WO2020004608A1 - ポリビニルアルコールフィルム、フィルムロールおよび偏光フィルム - Google Patents
ポリビニルアルコールフィルム、フィルムロールおよび偏光フィルム Download PDFInfo
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- WO2020004608A1 WO2020004608A1 PCT/JP2019/025770 JP2019025770W WO2020004608A1 WO 2020004608 A1 WO2020004608 A1 WO 2020004608A1 JP 2019025770 W JP2019025770 W JP 2019025770W WO 2020004608 A1 WO2020004608 A1 WO 2020004608A1
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- film
- pva
- polyvinyl alcohol
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
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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
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- 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
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
- G02B1/04—Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
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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
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
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- 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 (hereinafter, “polyvinyl alcohol” may be abbreviated as “PVA”) suitably used for manufacturing a polarizing film and the like, and a film roll obtained by winding the PVA film into a roll shape.
- PVA polyvinyl alcohol
- the present invention also relates to a polarizing film obtained using such a PVA film.
- Liquid crystal display devices are used in a wide range of fields, such as small devices such as calculators and watches, notebook computers, liquid crystal monitors, liquid crystal color projectors, liquid crystal televisions, in-car navigation systems, mobile phones, and measuring instruments used indoors and outdoors.
- a polarizing film having a function of transmitting and blocking light is a fundamental component of an LCD together with a liquid crystal having a function of switching light.
- dichroic dye such as a matrix produced by uniaxially stretching a PVA film as a polarizing film (uniaxially stretched oriented film was oriented to) the iodine dye (I 3- or I 5-like) is adsorbed Is the mainstream.
- a polarizing film is obtained by uniaxially stretching a PVA film previously containing a dichroic dye, adsorbing a dichroic dye simultaneously with the uniaxial stretching of the PVA film, or dichroicly stretching the PVA film uniaxially. It is produced by adsorbing a dye.
- polarizing plates used in LCDs for mobile applications such as small notebook computers and mobile phones.
- One means for reducing the thickness of a polarizing plate is to reduce the thickness of a PVA film, which is a raw material of a polarizing film.
- the stretching treatment of a thin PVA film is performed at a relatively high temperature, so that the amount of PVA eluted into the treatment liquid tends to increase.
- concentration of PVA in the treatment liquid increases, PVA fine particles precipitate in the treatment liquid and adhere to the PVA film due to progress of boric acid crosslinking and the like.
- foreign matters derived from the PVA fine particles remain on the surface of the obtained polarizing film and cause defects.
- Patent Literature 1 describes removing foreign matters attached to a film before stretching by a method of spraying water, a method of jetting gas, or a method using a blade of cloth, rubber, or the like.
- Patent Literature 2 discloses a method of removing a PVA in a processing liquid by adsorbing a processing liquid containing a crosslinking agent and an iodide used in manufacturing a polarizing film on activated carbon.
- Patent Document 3 describes a method of intentionally accelerating the deposition of PVA by bubbling each processing solution used in manufacturing a polarizing film, and removing the deposited PVA using a filter or the like. Have been.
- Patent Literatures 1 and 3 require dedicated equipment for removing foreign matter. Further, in the method described in Patent Document 2, it was necessary to frequently exchange activated carbon. For these reasons, the methods described in Patent Documents 1 to 3 have a problem in cost.
- the present invention has been made to solve the above problems, and an object of the present invention is to provide a PVA film and a PVA film roll capable of obtaining a polarizing film with a reduced number of foreign substances without using additional equipment. Moreover, it aims at providing the manufacturing method of such a PVA film. Still another object is to provide a polarizing film with a reduced number of foreign substances and a method for manufacturing the same.
- the present inventors have conducted intensive studies to solve the above problems, and as a result, when continuously producing a polarizing film using a long PVA film, PVA having a small amount of alkoxyl group and a nonionic surfactant were used.
- the present inventors have found that a polarizing film in which the number of foreign substances is significantly reduced can be obtained by using a contained PVA film, and the present invention has been completed.
- the present invention [1] It contains PVA and a nonionic surfactant having an alkoxyl group content of 0.0005 to 1 mol% and a saponification degree of 85 mol% or more, and the content of the nonionic surfactant is 0.1 to 100 parts by mass of the PVA. 001 to 1 part by mass of a PVA film; [2] The PVA film of [1], wherein the PVA further contains an ethylene unit, and the content thereof is 1 to 12 mol%.
- a vinyl ester is polymerized using a polymerization initiator having an alkoxyl group to obtain a polyvinyl ester, and then the PVA is obtained by saponifying the polyvinyl ester, and then the PVA and the nonionic surfactant are mixed.
- the PVA film of the present invention contains a PVA having an alkoxyl group content of 0.0005 to 1 mol% and a saponification degree of 85 mol% or more and a nonionic surfactant, and contains the nonionic surfactant based on 100 parts by mass of the PVA.
- the amount is 0.001 to 1 part by mass.
- PVA constituting the PVA film it is important to use, as PVA constituting the PVA film, one containing 0.0005 to 1 mol% of an alkoxyl group.
