as the number of microcracks.
- Polarization unevenness A polarizing film having a length of 1 m and a width of 1 m is sandwiched between two polarizing plates in a crossed Nicols state (single transmittance 43.5%, polarization degree 99.9%) at an angle of 45 °. Later, using a light box with a surface illuminance of 14000 lx, optical color unevenness is observed in the transmission mode and evaluated according to the following criteria. (Evaluation criteria) ⁇ ... No color unevenness. ⁇ ⁇ ⁇ ⁇ There is uneven color.
- Example 1 Manufacture of polyvinyl alcohol film
- 1,000 kg of polyvinyl alcohol resin having a weight average molecular weight of 142,000 and a saponification degree of 99.8 mol%, 2,500 kg of water, 105 kg of glycerin as a plasticizer, and sodium dodecyl sulfate as a surfactant 0 .25 kg was added, heated to 150 ° C. with stirring, and dissolved under pressure to obtain a polyvinyl alcohol resin aqueous solution having a resin concentration of 25%.
- the polyvinyl alcohol-based resin aqueous solution is supplied to a twin-screw extruder and defoamed, and then the aqueous solution temperature is set to 95 ° C., and then flows from the T-type slit die discharge port to the cast drum at a discharge speed of 1.25 m / min. Then, a film was formed. As shown in Table 1, six microcracks were present on the surface of the cast drum used.
- Example 2 A polyvinyl alcohol film and a polarizing film were obtained in the same manner as in Example 1 except that a cast drum having 11 microcracks was used. Table 1 shows the characteristics of the obtained polyvinyl alcohol film, and Table 2 shows the characteristics of the polarizing film.
- Example 3 A polyvinyl alcohol film and a polarizing film were obtained in the same manner as in Example 1 except that a cast drum having 28 microcracks was used. Table 1 shows the characteristics of the obtained polyvinyl alcohol film, and Table 2 shows the characteristics of the polarizing film.
- Example 1 A polyvinyl alcohol film was produced in the same manner as in Example 1 except that a cast drum having only two microcracks was used, but only a length of 0.1 km was produced due to poor peeling, and the production of a polarizing film was It was impossible.
- Example 2 A polyvinyl alcohol film and a polarizing film were obtained in the same manner as in Example 1 except that a cast drum having 40 microcracks was used. Table 1 shows the characteristics of the obtained polyvinyl alcohol film, and Table 2 shows the characteristics of the polarizing film.
- the polyvinyl alcohol films of Examples 1 to 3 contain the number of linear protrusions within the range of 1 to 10, whereas the polyvinyl alcohol film of Comparative Example 1 has 0 films below the lower limit value.
- a polyvinyl alcohol-type film contains 18 pieces more than an upper limit.
- the polarizing films obtained from the polyvinyl alcohol films of Examples 1 to 3 have excellent polarization characteristics, whereas Comparative Example 1 cannot produce a polarizing film, and the polarizing film of Comparative Example 2 has a polarizing performance. It turns out that it is inferior to.
- the polarizing film or polarizing plate obtained by the present invention has no polarization unevenness and excellent polarization performance, and is a portable information terminal, personal computer, TV, projector, signage, electronic desk calculator, electronic clock, word processor, electronic paper, game machine , Video, camera, photo album, thermometer, audio, liquid crystal display devices such as automobile and machinery instruments, sunglasses, anti-glare glasses, stereoscopic glasses, wearable display, display elements (CRT, LCD, organic EL, electronic paper) Etc.) for reflection-reducing layers, optical communication equipment, medical equipment, building materials, toys and the like.
