WO2020087773A1 - 一种偏光板及其制造方法 - Google Patents

一种偏光板及其制造方法 Download PDF

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Publication number
WO2020087773A1
WO2020087773A1 PCT/CN2019/070202 CN2019070202W WO2020087773A1 WO 2020087773 A1 WO2020087773 A1 WO 2020087773A1 CN 2019070202 W CN2019070202 W CN 2019070202W WO 2020087773 A1 WO2020087773 A1 WO 2020087773A1
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Prior art keywords
polyvinyl alcohol
layer
polarizing plate
alcohol layer
support layer
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PCT/CN2019/070202
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English (en)
French (fr)
Inventor
马贵智
李永凯
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武汉华星光电技术有限公司
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Application filed by 武汉华星光电技术有限公司 filed Critical 武汉华星光电技术有限公司
Priority to US16/334,014 priority Critical patent/US20200142114A1/en
Publication of WO2020087773A1 publication Critical patent/WO2020087773A1/zh

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    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
    • G02B5/305—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers

Definitions

  • the invention relates to the technical field of flat display, in particular, one of them can be used in a flat display panel and its manufacturing method.
  • liquid crystal display screens or OLED display screens have been widely used and generally accepted by the market due to their advantages such as lightness, thinness, and good display effect.
  • advantages such as lightness, thinness, and good display effect.
  • the market's requirements for light and thin display screens are constantly improving.
  • the thickness of mobile phone screens (TFT-LCD ⁇ OLED) has continued to be reduced.
  • the polarizer is one of the main structures of the screen.
  • the thickness of the polarizer body is also expected to be thinner and thinner while maintaining normal function, thereby reducing the overall thickness of the screen.
  • the overall thickness is reduced to about 80 ⁇ m.
  • POL with reduced TAC layer is mostly used in the lower polarizer with anti-reflective coating, so that the overall thickness of the upper and lower polarizers can be reduced to about 160um.
  • FIG. 10 illustrates a conventional polarizer structure.
  • its own thickness is relatively thick, about 10-50 ⁇ m, so that the overall thickness of the existing polarizer is relatively thick.
  • the thickness of the polarizing plate is continuously thinning, the industry's demand for thinning the thickness of the polarizing plate has not stopped, and it is constantly exploring possible solutions that can reduce the overall thickness of the polarizing plate.
  • One aspect of the present invention is to provide a polarizing plate which adopts a brand-new structural design to make its overall thickness thinner, so that the flat display panel where it is located is lighter and thinner, and thus meet the requirements of the industry.
  • a polarizing plate includes a polyvinyl alcohol layer (PVA) and a supporting layer, wherein the supporting layer is in contact with and supporting the PVA layer.
  • PVA polyvinyl alcohol layer
  • the support layer is a hardened adhesive coating, which is composed of at least one material of thermal curing material, optical adhesive and UV curing adhesive.
  • the invention adopts a brand-new polarizing plate structure design, and uses a hardened glue coating to replace the existing common COP / TAC / CAT and other supporting layers, which play a supporting and protective role for the polyvinyl alcohol layer.
  • the hardened adhesive coating can effectively reduce the thickness on the basis of achieving the same effect of the existing COP / TAC / CAT support layer, and thereby reduce the overall thickness of the polarizing plate where it is located.
  • the hardened glue coating layer may be a heat-curable material, such as a modified polyurethane system; it may also be an optical glue; or a UV-curable glue, such as a modified polyurethane acrylic system.
  • the thickness of the support layer is 5-20 ⁇ m.
  • polyvinyl alcohol (PVA) layer involved therein may also be an equivalent transformation structure layer composed of similar materials, for example, an MSPVA layer.
  • the given polyvinyl alcohol (PVA) layer is only for illustrative purposes and is not limited.
  • the support layer is provided on the upper and / or lower surface of the polyvinyl alcohol layer.
  • the support layer includes two layers respectively disposed on the upper and lower sides of the polyvinyl alcohol layer, the upper support layer is provided with a protective film, and the lower support layer is under The pressure sensitive adhesive and the release film are arranged in sequence.
  • a protective film is provided thereon, and a pressure-sensitive adhesive and a release film are sequentially provided under the polyvinyl alcohol layer.
  • the support layer includes two layers respectively disposed on the upper and lower sides of the polyvinyl alcohol layer, and an anti-reflection film and a protective film are sequentially arranged on the upper support layer, the A pressure-sensitive adhesive and a release film are sequentially arranged under the lower support layer.
  • a pressure-sensitive adhesive and a release film are sequentially disposed thereunder, and an anti-reflection coating is sequentially disposed on the polyvinyl alcohol layer Membrane and protective film.
  • the support layer is coated on the polyvinyl alcohol layer after the polyvinyl alcohol layer is stretched.
  • the support layer is cured on the polyvinyl alcohol layer by thermal curing or UV curing.
  • the support layer simultaneously performs its surface functional treatment during the coating process.
  • HC HC, AG, LR, etc., but not limited to.
  • the support layer may be added to different substances, for example, SiO2 particles.
  • the material and thickness of the support layer selected should also be adjusted accordingly.