- a nonionic surfactant By using such PVA together with a nonionic surfactant, adhesion of the PVA fine particles to the PVA film is suppressed, so that the number of foreign substances such as blue foreign substances derived from the PVA fine particles is significantly reduced. Is obtained.
- the alkoxyl group those represented by the following formula (1) are preferable.
- R represents an alkyl group having 1 to 5 carbon atoms.
- the number of carbon atoms in ⁇ R is preferably 3 or less, more preferably 2 or less, and even more preferably 1.
- the content of the alkoxyl group in the PVA is 0.0005 to 1 mol% based on the number of moles of all structural units (all monomer units and units having an alkoxyl group) constituting the PVA.
- the content is preferably 0.0007 mol% or more, more preferably 0.001 mol% or more.
- the content of the alkoxyl group is 1 mol% or less, a polarizing film having excellent polarizing performance can be obtained.
- the content is preferably 0.5 mol% or less, more preferably 0.3 mol% or less.
- the method for producing the PVA is not particularly limited, but a method for saponifying a polyvinyl ester obtained by copolymerizing a vinyl ester and an unsaturated monomer having an alkoxyl group is preferable.
- the monomer containing an alkoxyl group is not particularly limited as long as it has an alkoxyl group and is an unsaturated monomer copolymerizable with a vinyl ester.
- alkyl vinyl ether, alkyl allyl ether, N-alkoxyalkyl ( (Meth) acrylamide, and N-alkoxyalkyl (meth) acrylamide is preferable.
- the monomer containing an alkoxyl group can be used alone or in combination of two or more, but the former is preferred.
- vinyl ester examples include vinyl acetate, vinyl formate, vinyl propionate, vinyl butyrate, vinyl pivalate, vinyl versatate, vinyl laurate, vinyl stearate, and vinyl benzoate.
- Vinyl acetate is more preferred.
- the vinyl esters can be used alone or in combination of two or more, but the former is preferred.
- a hydrophobic monomer such as an ⁇ -olefin together with the vinyl ester and the unsaturated monomer having an alkoxyl group.
- elution of PVA is suppressed when the obtained PVA film is immersed in a processing solution used for producing a polarizing film or the like.
- the PVA concentration in the treatment liquid is reduced, and the deposition of PVA is suppressed, so that the number of PVA fine particles adhering to the PVA film is further reduced.
- ⁇ -olefins examples include ⁇ -olefins having 2 to 30 carbon atoms, such as ethylene, propylene, 1-butene, and isobutene.
- ethylene is particularly preferred from the viewpoint that the number of foreign substances can be further reduced while suppressing a decrease in polarizing performance.
- the content of ethylene units in the obtained PVA is preferably 1 to 12 mol% based on the number of moles of all the structural units constituting the PVA.
- the content of the ethylene unit is 12 mol% or less, when the PVA film of the present invention is used for producing a polarizing film, the number of foreign substances can be reduced while suppressing a decrease in polarizing performance.
- the content of the ethylene unit is 12 mol% or less, the stability of a PVA solution used as a stock solution used for producing a PVA film is improved.
- the content is more preferably 9 mol% or less, further preferably 6 mol% or less.
- the content of the ethylene unit is 1 mol% or more, adhesion of the PVA fine particles to the PVA film is further suppressed.
- the content is more preferably 1.5 mol% or more, further preferably 2 mol% or more, and particularly preferably 3 mol% or more.
- a monomer other than the above-mentioned vinyl ester, unsaturated monomer having an alkoxyl group and ⁇ -olefin may be further copolymerized.
- Other monomers copolymerizable with the vinyl ester and the unsaturated monomer having an alkoxyl group include (meth) acrylic acid or a salt thereof; methyl (meth) acrylate, ethyl (meth) acrylate, ( N-propyl (meth) acrylate, i-propyl (meth) acrylate, n-butyl (meth) acrylate, i-butyl (meth) acrylate, t-butyl (meth) acrylate, (meth) acrylic acid 2 (Meth) acrylic esters such as -ethylhexyl, dodecyl (meth) acrylate and octadecyl (meth) acrylate; (meth) acrylamide; N-methyl (meth) acrylamide, N-ethyl (meth) acrylamide, N, N-dimethyl (meth) acrylamide, diacetone (meth) acrylamide, (meth)
- Vinyl amide vinyl ether 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, polyoxyethylene vinyl ether; Vinyl cyanide such as acrylonitrile; vinyl halide such as vinyl chloride, vinylidene chloride, vinyl fluoride, and vinylidene fluoride; vinyl ethyl carbonate Vinyl carbonates such as sodium acetate; dihydroxybutene derivatives such as 3,4-diacetoxy-1-butene and 3,4-diethoxy-1-butene; allyl compounds such as allyl acetate and allyl chloride; maleic acid or salts, esters or Acid anhydride; itaconic acid or a salt, ester or acid anhydride thereof; vinylsilyl compound such as vinyl
- the content of the unit derived from the other monomer in the PVA is preferably 10 mol% or less, more preferably 5 mol% or less, still more preferably 1 mol% or less, and particularly preferably, it is substantially not contained. preferable.