- a portable information terminal personal computer, TV, projector, signage, electronic desk calculator, electronic clock, word processor, electronic paper, game machine , Video, camera, photo album, thermometer, audio, liquid crystal display devices such as automobile and machinery instruments, sunglasses, anti-glare glasses, stereoscopic glasses, wearable display, display elements (CRT, LCD, organic EL, electronic paper) Etc.) for reflection-reducing layers, optical communication equipment, medical equipment, building materials
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- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Optics & Photonics (AREA)
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- Manufacture Of Macromolecular Shaped Articles (AREA)
Abstract
Description
・特許文献1では、ポリビニルアルコール系フィルムの表面粗さを低減するため、SUSに対する動摩擦係数の低いポリビニルアルコール系フィルムが提案されており、
・特許文献2では、表面粗さの低減のため、特定組成の原液(ポリビニルアルコール系樹脂水溶液)を用いて、特定の製膜条件で、偏光膜用ポリビニルアルコール系フィルムを製造する手法が提案されており、
・特許文献3では、ヘイズ対策として、たとえば、分子量の異なる2種類のポリビニルアルコール系樹脂を用いたポリビニルアルコール系フィルムが提案されており、
・特許文献4では、特定の添加剤を用いるポリビニルアルコール系フィルムの製造法が提案されており、
・特許文献5では、フィルムの厚さを均一化するため、表面粗さが3S(最大高さ3μm)以下である金属表面(キャスト型表面)上で製膜する手法が提案されている。
更に本発明のポリビニルアルコール系フィルムは、製膜時のキャスト型からの剥離性に優れ、気泡や析出物などの欠点が無いポリビニルアルコール系フィルムであるため高い生産性で製造することが可能である。
なお、本発明においては、アスペクト比10以上をもって線状と定義する。
ここで、本発明における平均ケン化度は、JIS K 6726に準じて測定されるものである。
(A)キャスト法によりフィルムを製膜する工程。
(B)製膜されたフィルムを加熱して乾燥する工程。
(C)乾燥されたフィルムをスリットした後、ロールに巻き取る工程。
以下、キャスト型がキャストドラムの場合を例にとって説明する。なお、後述のキャストドラムにおいて、特定条件でのキャストドラム表面のマイクロクラックの本数、キャストドラム表面の表面粗さRz、キャストドラムからフィルムを剥離する時の剥離強度の、各々の特定範囲の設定は、例えばエンドレスベルト等、キャストドラム(ドラム型ロール)以外のキャスト型においても適用される。
かかるポリビニルアルコール系樹脂ウェットケーキを温水または熱水に溶解して、ポリビニルアルコール系樹脂水溶液を調整する。
かかるポリビニルアルコール系樹脂水溶液の温度が低すぎると流動不良となる傾向があり、高すぎると発泡する傾向がある。
かかる水溶液の粘度が、低すぎると流動不良となる傾向があり、高すぎると流涎が困難となる傾向がある。
かかる吐出速度が遅すぎると生産性が低下する傾向があり、速すぎると流涎が困難となる傾向がある。
かかる直径が小さすぎると乾燥長が不足し速度が出にくい傾向があり、大きすぎると輸送性が低下する傾向がある。
キャストドラムの幅が小さすぎると生産性が低下する傾向がある。
かかる回転速度が遅すぎると生産性が低下する傾向があり、速すぎると乾燥が不十分となる傾向がある。