  • the side of the polyvinyl alcohol layer in contact with the pressure-sensitive adhesive (PSA) and the side in contact with the anti-reflection film (APF) may not be coated with the hardened adhesive coating, and the pressure-sensitive adhesive / anti-reflection film may It also plays a supporting role.
  • Another aspect of the present invention is to provide a method for manufacturing the polarizing plate according to the present invention. Since the polarizing plate adopts a completely new structural design, the manufacturing method related to the polarizing plate uses fewer manufacturing processes and Less material is prepared, thereby reducing the production cost of the polarizing plate involved in the present invention.
  • a method of manufacturing a polarizing plate includes the following steps:
  • the provided polyvinyl alcohol (PVA) layer is immersed in an aqueous solution of iodine for dyeing, and replaced by iodine ions to achieve absorption of light of different wavelengths;
  • the dyed polyvinyl alcohol layer is stretched, the stretching length is 5 to 15 times, and the thickness is controlled at 10 to 30 ⁇ m;
  • the polyvinyl alcohol layer after dyeing and drying is coated with hardening glue, wherein the materials used include at least one of heat curing material, optical glue and UV curing glue, and the coating thickness within 5-20 ⁇ m;
  • the coated polyvinyl alcohol layer is subjected to thermal curing or UV light curing according to the material selected for the support layer.
  • the polyvinyl alcohol layer is stretched in an aqueous solution of boric acid and potassium iodide.
  • the polyvinyl alcohol layer is washed with an aqueous solution, and at least one of zinc sulfate, zinc chloride, potassium iodide, potassium chloride, and boric acid is added Substances to improve the uniformity and material strength of the polyvinyl alcohol layer and remove surface dirt.
  • the drying temperature of the washed polyvinyl alcohol layer is 50 to 120 degrees, and the duration is 0 to 60 minutes. Be careful not to over-dry during this process, as long as the surface of the polyvinyl alcohol layer is dry.
  • PSA pressure sensitive adhesive
  • it also includes an anti-reflective film attaching (lower polarizing plate) step, and its manufacturing process is similar to the existing manufacturing process.
  • the invention relates to a polarizing plate structure, which adopts a completely new structural design.
  • the hardened glue coating plays the same support and protection role, but The required thickness is thinner, so that the overall thickness of the polarizing plate is thinner, so that the display panel where it is located is lighter and thinner, and thus meets the requirements of the industry.
  • the reduction in the thickness of the polarizing plate structure will also reserve more space for the stack of TFT-LCD modules, thereby further optimizing the brightness requirements of the whole machine.
  • the manufacturing method of the polarizing plate according to the present invention because the polarizing plate adopts a new structure and material, so that the manufacturing process is simplified and the manufacturing materials involved are reduced, thereby realizing the manufacturing cost of the polarizing plate Decreasing, further improving the competitiveness of products.
  • FIG. 1 is a structural schematic diagram of a polarizing plate structure provided by an embodiment of the present invention.
  • FIG. 2 is a structural schematic diagram of a polarizing plate structure provided by another embodiment of the present invention.
  • FIG. 3 is a structural schematic diagram of a polarizing plate structure provided by another embodiment of the present invention.
  • FIG. 4 is a schematic structural diagram of a polarizing plate structure provided by another embodiment of the present invention.
  • FIG. 5 is a schematic structural diagram of a polarizing plate structure provided by another embodiment of the present invention.
  • FIG. 6 is a structural schematic diagram of a polarizing plate structure provided by another embodiment of the present invention.
  • FIG. 7 is a structural schematic diagram of a polarizing plate structure provided by another embodiment of the present invention.
  • FIG. 8 is a schematic structural diagram of a polarizing plate structure provided by yet another embodiment of the present invention.
  • FIG. 9 is a schematic structural diagram of a polarizing plate structure provided by another embodiment of the present invention.
  • FIG. 10 is a structural schematic diagram of a polarizing plate structure in the prior art.
  • One embodiment of the present invention provides a polarizing plate including a polyvinyl alcohol (PVA) layer and a support layer, wherein the support layer is in contact with and supports the PVA layer.
  • the support layer is a hardened adhesive coating, which is composed of at least one material of thermal curing material, optical adhesive, and UV curing adhesive, and its thickness is 5-20 ⁇ m.
  • the invention adopts a brand-new polarizing plate structure design, and uses a hardened glue coating to replace the existing common COP / TAC / CAT and other supporting layers, which play a supporting and protective role for the polyvinyl alcohol layer.
  • the hardened adhesive coating can effectively reduce the thickness on the basis of achieving the same effect of the existing COP / TAC / CAT support layer, and thereby reduce the overall thickness of the polarizing plate where it is located.
  • the hardened glue coating layer may be a heat-curable material, such as a modified polyurethane system; it may also be an optical glue; or a UV-curable glue, such as a modified polyurethane acrylic system.
  • the arrangement manner between the polyvinyl alcohol (PVA) layer and the support layer may include three types.
  • the first arrangement is that the support layer 20 is arranged on the polyvinyl alcohol (PVA) layer 10.