- Examples of the method of copolymerizing the vinyl ester and the unsaturated monomer having an alkoxyl group include known methods such as bulk polymerization, solution polymerization, suspension polymerization, and emulsion polymerization. Among them, a bulk polymerization method or a solution polymerization method in which polymerization is performed without a solvent or in a solvent such as an alcohol is usually employed. Examples of the alcohol used as a solvent during the solution polymerization include lower alcohols such as methanol, ethanol, and propanol.
- the initiator used for the copolymerization examples include 2,2′-azobisisobutyronitrile, 2,2′-azobis (2,4-dimethyl-valeronitrile), benzoyl peroxide, and n-propylperoxydioxy.
- Known initiators such as azo initiators such as carbonates and peroxide initiators are exemplified.
- the content of the alkoxyl group and the content of the ethylene unit in the PVA can be easily adjusted by changing the amount of the monomer as a raw material and the pressure (pressure of ethylene).
- the saponification degree of the PVA needs to be 85 mol% or more.
- the degree of saponification is preferably at least 90 mol%, more preferably at least 95 mol%, even more preferably at least 99 mol%.
- the degree of saponification of PVA is determined based on the total number of moles of a structural unit (typically, a vinyl ester unit) and a vinyl alcohol unit which can be converted into a vinyl alcohol unit by saponification of PVA. It means the ratio (mol%) occupied by the number of moles.
- the degree of saponification of PVA can be measured according to JIS K6726-1994.
- the 1,2-glycol bond content of the PVA is 0.2 to 1.5 mol% based on the number of moles of all structural units (all monomer units and units having an alkoxyl group) constituting the PVA. It is preferable that When the content of the 1,2-glycol bond is 1.5 mol% or less, when the obtained PVA film is immersed in the treatment liquid, the elution of PVA is suppressed, and the number of foreign substances is further reduced. A polarizing film is obtained. In this respect, the content is more preferably equal to or less than 1.4 mol%, and still more preferably equal to or less than 1.3 mol%.
- the content is more preferably 0.3 mol% or more, and further preferably 0.4 mol% or more.
- the content of the 1,2-glycol bond of PVA can be adjusted by the polymerization temperature and the like.
- the content of the 1,2-glycol bond in PVA can be determined from the NMR peak. After saponification saponification degree 99.9 mol%, carefully washed with methanol and then dissolved PVA was 90 ° C. vacuum dried for 2 days in DMSO-D 6, a few drops of trifluoroacetic acid was added and samples of 500MHz It is measured at 80 ° C. using proton NMR (JEOLX-500).
- the peak derived from methine in the vinyl alcohol unit is attributed to 3.2 to 4.0 ppm (integral value A), and the peak derived from one methine having 1,2-glycol bond is attributed to 3.25 ppm (integral value B).
- the content of 1,2-glycol bonds can be calculated.
- C represents an ethylene modification amount (mol%).
- Content of 1,2-glycol bond (mol%) B (100-C) / A
- a part of the hydroxyl groups may or may not be crosslinked. Further, in the above-mentioned PVA, a part of the hydroxyl group may react with an aldehyde such as formalin, acetaldehyde, butyraldehyde, benzaldehyde or the like to form an acetal structure, or may not form an acetal structure.
- an aldehyde such as formalin, acetaldehyde, butyraldehyde, benzaldehyde or the like to form an acetal structure, or may not form an acetal structure.
- the degree of polymerization of the PVA is 1,000 or more. Is preferable, and it is more preferable that it is 2,000 or more.
- the upper limit of the degree of polymerization of PVA is not particularly limited, but is preferably 10,000 or less, more preferably 8,000 or less, and 6,000 or less, from the viewpoint that industrial production of PVA is easy. It is more preferred that:
- the degree of polymerization of PVA means the average degree of polymerization measured according to JIS K6726-1994.
- a method of saponifying a polyvinyl ester obtained by polymerizing a vinyl ester using a polymerization initiator having an alkoxyl group is also preferable. Copolymerization of the vinyl ester and the unsaturated monomer having an alkoxyl group described above except that the polymerization initiator having an alkoxyl group is not used and that there is no need to copolymerize the unsaturated monomer having an alkoxyl group. In the same manner as in the method of saponifying the obtained polyvinyl ester, PVA containing an alkoxyl group can be obtained.
- the content of the alkoxyl group in the PVA can be easily adjusted by appropriately changing the addition amount of the polymerization initiator having the alkoxyl group, the polymerization temperature, and the type and amount of the polymerization solvent. From the viewpoint of further suppressing the attachment of the PVA fine particles to the PVA film, an azo compound having an alkoxyl group is preferable as the polymerization initiator having an alkoxyl group, and an azo compound represented by the following formula (2) is more preferable.
- X, X ′, Y and Y ′ each independently represent an alkyl group having 1 to 5 carbon atoms, and Z and Z ′ each independently represent an alkoxyl group having 1 to 5 carbon atoms. Represents ]
- the number of carbon atoms of 'X, X', Y and Y ' is preferably 3 or less, more preferably 2 or less.
- the carbon number of Z and Z ' is preferably 3 or less, more preferably 2 or less.
