WO2019176827A1 - フィルムロール及びその製造方法 - Google Patents

フィルムロール及びその製造方法 Download PDF

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Publication number
WO2019176827A1
WO2019176827A1 PCT/JP2019/009582 JP2019009582W WO2019176827A1 WO 2019176827 A1 WO2019176827 A1 WO 2019176827A1 JP 2019009582 W JP2019009582 W JP 2019009582W WO 2019176827 A1 WO2019176827 A1 WO 2019176827A1
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WIPO (PCT)
Prior art keywords
film
sdr
polyvinyl alcohol
pva
winding
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PCT/JP2019/009582
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English (en)
French (fr)
Japanese (ja)
Inventor
良治 勝野
修 風藤
太我 油井
松田　一彦
友 渡邉
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株式会社クラレ
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Application filed by 株式会社クラレ filed Critical 株式会社クラレ
Priority to KR1020207026606A priority Critical patent/KR20200130311A/ko
Priority to JP2020506497A priority patent/JP7279016B2/ja
Priority to CN201980018843.5A priority patent/CN111819479B/zh
Publication of WO2019176827A1 publication Critical patent/WO2019176827A1/ja

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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
    • 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
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D1/00—Cutting through work characterised by the nature or movement of the cutting member or particular materials not otherwise provided for; Apparatus or machines therefor; Cutting members therefor
    • B26D1/0006—Cutting members therefor
    • B26D2001/0086—Cutting members therefor having a radiussed blunt cutting edge

Definitions

  • the present invention relates to a film roll formed by winding a polyvinyl alcohol film. Moreover, this invention relates to the manufacturing method of the said film roll.
  • a polarizing plate having a light transmission and shielding function is a basic component of a liquid crystal display (LCD) together with a liquid crystal having a light switching function.
  • LCD liquid crystal display
  • This LCD is also used in a wide range from small devices such as calculators and watches in the early stages of development to laptop computers, LCD color projectors, in-vehicle navigation systems, LCD TVs, smartphones, and indoor and outdoor measuring devices. In view of this, there is a demand for polarizing plates with higher quality and lower cost.
  • the polarizing plate is generally uniaxially stretched after dyeing a polyvinyl alcohol film (hereinafter, polyvinyl alcohol may be abbreviated as “PVA” and polyvinyl alcohol film may be abbreviated as “PVA film”), or uniaxially stretched while being dyed, or By making a uniaxially stretched film dyed and dyed after being uniaxially stretched and fixing it with a boron compound, or by fixing it with a boron compound at the same time as dyeing during the uniaxial stretching and dyeing process, etc. After manufacturing a polarizing film, it manufactures by bonding protective films, such as a cellulose triacetate (TAC) film and an acetic acid and a cellulose butyrate (CAB) film, on the surface of the polarizing film.
  • TAC cellulose triacetate
  • CAB acetic acid and a cellulose butyrate
  • both end portions in the width direction of the PVA film after film formation have different thicknesses from the center portion, or the degree of drying is different, and stable stretching when uniaxial stretching is performed while leaving both end portions in the width direction. Since it is difficult to cut and remove both end portions in the width direction of the film, it is generally carried out in a roll shape and supplied to a customer such as a polarizing plate manufacturer.
  • Patent Document 1 discloses a method of cutting using a blade so as to remove both ends in the width direction of a vinyl alcohol polymer film in advance before stretching, and the vinyl alcohol heavy used for the cutting.
  • a method for cutting a vinyl alcohol polymer film for stretching is described in which the temperature of the coalesced film is 10 ° C. to 70 ° C. and the volatile content is 0.1% to 10%. According to this method, it is said that there is little breakage from both ends in the width direction of the film at the time of stretching, uniform stretching is easy, and a PVA film useful as a raw material for producing a cold chill or a polarizing film can be obtained.
  • At least one of two end portions along the length direction of the film is a long polyvinyl alcohol polymer film that is a cut end portion formed by a cutting blade, and A polyvinyl alcohol polymer film is described in which the degree of surface roughness of the cut end surface is such that the maximum height (Ry) is 50 ⁇ m or less over the entire length of the film.
  • This polyvinyl alcohol-based polymer film has a smooth cut end face with a very low degree of roughening over the entire length of the film even when the film length is as long as 3000 m or more.