かかる表面温度が低すぎると乾燥不良となる傾向があり、高すぎると発泡してしまう傾向がある。
かかるマイクロクラックの本数が、少なすぎるとフィルムの剥離性が低下し、ポリビニルアルコール系フィルムの生産性が低下する傾向があり、多すぎるとポリビニルアルコール系フィルムの表面粗さが増大し偏光膜の偏光性能が低下する傾向がある。
表面粗さRzが小さすぎると、ポリビニルアルコール系フィルムを高い生産性で製造することが困難となる傾向があり、大きすぎるとポリビニルアルコール系フィルムの表面粗さが増大し、偏光膜の偏光度が低下する傾向がある。
かかる剥離強度が大きすぎると、キャストドラムからのフィルムの剥離性が低下し、フィルムが破断したり、ポリビニルアルコール系フィルムのリタデーションが増大する傾向があり、小さすぎると、製膜中にキャストドラムからフィルムが剥離し、フィルムの平滑性が低下する傾向があるため、いずれの場合においてもポリビニルアルコール系フィルムを高い生産性で製造することが困難となる。
また、熱ロールは、例えば、表面をハードクロムメッキ処理又は鏡面処理した、直径0.2~2mのロールであり、通常2~30本、好ましくは10~25本を用いて乾燥を行うことが好ましい。
なお、偏光度は、一般的に2枚の偏光膜を、その配向方向が同一方向になるように重ね合わせた状態で、波長λにおいて測定した光線透過率(H11)と、2枚の偏光膜を、配向方向が互いに直交する方向になる様に重ね合わせた状態で、波長λにおいて測定した光線透過率(H1)より、下式にしたがって算出される。
〔(H11-H1)/(H11+H1)〕1/2
単体透過率は、分光光度計を用いて偏光膜単体の光線透過率を測定して得られる値である。
以下、本発明の偏光板の製造方法について説明する。
尚、例中「部」、「%」とあるのは、重量基準を意味する。
各物性について、次のようにして測定を行った。
(1)マイクロクラック本数(本/mm)
キーエンス社製レーザーフォーカス顕微鏡VK-9700(対物レンズ:50倍)を用いて、微分干渉処理モードにてキャストドラム表面の10か所において、長さ1mmの仮想線を設けた場合、該仮想線と交差する幅1~10μmであり、かつ交点の深さが0.01~0.2μmのマイクロクラックをカウントし、10か所の平均値をマイクロクラック本数とした。
キーエンス社製レーザーフォーカス顕微鏡VK-9700(対物レンズ:50倍)を用いて、微分干渉処理モードにて、キャストドラムに接していたフィルム表面の10か所において、長さ1mmの仮想線を設けた場合、該仮想線と交差する幅1~10μmであり、かつ交点の高さが0.01~0.1μmの線状突起(アスペクト比10以上)をカウントし、10か所の平均値を線状突起数とした。
JIS B0601:2001に準拠し、キーエンス社製レーザーフォーカス顕微鏡VK-9700(測定長:1mm、対物レンズ:50倍)を用いて、微分干渉処理モードにてキャストドラムの10か所を測定し、平均値を表面粗さとした。
ロールフィルムから50mm×50mmの試験片を10枚採取し、日本電色工業社製ヘイズメーター「NDH-2000」を用いて測定し、10枚の平均値をヘイズとした。
キャストドラムに付着したフィルムの端部(幅25mm)を、ばね計りでキャストドラム表面に対して垂直になるように、0.1N、0.01N、0.001Nの力で引っ張り、下記の基準にて剥離性を評価した。
(評価基準)
○・・・剥離したもの。
×・・・全面もしくは一部が剥離しなかったもの。
得られた偏光膜から、長さ4cm×幅4cmのサンプルを切り出し、自動偏光フィルム測定装置(日本分光社製:VAP7070)を用いて、偏光度と単体透過率を測定した。
長さ1m×幅1mの偏光膜をクロスニコル状態の2枚の偏光板(単体透過率43.5%、偏光度99.9%)の間に45°の角度で挟んだのちに、表面照度14000lxのライトボックスを用いて、透過モードで光学的な色ムラを観察し、以下の基準で評価する。
(評価基準)
○・・・色ムラなし。
×・・・色ムラあり。
(ポリビニルアルコール系フィルムの製造)
5000lの溶解缶に、重量平均分子量142,000、ケン化度99.8モル%のポリビニルアルコール系樹脂1,000kg、水2,500kg、可塑剤としてグリセリン105kg、および界面活性剤としてドデシル硫酸ナトリウム0.25kgを入れ、撹拌しながら150℃まで昇温して加圧溶解を行い、樹脂濃度25%のポリビニルアルコール系樹脂水溶液を得た。