- X and X ' are the same from the viewpoint that the attachment of the PVA fine particles to the PVA film is further suppressed and the compound represented by the formula (2) can be efficiently produced. From the same viewpoint, it is also preferable that Y and Y 'are the same or that Y and Y' are the same.
- azo compound having an alkoxyl group examples include 2,2′-azobis (4-methoxy-2,4-dimethylvaleronitrile) and 2,2′-azobis (4-ethoxy-2,4-diethyl). Valeronitrile), 2,2'-azobis (4,4'-diethoxy-2-methylvaleronitrile) and the like, and among them, 2,2'-azobis (4-methoxy-2,4-dimethylvaleronitrile) preferable.
- the content of the nonionic surfactant in the PVA film is 0.001 to 1 part by mass based on 100 parts by mass of the PVA.
- the content is preferably at least 0.005 parts by mass, more preferably at least 0.01 parts by mass, and even more preferably at least 0.015 parts by mass.
- the content of the nonionic surfactant is 1 part by mass or less, blocking between the PVA films is suppressed, and adhesion of the PVA fine particles to the PVA film is suppressed.
- the content is preferably 0.8 parts by mass or less, more preferably 0.6 parts by mass or less, and still more preferably 0.5 parts by mass or less.
- the PVA film of the present invention When the PVA film of the present invention is used for the production of a polarizing film, the PVA film of the present invention further contains an anionic surfactant from the viewpoint of reducing film surface abnormalities such as streak-like defects in the obtained polarizing film.
- the content is preferably 0.001 to 1 part by mass based on 100 parts by mass of PVA. When the content of the anionic surfactant is less than 0.001 part by mass, such an effect may not be obtained.
- the content is more preferably 0.005 parts by mass or more, further preferably 0.01 parts by mass or more, and particularly preferably 0.015 parts by mass or more.
- the content of the anionic surfactant exceeds 1 part by mass, the thickness unevenness of the film may be increased.
- the content is more preferably 0.8 parts by mass or less, further preferably 0.6 parts by mass or less, and particularly preferably 0.5 parts by mass or less.
- the compound having a conjugated double bond between aliphatic double bonds is preferably sorbic acid, and the compound having a conjugated double bond between an aliphatic double bond and an aromatic ring is 2,4-diphenyl-4-methyl-. 1-pentene is preferred.
- the length of the PVA film is not particularly limited as long as it is appropriately determined according to the application, and may be, for example, in the range of 5 to 20,000 m. It is preferable that the PVA film is long from the viewpoint that a polarizing film can be continuously manufactured with high productivity.
- the PVA concentration in each processing solution increases with time, and PVA fine particles are easily precipitated. Even in such a case, adhesion of the PVA fine particles to the PVA film of the present invention is suppressed. Therefore, there is a great merit in using the PVA film of the present invention when continuously manufacturing a polarizing film.
- the length of the PVA film is preferably 4,000 m or more, more preferably 6,000 m or more, still more preferably 8,000 m or more, and particularly preferably 10,000 m or more.
- the width of the PVA film is not particularly limited, and may be, for example, 30 cm or more. In recent years, liquid crystal displays have become larger. For use in such applications, the width of the PVA film is preferably 1 m or more, more preferably 2 m or more, still more preferably 2.5 m or more, and more preferably 3 m or more. Particularly preferably, it is most preferably 4 m or more. In general, when the width of a raw PVA film used for manufacturing a polarizing film is increased, defective products are likely to be generated. On the other hand, by using the PVA film of the present invention, a polarizing film with few defects caused by foreign matters can be manufactured with high yield.
- a polarizing film containing the PVA, the nonionic surfactant, and the dichroic dye is also a preferred embodiment of the present invention.
- the content of the nonionic surfactant in the polarizing film is preferably 0.0002 to 0.4 parts by mass based on 100 parts by mass of the PVA. If the content is less than 0.0002 parts by mass, the number of foreign substances may not be sufficiently reduced.
- the amount of the nonionic surfactant is preferably 0.001 part by mass or more, more preferably 0.002 part by mass or more, and still more preferably 0.003 part by mass or more.
- a polarizing plate for observation is placed on a surface light source (backlight) in a dark room, and a polarizing film to be evaluated is placed on the polarizing film so that the absorption axis of the polarizing plate for observation is perpendicular to the absorption axis of the polarizing plate to be evaluated. Placed on Next, the backlight was irradiated with light (luminance: 15000 cd) from above the polarizing plate, and the polarizing film to be evaluated was visually observed from above by 1 m to evaluate color spots according to the following criteria. A: Almost no color spot was observed. B: Slight color spot was observed. C: Color spot was observed but practical. D: Vigorous color spot was observed and practically difficult.
- the light transmittance when tilted by 45 degrees with respect to the direction and the light transmittance when tilted by -45 degrees were measured, and the average value (Y1) was obtained.
- the light transmittance when tilted at 45 degrees and the light transmittance when tilted at -45 degrees were measured in the same manner as described above, and the average value (Y2) was obtained. I asked. Y1 and Y2 obtained above were averaged to obtain the transmittance (Y) (%) of the polarizing film.