  • the stretching process can be continuously performed with high productivity without causing breakage of the film as a starting point.
  • the present invention has been made to solve the above-mentioned problems, and prevents the film from breaking during stretching when a film roll formed by winding a long PVA film of 3,000 m or longer is produced. It aims at providing the film roll which can do.
  • the above-described problem is a film roll formed by winding a polyvinyl alcohol film; the polyvinyl alcohol film has a length of 3,000 to 20,000 m, and the polyvinyl alcohol film extends in the length direction of the film. At least one of the two end portions along the side has a cut end portion formed by being cut by a cutting blade, and the developed area ratio (Sdr) of the cut surface at the cut end portion satisfies the following formula (1)
  • the development area ratio Sdr (s) of the cut surface at the winding start portion of the polyvinyl alcohol film and the development area Sdr (e) of the cut surface at the winding end portion of the polyvinyl alcohol film satisfy the following formula (2). It is solved by providing a film roll characterized by filling.
  • the saponification degree of the polyvinyl alcohol constituting the polyvinyl alcohol film is preferably 95 to 99.9 mol%, and the viscosity average polymerization degree is preferably 1,000 to 8,000.
  • the thickness of the polyvinyl alcohol film is preferably 15 to 100 ⁇ m.
  • the number of breaks of the polyvinyl alcohol film when the polyvinyl alcohol film unwound from the film roll is stretched at a stretch ratio of 5 to 7 times is preferably 1 or less per 2000 m of the polyvinyl alcohol film.
  • the said subject is a manufacturing method of the said film roll, Comprising: While winding up the said polyvinyl alcohol film, at least one of the two edge parts along the length direction of this polyvinyl alcohol film cuts satisfying the following structure It is also solved by providing a method for producing a film roll that is cut using a blade.
  • a round blade made of a metal having a Vickers hardness of 690 or more and 1850 or less (b) The angle of the blade edge is 21 to 26 ° (c) The thickness of the non-tapered base portion in the blade portion is 0.05 to 1 mm (D) The diameter of the round blade is 40 to 60 mm.
  • the film roll of the present invention is formed by winding a long PVA film having a length of 3,000 m or more. Even in such a long PVA film, the film roll starts to wind up and winds.
  • the development area ratio (Sdr) of the cut surface at the cut end is not more than a certain value, and the development area ratio Sdr (s) of the cut surface in the winding start portion and the development area of the cut surface in the winding end portion.
  • the ratio with the ratio Sdr (e) is in a certain range. Therefore, the film roll which can prevent generation
  • the present invention relates to a film roll formed by winding a PVA film.
  • the PVA film in the present invention has a cut end portion formed by cutting at least one of two end portions along the length direction of the film with a cutting blade.
  • the developed area ratio (Sdr) of the cut surface at the cut end satisfies the following formula (1)
  • the developed area ratio Sdr (s) of the cut surface at the winding start portion of the PVA film and the winding end portion It is important that the development area Sdr (e) of the cut surface satisfies the following formula (2).
  • the film When producing a film roll having a developed area ratio of the cut surface satisfying the above formulas (1) and (2), the film can be prevented from breaking during stretching even if the length is 3,000 m or more. .
  • a suitable manufacturing method uses a cutting blade at least one of the two edge parts along the length direction of this PVA film, winding up a PVA film. It is the manufacturing method cut
  • FIG. 1 An example of the manufacturing method of a PVA film roll is demonstrated using FIG.
  • FIG. 1 is a diagram showing an example of a method for producing a PVA film roll. In order to simplify the description, FIG. 1 shows a mode in which one of two ends along the length direction of the PVA film is cut by a cutting blade.
  • a PVA film is set on a winding roll (not shown), and a cutting blade (not shown) is set. Then, the winding roll is rotated to start winding the PVA film, and the cutting edge of the PVA film is started to be cut by the cutting blade (“winding start portion” in FIG. 1). And while the length direction edge part of a PVA film is cut
  • an inspection film is collected within a predetermined range from the “winding start portion”. Specifically, as shown in FIG. 1, after the end film is removed, an inspection film is collected in a predetermined range. Hereinafter, this film is referred to as “inspection film (start of winding)”. And after the test
  • the inspection film collected at this time is subjected to various measurements for managing the quality of the PVA film roll.