  • the second arrangement is that the support layer 20 is arranged under the polyvinyl alcohol (PVA) layer 10.
  • the third setting method is that the supporting layer 20 is provided on both the upper and lower sides of the polyvinyl alcohol (PVA) layer 10. Which type of installation method is specifically selected may be determined according to the specific structure of the polarizing plate, and is not limited.
  • the polyvinyl alcohol layer 10 is in contact with the pressure sensitive adhesive (PSA) 30 and the antireflection film (APF) )
  • PSA pressure sensitive adhesive
  • APF antireflection film
  • the contact layer 40 may not be coated with the support layer 20, and the pressure-sensitive adhesive 30 / anti-reflection film 40 may also play a supporting role.
  • the polarizing plate involved in the present invention may have the following specific structures.
  • FIG. 6 another embodiment of the present invention provides a polarizing plate, which includes a protective film 60, a support layer 20, a polyvinyl alcohol layer 10, a support layer 20, a pressure-sensitive adhesive 30, and a release film 50 .
  • another embodiment of the present invention provides a polarizing plate, which includes a protective film 60, a supporting layer 20, a polyvinyl alcohol layer 10, a pressure-sensitive adhesive 30 and a release film 50.
  • another embodiment of the present invention provides a polarizing plate, which includes a protective film 60, an antireflection film 40, a support layer 20, a polyvinyl alcohol layer 10, a support layer 20, and a pressure-sensitive adhesive 30 ⁇ ⁇ ⁇ ⁇ 50.
  • another embodiment of the present invention provides a polarizing plate, which includes a protective film 60, an antireflection film 40, a polyvinyl alcohol layer 10, a support layer 20, a pressure sensitive adhesive 30, and a release film 50.
  • different substances such as SiO2 particles, may be added to the support layer 20 composed of the hardened glue coating. Further, considering the flexibility involved in using the material, the material and thickness of the hardened adhesive coating selected should also be adjusted accordingly.
  • polyvinyl alcohol (PVA) layer involved therein may also be an equivalent transformation structure layer composed of similar materials, for example, an MSPVA layer.
  • the given polyvinyl alcohol (PVA) layer is only for illustrative purposes and is not limited.
  • the polarizing plate involved in the present invention adopts a completely new structural design.
  • a hardened adhesive coating instead of the traditional COP / TAC / CAT support layer, it plays the same role of supporting and protecting, so that the whole polarizing plate is located.
  • the thickness is thinner, so that the display panel where it is located is lighter and thinner, thereby meeting the requirements of the industry.
  • the reduction in the thickness of the polarizing plate structure also reserves more space for the stacking of TFT-LCD modules in the display panel, thereby further optimizing the brightness requirements of the display panel.
  • Another aspect of the present invention is to provide a method for manufacturing the polarizing plate according to the present invention. Since the polarizing plate adopts a completely new structural design, the manufacturing method related to the polarizing plate uses fewer manufacturing processes and Less material is prepared, thereby reducing the production cost of the polarizing plate involved in the present invention.
  • a method for manufacturing a polarizing plate which includes a polyvinyl alcohol layer dyeing step, a polyvinyl alcohol layer stretching step, a polyvinyl alcohol layer cleaning and pre-drying step, a support layer coating step, a hardening treatment step, and a pressure-sensitive adhesive ( PSA) coating step and anti-reflective film application (lower polarizing plate) step, etc.
  • PSA pressure-sensitive adhesive
  • the provided polyvinyl alcohol (PVA) layer is immersed in an aqueous solution of iodine for dyeing, and replaced by iodine ions to achieve absorption of light of different wavelengths;
  • the stretching length is 5 to 15 times, and the thickness is controlled to 10 to 30 ⁇ m.
  • the stretching of the polyvinyl alcohol layer is performed in an aqueous solution of boric acid and potassium iodide.
  • the step of cleaning and pre-drying the polyvinyl alcohol layer it can be specifically divided into two steps: a cleaning step and a pre-drying step.
  • the polyvinyl alcohol layer is washed with an aqueous solution, and at least one substance of zinc sulfate, zinc chloride, potassium iodide, potassium chloride, and boric acid is added to improve the polyvinyl alcohol layer Uniformity and material strength, and remove surface dirt.
  • the drying temperature of the cleaned polyvinyl alcohol layer is 50 to 120 degrees, and the duration is 0 to 60 minutes; this process is careful not to over-dry the polyvinyl alcohol layer , To reach the surface dry.
  • the polyvinyl alcohol layer after dyeing and drying is coated with hardening glue, wherein the material used is at least one of a thermosetting material, optical glue and UV curing glue A kind of material, the coating thickness is 5-20 ⁇ m.
  • the coated polyvinyl alcohol layer is subjected to thermal curing or UV light curing according to the selected material of the support layer.
  • PSA pressure-sensitive adhesive
  • the step of the anti-reflective film coating (lower polarizing plate) process is similar to the existing process. To avoid unnecessary repetition, it will not be repeated here.
  • the manufacturing method of the polarizing plate according to the present invention because the polarizing plate adopts a new structure and material, so that the manufacturing process is simplified and the manufacturing materials involved are reduced, thereby realizing the manufacturing of the polarizing plate according to the present invention Cost reduction further improves the competitiveness of products.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Polarising Elements (AREA)