- the film surface where the first metal roll was not in contact with the second metal roll having a surface temperature of 70 ° C. and a diameter of 1 m was contacted and dried. Further, the film is sequentially contacted with third to sixth metal rolls (surface temperature of 80 to 120 ° C., diameter of 1 m) and dried so that one side and the other side of the film are alternately in contact with the metal roll, so that the width is 1 m, A 30 ⁇ m thick PVA film was obtained. The content of the compound having a conjugated double bond in the PVA film was measured, and the NMR and average polymerization degree of PVA in the PVA film were measured (according to JIS K 6726-1994). Table 1 shows the results.
- the obtained film roll was subjected to a swelling treatment, a dyeing treatment, a crosslinking treatment, a stretching treatment, a washing treatment, and a drying treatment in this order to continuously produce a polarizing film.
- the swelling treatment was performed by immersing the PVA film in a swelling treatment tank containing a treatment liquid (pure water) at 30 ° C., and during that time, stretching the film uniaxially 1.72 times in the length direction.
- the dyeing treatment the PVA film is immersed in a swelling treatment tank containing a treatment liquid at 32 ° C. (an aqueous solution of 0.05% by mass of iodine and 1.15% by mass of potassium iodide).
- the cleaning treatment was performed by immersing the PVA film in a cleaning treatment tank containing a cleaning treatment liquid (aqueous solution containing 1.5% by mass of boric acid and 5% by mass of potassium iodide) at 22 ° C. for 12 seconds.
- the drying treatment was performed by drying the PVA film at 60 ° C. for 1.5 minutes. The stretching of the PVA film was not performed during the washing treatment and the drying treatment.
- Example 2 An alkoxyl group was prepared in the same manner as in Example 1, except that vinyl acetate and ethylene were used as monomers, and 2,2′-azobis- (4-methoxy-2,4-dimethylvaleronitrile) was used as a polymerization initiator. Was manufactured and evaluated. Table 1 shows the results.
- Example 5 Production and evaluation of an alkoxyl-containing PVA, a PVA film and a polarizing film were performed in the same manner as in Example 1 except that SLS was not added. Table 1 shows the results.
- Example 13 PVA and PVA films containing an alkoxyl group in the same manner as in Example 1 except that vinyl acetate and N-ethoxymethylacrylamide were used as monomers, and a PVA film having a thickness of 50 ⁇ m was obtained by changing film forming conditions. And the production and evaluation of a polarizing film. Table 1 shows the results.