  • the collected inspection film by measuring the developed area ratio (Sdr; hereinafter, sometimes simply abbreviated as Sdr) of the cut surface by the cutting blade, the above formula (1) and Obtain the value of (2).
  • the present invention is not limited to this manufacturing example, and the winding end portion of FIG.
  • the PVA film roll can be continuously manufactured by replacing with a new cutting blade.
  • the production method is not limited to this, and after the PVA film roll is produced, the film is drawn out from the roll and inspected. It is also possible to collect film.
  • the development area ratio (Sdr) of the cut surface at the cut end formed by being cut by the cutting blade satisfies the following formula (1).
  • the development area ratio (Sdr) represents how much the surface area (development area) of the definition area increases with respect to the surface area of the definition area as a reference.
  • Sdr is a value measured by a method according to ISO 25178.
  • Sdr exceeds 0.085, the frequency of breakage increases during stretching and the production stability of the stretched film is poor. In addition, the draw ratio cannot be increased and the optical properties may be inferior. Sdr is preferably 0.084 or less.
  • the development area ratio Sdr (s) of the cut surface in the “winding start portion” of the PVA film and the development area Sdr (e) of the cut surface in the “winding end portion” of the PVA film are as follows. It is also important to satisfy equation (2).
  • Sdr (s) can be obtained by measuring Sdr of “inspection film (start of winding)”
  • Sdr (e) measures Sdr of “inspection film (end of winding)”. Can be obtained.
  • Sdr (s) / Sdr (e) are values measured by a method according to ISO 25178.
  • Sdr (s) / Sdr (e) When Sdr (s) / Sdr (e) is less than 0.10, the PVA film breaks during stretching.
  • Sdr (s) / Sdr (e) is preferably 0.12 or more, more preferably 0.4 or more, and further preferably 0.7 or more.
  • the length of the PVA film in the present invention is 3,000 to 20,000 m.
  • the length of the PVA film is preferably 5,000 m or more, more preferably 7,500 m or more, and further preferably 10,000 m or more.
  • the length of the PVA film is preferably 18,000 m or less, more preferably 16,000 m or less, and further preferably 14,000 m or less.
  • the thickness of the PVA film is not particularly limited and is preferably 15 to 100 ⁇ m. If the thickness of the PVA film is less than 15 ⁇ m, the PVA film may be broken during stretching.
  • the thickness of the PVA fill is more preferably 20 ⁇ m or more. On the other hand, when the thickness of the PVA film exceeds 100 ⁇ m, the cutting blade may be lost during the cutting of the film.
  • the thickness of the PVA film is more preferably 80 ⁇ m or less.
  • the width of the PVA film is not particularly limited and is preferably 100 mm or more.
  • the upper limit of the width of the PVA film is not particularly limited. However, if the width is too wide, it may be difficult to uniformly stretch the polarizing film in a case where a polarizing film is produced by a device that has been put into practical use.
  • the width of the PVA film is preferably 10,000 mm or less.
  • the width of the PVA film refers to the width of the product PVA film after the end film is cut, as illustrated in FIG.
  • the arithmetic average roughness (Ra) of the cut surface is preferably 0.190 ⁇ m or more. Moreover, it is also preferable that the maximum height (Ry) of the cut surface is 1.100 ⁇ m or more. Since the values of Ra and Ry indicate the degree of surface roughness of the cut surface, generally, when these values are high, the film tends to break during stretching. However, in the film roll of the present invention, even if Ra or Ry is equal to or higher than the above value, the film can be prevented from being broken during stretching by satisfying the above formulas (1) and (2). .
  • the number of breaks of the PVA film when the PVA film unwound from the film roll is stretched at a stretch ratio of 5 to 7 is 1 or less per 2000 m of the PVA film.
  • the number of breaks when stretching a 10,000 m PVA film is 5 the number of breaks is 1 per 2000 m of PVA film. From the viewpoint of performing stretching continuously and efficiently, it is more preferable that the number of breaks is substantially zero.
  • the PVA constituting the PVA film one produced by saponifying a vinyl ester polymer obtained by polymerizing a vinyl ester monomer can be used.