次に該ポリビニルアルコール系樹脂水溶液を、2軸押出機に供給して脱泡した後、水溶液温度を95℃にし、T型スリットダイ吐出口よりキャストドラムに、吐出速度1.25m/分で流延して製膜した。使用したキャストドラムの表面には、表1の通り、マイクロクラックが6本存在していた。
得られたポリビニルアルコール系フィルムを、水温25℃の水槽に浸漬しながら1.7倍に一軸延伸した。次に、ヨウ素0.5g/L、ヨウ化カリウム30g/Lよりなる28℃の水溶液中に浸漬しながら1.6倍に一軸延伸した。次に、ホウ酸40g/L、ヨウ化カリウム30g/Lよりなる55℃の水溶液に浸漬しながら2.1倍に一軸延伸した。最後に、ヨウ化カリウム水溶液で洗浄を行い、乾燥して総延伸倍率5.8倍の偏光膜を得た。得られた偏光膜の偏光特性を表2に示す。
マイクロクラックが11本存在するキャストドラムを用いた以外は、実施例1と同様にしてポリビニルアルコール系フィルム、及び偏光膜を得た。得られたポリビニルアルコール系フィルムの特性を表1、偏光膜の特性を表2に示す。
マイクロクラックが28本存在するキャストドラムを用いた以外は、実施例1と同様にしてポリビニルアルコール系フィルム、及び偏光膜を得た。得られたポリビニルアルコール系フィルムの特性を表1、偏光膜の特性を表2に示す。
マイクロクラックが2本しか存在しないキャストドラムを用いた以外は、実施例1と同様にしてポリビニルアルコール系フィルムを製造したが、剥離不良により長さ0.1kmしか製造できず、偏光膜の製造は不可能であった。
マイクロクラックが40本存在するキャストドラムを用いた以外は、実施例1と同様にしてポリビニルアルコール系フィルム、及び偏光膜を得た。得られたポリビニルアルコール系フィルムの特性を表1、偏光膜の特性を表2に示す。
そして、実施例1~3のポリビニルアルコール系フィルムから得られる偏光膜の偏光特性は優れるものであるのに対し、比較例1は偏光膜が製造できない結果となり、比較例2の偏光膜は偏光性能に劣るものであることがわかる。
Claims (8)
- 厚さ5~60μm、幅2m以上、長さ2km以上であるポリビニルアルコール系フィルムであって、フィルム表面の任意の位置に長さ1mmの仮想線を設けた際に、該仮想線と交差する幅1~10μmかつ交点の高さが0.01~0.1μmの線状突起数が、1~10本であることを特徴とするポリビニルアルコール系フィルム。
- 厚さが5~30μmであることを特徴とする請求項1記載のポリビニルアルコール系フィルム。
- ポリビニルアルコール系樹脂の水溶液を、キャスト型に吐出及び流延して製膜し、連続的に乾燥して得られることを特徴とする請求項1または2記載のポリビニルアルコール系フィルム。
- キャスト型が、キャスト型表面の任意の位置に長さ1mmの仮想線を設けた際に、該仮想線と交差する幅1~10μmかつ交点の深さが0.01~0.2μmのマイクロクラックを5~30本含有するキャスト型であることを特徴とする請求項3記載のポリビニルアルコール系フィルム。
- キャスト型が、キャスト型表面が撥水性を有するキャスト型であることを特徴とする請求項3または4記載のポリビニルアルコール系フィルム。
- キャスト型が、キャスト型表面の表面粗さRzが0.1~0.3μmであるキャスト型であることを特徴とする請求項3~5いずれか記載のポリビニルアルコール系フィルム。
- 請求項1~6いずれか記載のポリビニルアルコール系フィルムからなることを特徴とする偏光膜。
- ポリビニルアルコール系樹脂の水溶液を、キャスト型に吐出及び流涎して製膜し、連続的に乾燥して得られるポリビニルアルコール系フィルムの製造方法であり、キャスト型からフィルムを剥離する時の剥離強度が、0.001~0.1N/25mmであることを特徴とするポリビニルアルコール系フィルムの製造方法。
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JP2014104671A (ja) * | 2012-11-28 | 2014-06-09 | Mitsubishi Chemicals Corp | ポリカーボネート樹脂無延伸フィルム、及びその製造方法 |
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JP2016224410A (ja) * | 2015-05-29 | 2016-12-28 | 日本合成化学工業株式会社 | ポリビニルアルコール系フィルム及び偏光膜、ならびにポリビニルアルコール系フィルムの製造方法 |
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