- Comparative Example 4 Production and evaluation of an alkoxyl group-containing PVA, PVA film and polarizing film were carried out in the same manner as in Example 2 except that the amount of LADEA was changed to 1.1 parts by mass. Table 1 shows the results.
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Abstract
Description
[1]アルコキシル基含有率0.0005~1モル%、けん化度85モル%以上のPVA及びノニオン系界面活性剤を含有し、前記PVA100質量部に対する前記ノニオン系界面活性剤の含有量が0.001~1質量部である、PVAフィルム;
[2]前記PVAがさらにエチレン単位を含有し、その含有率が1~12モル%である、[1]のPVAフィルム;
[3]さらに共役二重結合を有する分子量1000以下の化合物を0.1~3000ppm含有する、[1]または[2]のPVAフィルム;
[4]前記PVAの1,2-グリコール結合の含有量が0.2~1.5モル%である、[1]~[3]のいずれかのPVAフィルム;
[5]前記PVA100質量部に対して、さらにアニオン系界面活性剤を0.001~1質量部含有する、[1]~[4]のいずれかのPVAフィルム;
[6]前記PVA100質量部に対して、さらに可塑剤を1~30質量部含有する、[1]~[5]のいずれかに記載のPVAフィルム;
[7]厚みが10~50μmである、[1]~[6]のいずれかのPVAフィルム;
[8][1]~[7]のいずれかのPVAフィルムが円筒状のコアに巻き取られてなるフィルムロールであって、フィルム長さが4000m以上である、PVAフィルムロール;
[9]ビニルエステル及びアルコキシル基を有する不飽和単量体を共重合させてポリビニルエステルを得てから、該ポリビニルエステルをけん化することによりPVAを得た後、該PVA及びノニオン系界面活性剤を混合してから製膜する、[1]~[7]のいずれかのPVAフィルムの製造方法;
[10]アルコキシル基を有する重合開始剤を用いてビニルエステルを重合させてポリビニルエステルを得てから、該ポリビニルエステルをけん化することによりPVAを得た後、該PVA及びノニオン系界面活性剤を混合してから製膜する、[1]~[7]のいずれかのPVAフィルムの製造方法;
[11]前記ポリビニルエステルに、共役二重結合を有する分子量が1000以下の化合物を含有させてから、該ポリビニルエステルをけん化することによりPVAを得る、[9]又は[10]のPVAフィルムの製造方法。
[12]前記PVA及びノニオン系界面活性剤を含み、揮発性成分率が50~90質量%である製膜原液を、スリットダイから支持体上へフィルム状に流延した後乾燥する、[9]~[11]のいずれかのPVAフィルムの製造方法;
[13]アルコキシル基含有率0.0005~1モル%、けん化度85モル%以上のPVA、ノニオン系界面活性剤及び二色性色素を含有し、前記PVA100質量部に対する前記ノニオン系界面活性剤の含有量が0.0002~0.4質量部であり、かつ厚みが2~20μmである、偏光フィルム;
[14][1]~[7]のいずれかのPVAフィルムを二色性色素で染色する工程と延伸する工程とを有する、偏光フィルムの製造方法;に関する。
本発明のPVAフィルムは、アルコキシル基含有率0.0005~1モル%、けん化度85モル%以上のPVA及びノニオン系界面活性剤を含有し、前記PVA100質量部に対する前記ノニオン系界面活性剤の含有量が0.001~1質量部であるものである。
1,2-グリコール結合の含有量(モル%)=B(100-C)/A
前記PVAフィルムを染色処理する工程と延伸処理する工程とを有する偏光フィルムの製造方法が本発明の好適な実施態様である。当該製造方法が前記PVAフィルムに対して、さらに膨潤処理、架橋処理、固定処理、洗浄処理、乾燥処理、熱処理等を行う工程を有していてもよい。この場合、各処理の順序は特に制限されないが、膨潤処理、架橋処理、延伸処理、固定処理をこの順で行うことが好ましい。染色処理は架橋処理の前に行うことが好ましい。2種類以上の処理を同時に行うことや各処理を複数回行うこともできる。特に延伸処理を2段以上に分けると均一な延伸を行いやすくなるため好ましい。延伸方法として、熱可塑性樹脂フィルム上にPVAフィルムを形成して積層体を形成させた後、当該積層体を一軸延伸する方法を採用してもよい。このような方法によれば、PVAフィルムの破断をより低減することができる。
溶媒として、試料のPVAフィルムに含まれるPVA以外の成分は溶解するが、PVAは実質的に溶解しない溶媒(クロロホルム等)を用いて、ソックスレー抽出器で抽出することにより、PVAフィルム中のPVA以外の成分を十分に除去した。得られたPVAをジメチルスルホキシド(DMSO)に溶解させた後、その溶液をアセトンに添加してPVAを析出させることにより精製した。当該PVAのDMSO-d6溶液にトリフルオロ酢酸(TFA)を1~2滴滴下し、直ちにNMR測定を行った。得られたNMRスペクトルからPVAのアルコキシル基含有率、エチレン含有率、1,2-グリコール結合含有量及びけん化度を求めた。
使用装置:日本電子株式会社製超伝導核磁気共鳴装置「Lambda500」
溶媒:DMSO-d6(TFA滴下)
濃度:5質量%
温度:80℃
共鳴周波数:1H 500MHz
フリップアングル:45°
パルスディレイタイム:4.0秒
積算回数:6000回
PVAフィルムを凍結粉砕により粉砕し、呼び寸法0.150mm(100メッシュ)のふるい(JIS規格Z8801-1~3準拠)によって粗大粒子を除去して得た粉砕物10gをソックスレー抽出器に充填し、クロロホルム100mLを用いて48時間抽出処理した。この抽出液中の共役二重結合化合物の量を、高速液体クロマトグラフィーにて定量分析することで定量した。なお、定量に際しては、それぞれの共役二重結合化合物の標品を用いて作成した検量線を使用した。
PVAフィルムロールの幅方向中央部から幅方向30mm、流れ方向60mmの長方形の試験片を採取した。当該試験片を引張試験機にチャック間隔15mmでセットした後、所定の温度に設定した恒温水槽中で延伸して破断時の延伸倍率を測定した。これを3回繰り返し、破断時の延伸倍率の平均値を求めた。この平均値が6.5倍以上であれば、恒温水槽の温度を1℃下げ、6.5倍未満であれば恒温水槽の温度を1℃上げ、破断時の延伸倍率の平均値が6.5倍以上となる限界の温度(平均値が6.5倍以上となる最低温度)を求めた。