  • vinyl ester monomers include vinyl formate, vinyl acetate, vinyl propionate, vinyl valerate, vinyl laurate, vinyl stearate, vinyl benzoate, vinyl pivalate, vinyl versatate, and the like. Among these, vinyl acetate is preferable.
  • the polymerization method of vinyl ester may be any of batch polymerization, semi-batch polymerization, continuous polymerization, semi-continuous polymerization, etc., and polymerization methods include bulk polymerization, solution polymerization, suspension polymerization, emulsion polymerization, etc. The known methods can be applied.
  • the polymerization initiator used when the vinyl ester is subjected to the polymerization reaction may be selected from known polymerization initiators such as azo initiators, peroxide initiators, and redox initiators according to the polymerization method. it can.
  • the vinyl ester polymer is preferably obtained by using only one or two or more vinyl ester monomers as a monomer, and using only one vinyl ester monomer as a monomer. Although what was obtained is more preferable, the copolymer of 1 type, or 2 or more types of vinyl-ester type monomers and the other monomer copolymerizable with this may be sufficient.
  • vinyl ester monomers include, for example, ethylene; olefins having 3 to 30 carbon atoms such as propylene, 1-butene and isobutene; acrylic acid or salts thereof; methyl acrylate, acrylic Such as ethyl acrylate, n-propyl acrylate, i-propyl acrylate, n-butyl acrylate, i-butyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, dodecyl acrylate, octadecyl acrylate, etc.
  • Acrylic acid ester methacrylic acid or salt thereof; methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, i-propyl methacrylate, n-butyl methacrylate, i-butyl methacrylate, t-butyl methacrylate, methacrylic acid 2-ethylhexyl, dodecyl methacrylate
  • Methacrylic acid esters such as octadecyl methacrylate; acrylamide, N-methylacrylamide, N-ethylacrylamide, N, N-dimethylacrylamide, diacetone acrylamide, acrylamide propanesulfonic acid or salt thereof, acrylamidopropyldimethylamine or salt thereof, N Acrylamide derivatives such as methylolacrylamide or derivatives thereof; methacrylamide, N-methylmethacrylamide, N-ethylmethacrylamide, methacrylamidepropanesulfonic acid or
  • vinyl ethers such as methyl vinyl ether, ethyl vinyl ether, n-propyl vinyl ether, i-propyl vinyl ether, n-butyl vinyl ether, i-butyl vinyl ether, t-butyl vinyl ether, dodecyl vinyl ether, stearyl vinyl ether; acrylonitrile, methacrylonitrile, etc.
  • Vinyl cyanide vinyl halides such as vinyl chloride, vinylidene chloride, vinyl fluoride, and vinylidene fluoride; allyl compounds such as allyl acetate and allyl chloride; maleic acid or its salt, ester or acid anhydride; itaconic acid or its salt , Esters or acid anhydrides; vinylsilyl compounds such as vinyltrimethoxysilane; isopropenyl acetate and the like.
  • the vinyl ester polymer can have a structural unit derived from one or more of these other monomers.
  • the proportion of the structural unit derived from the other monomer in the vinyl ester polymer is not particularly limited, but based on the number of moles of all structural units constituting the vinyl ester polymer, it is 15 mol% or less. It is preferable that it is 5 mol% or less.
  • the saponification degree of the PVA constituting the PVA film is preferably 95 to 99.9 mol%.
  • the saponification degree is more preferably 99 mol% or more, further preferably 99.3 mol% or more, and particularly preferably 99.8 mol% or more.
  • PVA exceeding 99.99 mol% is difficult to produce.
  • the saponification degree is a value obtained by measuring according to JIS K6726 (1994).
  • the viscosity average degree of polymerization of PVA (hereinafter sometimes abbreviated as “polymerization degree”) is preferably 1,000 to 8,000.
  • the degree of polymerization is more preferably 1,500 or more, and further preferably 2,000 or more.
  • the degree of polymerization of PVA is more preferably 8,000 or less, and further preferably 6,000 or less.
  • the polymerization degree of PVA as used in this specification means the average degree of polymerization measured according to description of JIS K6726 (1994), and is the limit measured in 30 ° C. water after re-saponifying and purifying PVA. It can be determined from the viscosity.