PVAフィルムロールの幅方向中央部より長さ方向(延伸方向)15cm、幅方向15cmの長方形の試験片を10枚採取して、それらを重ね合わせた後、鉄板上に置いた。重ね合わされた試験片の中央部付近に2kgの鉄板(厚さ20mm、長さ127mm、幅100mm)を載置して、23℃-50%RHの部屋に保管した。3日後、フィルムのブロッキングの状態を、以下の基準で判定した。
A:ブロッキングは生じていなかった
B:ブロッキングが生じていた
長さ方向(延伸方向)30cm、幅方向20cmにカットした偏光フィルムの表面に存在する青色異物を目視で観察して最長径が5~500μmである異物の数を求めた。これを3回繰り返して、異物数の平均値を求めた。異物の最長径は微分干渉顕微鏡(倍率:200倍)を用いて測定した。
暗室内で面光源(バックライト)上に観察用偏光板を載置し、その上に評価対象の偏光フィルムを、観察用偏光板の吸収軸と評価対象の偏光板の吸収軸が直交するように載置した。次に、バックライトからその上の偏光板に光を照射(輝度15000cd)し、評価対象の偏光フィルムを1m上方から目視で観察することにより色斑を下記の判定基準で評価した。
A:色斑がほとんど確認されなかった
B:僅かな色斑が確認された
C:色斑が確認されたが実用可能であった
D:激しい色斑が確認され実用困難であった
(1)透過率:
偏光フィルムの幅方向の中央部から、偏光フィルムの長さ方向(延伸方向)1.5cm、幅方向1.5cmの正方形のサンプルを2枚採取し、それぞれについて日立製作所製の分光光度計V-7100(積分球付属)を用いて、JIS Z8722(物体色の測定方法)に準拠し、C光源、2度視野の可視光領域の視感度補正を行い、1枚の偏光フィルムサンプルについて、延伸軸方向に対して45度傾けた場合の光の透過率と-45度傾けた場合の光の透過率を測定して、それらの平均値(Y1)を求めた。
もう一枚の偏光フィルムサンプルについても、前記と同様にして45度傾けた場合の光の透過率と-45度傾けた場合の光の透過率を測定して、それらの平均値(Y2)を求めた。
前記で求めたY1とY2を平均して偏光フィルムの透過率(Y)(%)とした。
上記(1)で採取した2枚の偏光フィルムサンプルを、それらの長さ方向(延伸方向)が平行になるように重ねた場合の光の透過率(Y∥)、および長さ方向(延伸方向)が直交するように重ねた場合の光の透過率(Y⊥)を、上記透過率の測定方法と同様の方法にて測定し、下記の式から偏光度(V)(%)を求めた。
偏光度(V)(%)={(Y∥-Y⊥)/(Y∥+Y⊥)}1/2×100
偏光フィルムから、幅方向の両端を含み、長さ方向(延伸方向)が20cmである長方形のサンプルを採取し、蛍光灯下で偏光フィルム表面からの反射光を目視で観察して、以下の判定基準で評価を行った。
A:スジ状欠点がほとんど確認されなかった
B:スジ状欠点が僅かに確認された
C:スジ状欠点が確認されたが実用可能であった
D:スジ状欠点が多数確認され実用困難であった
ノニオン系界面活性剤が炭素、水素及び酸素以外の元素(硫黄や窒素等)を含有する場合には、原子吸光分析法により、偏光フィルム中の当該ノニオン系界面活性剤の含有量を求めた。ノニオン系界面活性剤が炭素、水素及び酸素以外の元素を含有しない場合には、上述した共役二重結合を有する化合物の含有量の測定方法と同様にして偏光フィルム中の当該ノニオン系界面活性剤の含有量を求めた。
モノマーとして酢酸ビニル、エチレンおよびN-エトキシメチルアクリルアミド、重合開始剤としてアゾビスイソブチロニトリル、溶媒としてメタノールを用いて、温度60℃で重合を行った後、共役二重結合を有する分子量1000以下の化合物として2,4-ジフェニル-4-メチル-1-ペンテン(DPMP)を添加した。モノマー(酢酸ビニル及びN-エトキシメチルアクリルアミド)及びその他の添加剤の添加量、エチレン圧力、並びに重合時間は、目標とする、PVAの組成及び重合度、並びにPVAフィルムの組成に合わせて調整した。得られたポリ酢酸ビニルのメタノール溶液に、当該ポリ酢酸ビニルの酢酸ビニル単位に対する水酸化ナトリウムのモル比が0.023となるように、水酸化ナトリウムの6質量%メタノール溶液を撹拌下に加えて、30℃でケン化反応を開始させた。ケン化反応の進行に伴ってゲル化物が生成した。ケン化反応の開始から50分経過した時点でゲル化物を粉砕してメタノールで膨潤したアルコキシル基を含有するPVAを得た。当該PVAをその5倍の質量のメタノールで洗浄し、次いで55℃で1時間、100℃で2時間乾燥した。
モノマーとして酢酸ビニル及びエチレンを用いたこと、重合開始剤として2,2’-アゾビス-(4-メトキシ-2,4-ジメチルバレロニトリル)を用いたこと以外は実施例1と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
モノマーとして酢酸ビニル及びN-エトキシメチルアクリルアミドを用いたこと以外は実施例1と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
重合温度を90℃に高めたこと以外は実施例3と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
SLSを添加しなかったこと以外は、実施例1と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
DPMPを添加しなかったこと以外は、実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
DPMPの代わりにソルビン酸(SA)を用いたこと及びその添加量を目標とするPVAフィルムの組成に合わせて調整したこと以外は実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
LADEAの代わりにラウリン酸オレイルエーテル(LOE)を用いたこと以外は、実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
DPMPの添加量を目標とするPVAフィルムの組成に合わせて調整したこと以外は実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
エチレン圧力を目標とするPVAフィルムの組成に合わせて調整したこと以外は実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
SLSをアルキルスルホン酸(AS)に変更したこと以外は実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
モノマーとして酢酸ビニル及びN-エトキシメチルアクリルアミドを用いたこと及び製膜条件を変更して厚みが50μmのPVAフィルムを得たこと以外は実施例1と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
N-エトキシメチルアクリルアミドの添加量を目標とするPVAの組成に合わせて調整したこと以外は実施例1と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
LADEAを添加しなかったこと以外は、実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
モノマーとして酢酸ビニル及びエチレンを用いたこと以外は実施例1と同様にしてアルコキシル基を含有しないPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
モノマーとして酢酸ビニル及びN-エトキシメチルアクリルアミドを用いたこと及びN-エトキシメチルアクリルアミドの添加量を目標とするPVAの組成に合わせて調整したこと以外は実施例1と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
LADEAの添加量を1.1質量部に変更したこと以外は実施例2と同様にしてアルコキシル基を含有するPVA、PVAフィルム及び偏光フィルムの製造及び評価を行った。その結果を表1に示す。
Claims (14)
- アルコキシル基含有率0.0005~1モル%、けん化度85モル%以上のポリビニルアルコール及びノニオン系界面活性剤を含有し、前記ポリビニルアルコール100質量部に対する前記ノニオン系界面活性剤の含有量が0.001~1質量部である、ポリビニルアルコールフィルム。
- 前記ポリビニルアルコールがさらにエチレン単位を含有し、その含有率が1~12モル%である、請求項1に記載のポリビニルアルコールフィルム。
- さらに共役二重結合を有する分子量1000以下の化合物を0.1~3000ppm含有する、請求項1または2に記載のポリビニルアルコールフィルム。
- 前記ポリビニルアルコールの1,2-グリコール結合の含有量が0.2~1.5モル%である、請求項1~3のいずれかに記載のポリビニルアルコールフィルム。
- 前記ポリビニルアルコール100質量部に対して、さらにアニオン系界面活性剤を0.001~1質量部含有する、請求項1~4のいずれかに記載のポリビニルアルコールフィルム。
- 前記ポリビニルアルコール100質量部に対して、さらに可塑剤を1~30質量部含有する、請求項1~5のいずれかに記載のポリビニルアルコールフィルム。
- 厚みが10~50μmである、請求項1~6のいずれかに記載のポリビニルアルコールフィルム。
- 請求項1~7のいずれかに記載のポリビニルアルコールフィルムが円筒状のコアに巻き取られてなるフィルムロールであって、フィルム長さが4000m以上である、ポリビニルアルコールフィルムロール。
- ビニルエステル及びアルコキシル基を有する不飽和単量体を共重合させてポリビニルエステルを得てから、該ポリビニルエステルをけん化することによりポリビニルアルコールを得た後、該ポリビニルアルコール及びノニオン系界面活性剤を混合してから製膜する、請求項1~7のいずれかに記載のポリビニルアルコールフィルムの製造方法。
- アルコキシル基を有する重合開始剤を用いてビニルエステルを重合させてポリビニルエステルを得てから、該ポリビニルエステルをけん化することによりポリビニルアルコールを得た後、該ポリビニルアルコール及びノニオン系界面活性剤を混合してから製膜する、請求項1~7のいずれかに記載のポリビニルアルコールフィルムの製造方法。
- 前記ポリビニルエステルに、共役二重結合を有する分子量が1000以下の化合物を含有させてから、該ポリビニルエステルをけん化することによりポリビニルアルコールを得る、請求項9又は10に記載のポリビニルアルコールフィルムの製造方法。
- 前記ポリビニルアルコール及びノニオン系界面活性剤を含み、揮発性成分含有率が50~90質量%である製膜原液を、スリットダイから支持体上へフィルム状に流延した後乾燥する、請求項9~11のいずれかに記載のポリビニルアルコールフィルムの製造方法。
- アルコキシル基含有率0.0005~1モル%、けん化度85モル%以上のポリビニルアルコール、ノニオン系界面活性剤及び二色性色素を含有し、
前記ポリビニルアルコール100質量部に対する前記ノニオン系界面活性剤の含有量が0.0002~0.4質量部であり、かつ
厚みが2~20μmである、偏光フィルム。 - 請求項1~7のいずれかに記載のポリビニルアルコールフィルムを二色性色素で染色する工程と延伸する工程とを有する、偏光フィルムの製造方法。
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WO2022004344A1 (ja) * | 2020-06-29 | 2022-01-06 | 株式会社クラレ | 水溶性フィルムおよび包装体 |
WO2022080472A1 (ja) * | 2020-10-15 | 2022-04-21 | 株式会社クラレ | ポリビニルアルコール樹脂フィルム、ポリビニルアルコール樹脂フィルムの判別方法、及びポリビニルアルコール樹脂フィルムの製造方法 |
WO2022092038A1 (ja) * | 2020-10-28 | 2022-05-05 | 株式会社クラレ | ポリビニルアルコールフィルム及びそれを用いた偏光フィルム |
CN115996962A (zh) * | 2020-06-30 | 2023-04-21 | 株式会社可乐丽 | 乙酸乙烯酯、乙酸乙烯酯聚合物及乙烯醇聚合物 |
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CN116490565A (zh) * | 2020-10-28 | 2023-07-25 | 株式会社可乐丽 | 聚乙烯醇膜和使用其的偏振膜 |
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