  • one type of PVA may be used alone, or two or more types of PVA that are different from each other in one or more of the degree of polymerization, the degree of saponification, the degree of modification, and the like. You may use together.
  • the content of PVA in the PVA film is preferably 50% by mass or more, more preferably 70% by mass or more, and further preferably 85% by mass or more.
  • the PVA film preferably contains a plasticizer.
  • a PVA film contains a plasticizer, generation
  • the plasticizer is preferably a polyhydric alcohol, and specific examples include ethylene glycol, glycerin, diglycerin, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, and trimethylolpropane. These plasticizers may be used alone or in combination of two or more. Among these plasticizers, ethylene glycol or glycerin is preferable from the viewpoint of compatibility with PVA and availability.
  • the content of the plasticizer in the PVA film is preferably 1 to 30 parts by mass, more preferably 3 to 25 parts by mass, and further preferably 5 to 20 parts by mass with respect to 100 parts by mass of PVA. .
  • the PVA film preferably contains a surfactant from the viewpoint of improving the peelability from the metal support used for the production and improving the handleability of the PVA film.
  • a surfactant from the viewpoint of improving the peelability from the metal support used for the production and improving the handleability of the PVA film.
  • Anionic or nonionic surfactant can be used preferably.
  • the anionic surfactant include carboxylic acid types such as potassium laurate, sulfate ester types such as octyl sulfate, and sulfonic acid types such as dodecylbenzene sulfonate.
  • Nonionic surfactants include, for example, alkyl ether types such as polyoxyethylene oleyl ether, alkylphenyl ether types such as polyoxyethylene octylphenyl ether, alkyl ester types such as polyoxyethylene laurate, and polyoxyethylene laurylamino.
  • Alkylamine type such as ether
  • alkylamide type such as polyoxyethylene lauric acid amide
  • polypropylene glycol ether type such as polyoxyethylene polyoxypropylene ether
  • alkanolamide type such as lauric acid diethanolamide, oleic acid diethanolamide
  • polyoxy Examples include allyl phenyl ether type such as alkylene allyl phenyl ether.
  • the content of the surfactant in the PVA film is preferably 0.01 to 1 part by mass with respect to 100 parts by mass of PVA from the viewpoints of peelability from the metal support and handleability of the PVA film.
  • the amount is more preferably 02 to 0.5 parts by mass, and further preferably 0.05 to 0.3 parts by mass.
  • the PVA film may further contain other components other than the above-described PVA polymer, plasticizer, and surfactant, if necessary.
  • other components include moisture, antioxidants, ultraviolet absorbers, lubricants, colorants, fillers (inorganic particles, starch, etc.), preservatives, antifungal agents, and other components other than those described above. Examples thereof include polymer compounds.
  • the production method of the PVA film is not particularly limited, and can be produced by a conventionally known method.
  • PVA is mixed with a liquid medium or a melting aid, or a film-forming stock solution or melt is prepared using pellets containing the liquid medium or a melt aid, and the stock solution or melt is It is manufactured by forming into a film.
  • liquid medium for preparing a film-forming stock solution and a melt examples include dimethyl sulfoxide, dimethylformamide, dimethylacetamide, N-methylpyrrolidone, ethylenediamine, diethylenetriamine, water, and the like. Or 2 or more types can be used. Among these, dimethyl sulfoxide, water, and a mixture thereof are preferably used, and water is particularly preferably used.
  • the PVA film it is preferable to contain a plasticizer and a surfactant in the above-described stock solution or melt.
  • a plasticizer and a surfactant those described above can be used.
  • the compounding quantity of a plasticizer and surfactant can be made into said quantity.
  • Method for producing PVA film roll As a preferred method for producing the PVA film roll of the present invention, at least one of the two end portions along the length direction of the PVA film is wound on the PVA film while the following configurations (a) to (d) This is a method for producing a film roll that is cut using a cutting blade that satisfies the above.
  • a round blade made of a metal having a Vickers hardness of 690 or more and 1850 or less (b) The angle of the blade edge is 21 to 26 ° (c) The thickness of the non-tapered base portion in the blade portion is 0.05 to 1 mm (D) The diameter of the round blade is 40 to 60 mm.
  • the cutting blade is preferably a round blade made of a metal having a Vickers hardness of 690 or more and 1850 or less.
  • a round blade made of a metal having a Vickers hardness of less than 690 has a poor sharpness, and a PVA film having a smooth cut end face cannot be obtained. Therefore, there is a possibility that the PVA film is easily broken during the stretching process.
  • the Vickers hardness is more preferably 700 or more.
  • a round blade made of a metal having a Vickers hardness exceeding 1850 has an advantage of good sharpness.
  • the cutting edge is chipped during the cutting of the PVA film, and a PVA film having a smooth cut end surface until the end of winding cannot be obtained. Therefore, also in this case, the PVA film may be easily broken during the stretching process.
  • the Vickers hardness is more preferably 1500 or less, further preferably 1000 or less, and particularly preferably 790 or less.
  • Examples of the metal used for the round blade include metals such as iron, silicon, manganese, chromium, tungsten, and alloys thereof.
  • metals such as iron, silicon, manganese, chromium, tungsten, and alloys thereof.
  • SKS7 and SKS81 shown by JIS ⁇ G4308 are mentioned.
  • the angle of the blade edge is preferably 21 to 26 °. When the angle of the cutting edge is less than 21 °, the durability of the cutting edge may be insufficient. On the other hand, when the angle of the blade edge exceeds 26 °, the sharpness may be insufficient.
  • the angle of the blade edge is more preferably 25 ° or less.
  • the angle of the cutting edge in the present invention is defined as follows. As shown in FIGS. 2 and 3, the polished portion of the round blade is approximated to an isosceles triangle ABC. At this time, the tip of the blade is designated as vertex A. Then, a line is drawn from the vertex A toward the side BC so as to intersect the side BC at a right angle, and the intersection is set to H. The angle ⁇ BAH in the right triangle ABH is calculated from the length of the side AH and the length of the side BH. A value obtained by doubling the angle ⁇ BAH is defined as the blade edge angle.
  • the wall thickness of the non-tapered base in the blade portion is preferably 0.05 to 1 mm.
  • the wall thickness is more preferably 0.1 mm or more.
  • the thickness exceeds 1 mm, the film end after cutting may be curled.
  • the wall thickness is more preferably 0.8 mm or less.
  • the diameter of the round blade is preferably 40 to 60 mm. When the diameter of the round blade is less than 40 mm, the cutting edge may be cut many times at the same portion of the cutting edge, and the cutting edge may be lost.
  • the diameter of the round blade is more preferably 42 mm or more. On the other hand, when the diameter of the round blade exceeds 60 mm, it may take time to inspect the blade edge.
  • the diameter of the round blade is more preferably 55 mm or less.
  • a stretched film can be obtained by stretching the PVA film in the PVA film roll thus obtained. Since the film can be prevented from being broken at the time of stretching, a polarizing film having good polarization performance can be suitably produced.
  • the PVA film may be dyed, uniaxially stretched, fixed, dried, and further heat treated as necessary. There is no. Each operation may be performed twice or more.
  • Dyeing can be performed before uniaxial stretching, during uniaxial stretching, or after uniaxial stretching.
  • dyes used for dyeing iodine-potassium iodide, various dichroic dyes, and the like can be used in one kind or a mixture of two or more kinds.
  • the dyeing is generally performed by immersing the PVA film in a solution containing the above-mentioned dye, but the processing conditions such as coating on the PVA film or mixing with the PVA film to form a film.
  • the processing method is not particularly limited.
  • Uniaxial stretching can be performed by wet stretching or dry heat stretching, and can be performed in warm water (in a solution containing the dye or in a fixing treatment bath described later) or in the air using a PVA film after water absorption.
  • the stretching temperature is not particularly limited, but the temperature when stretching the PVA film in warm water (wet stretching) is usually 30 to 90 ° C. In the case of dry heat drawing, the temperature is usually 50 to 180 ° C.
  • the stretching ratio of the uniaxial stretching treatment (the total stretching ratio when performing uniaxial stretching in multiple stages) is preferably 5 times or more from the viewpoint of polarization performance.
  • the upper limit of a draw ratio is not specifically limited, In order to perform uniform extending
  • the film thickness after stretching is usually 3 to 75 ⁇ m.
  • Fixing is often performed for the purpose of strengthening the adsorption of the dye to the stretched film.
  • boric acid and / or boron compounds are added to the treatment bath used for the fixing treatment.
  • the temperature of drying treatment (heat treatment) of the stretched film is usually 30 to 150 ° C.
  • Example 1 Production of film roll
  • a PVA water-containing chip was obtained.
  • the volatile content in the PVA water-containing chip was 70% by mass.
  • the obtained molten PVA is cooled to 100 ° C. with a heat exchanger, and then extruded from a coat hanger die having a width of 900 mm onto a drum having a surface temperature of 90 ° C., and further dried through a hot air drying furnace.
  • Both ends (ears) in the width direction are round blades made of SKS7, which is an alloy tool steel specified in JIS G4404 (Vickers hardness: 700, diameter: 45 mm, blade angle: 21 °, thickness of non-tapered portion : 0.3 mm) was used to continuously produce a long PVA film having a width of 0.7 m.
  • the film forming speed was 8 m / min.
  • the PVA film (thickness 75 ⁇ m, length 10,000 m) after the film formation was stabilized was continuously wound around an aluminum cylindrical core having a diameter of 8 inches to form a film roll.
  • the point at which the film winding is started and the cutting is started is referred to as a “winding start portion”, and the point at which the film winding is finished and the cutting is finished is referred to as a “winding end portion”. is there.
  • FIG. 2 is a schematic view of the round blade as viewed from the side.
  • the round blade has a non-tapered portion and a blade edge portion, and the blade edge portion has a polished portion.
  • the film is cut at this polished portion.
  • FIG. 3 is a schematic view of a polished portion. The polished portion was observed using a laser microscope (50 times), and the polished portion was approximated to an isosceles triangle ABC. At this time, the tip of the blade was designated as vertex A.
  • a line was drawn from the vertex A toward the side BC so as to intersect the side BC at a right angle, and the intersection point was designated as H.
  • the lengths AH and BH were then measured.
  • the angle ⁇ BAH in the right triangle ABH was calculated from the measured lengths AH and BH, and a value obtained by doubling the angle ⁇ BAH was defined as the blade edge angle.
  • the number of chippings on the cutting edge before the start of cutting and the number of chippings on the cutting edge after the end of cutting were measured according to the following evaluation criteria.
  • the edge of the round blade was observed with a microscope once to confirm whether the blade was chipped.
  • the chip was approximated to a triangle and the area was calculated from the width and height. As a result, when the area was 7.5 ⁇ m 2 or more, the chip was counted as one “chip chip”.
  • Examples 2 to 6 Comparative Examples 1 to 4
  • the thickness of the PVA film and the type of round blade (Vickers hardness and blade angle) for cutting the PVA film were changed. And like Example 1, after manufacturing a PVA film by cut
  • Example 2 the film could be stretched without breaking from the unwinding start point to the end point.
  • Example 6 of Table 1 the film broke once during the period from the start of stretching to the stretching of 2000 m, but thereafter, the film could be stretched without breaking.
  • Comparative Examples 1 to 4 in Table 1 5 times (Comparative Example 1), 7 times (Comparative Example 2), 3 times (Comparative Example 3) from the start of stretching to the stretching of 2000 m. Since rupture occurred twice (Comparative Example 4), stretching was stopped (“Evaluation Stop” in Table 1).

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  • Polymers & Plastics (AREA)
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  • Shaping By String And By Release Of Stress In Plastics And The Like (AREA)
  • Polarising Elements (AREA)
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WO2022201708A1 (ja) * 2021-03-25 2022-09-29 日東電工株式会社 偏光板の製造方法および偏光板

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JP2015033727A (ja) * 2013-08-07 2015-02-19 住友化学株式会社 切断装置及び切断方法
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JP2022047611A (ja) * 2020-09-14 2022-03-25 日東電工株式会社 偏光板、位相差層付偏光板、ならびに、該偏光板または該位相差層付偏光板を含む画像表示装置
WO2022201708A1 (ja) * 2021-03-25 2022-09-29 日東電工株式会社 偏光板の製造方法および偏光板
JP2022149242A (ja) * 2021-03-25 2022-10-06 日東電工株式会社 偏光板の製造方法および偏光板
JP7203879B2 (ja) 2021-03-25 2023-01-13 日東電工株式会社 偏光板の製造方法および偏光板

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