Abstract

本发明提供了一种偏光板及其制备方法，其中所述偏光板包括聚乙烯醇层（PVA）和支撑层，其中所述支撑层与所述聚乙烯醇层相接并对其进行支撑。其中所述支撑层是一种硬化胶涂层，其由热固化材质、光学胶以及UV固化胶中的至少一种材质构成，其厚度在5-20μm。本发明采用全新的偏光板结构设计，使用硬化胶涂层对所述聚乙烯醇层起到支撑保护作用。所述硬化胶涂层可以在实现现有COP/TAC/CAT支撑层相同功效的基础上，有效的缩减厚度，进而缩减所在偏光板的整体厚度。

Description

一种偏光板及其制造方法 技术领域
本发明涉及平面显示技术领域，尤其是，其中的一种可用在平面显示面板中的偏光板及其制造方法。
 背景技术
已知，液晶显示屏或是OLED显示屏，由于其轻、薄，显示效果好等优点，已被广泛应用并被市场普遍接受。但市场对于显示屏的轻、薄要求，却是在不断提高。
近年来，由其是手机制造商对整机厚度减薄的持续需求，使得其对手机屏幕（TFT-LCD\OLED）的厚度持续要求减薄。这其中偏光板作为屏幕构成的主要结构之一，对偏光板的本体厚度的要求也是希望其能在保持正常功能的同时，能够越来越薄，从而减薄屏幕的整体厚度。
对此，业界不断研发，将偏光板的厚度从最初的单偏200μm左右，通过TAC 及PVA 结构减薄，将其整体厚度逐渐降到100μm。之后，各偏光板供应商开始探索通过将TAC更换为更薄的COP材料以进一步的降低厚度。
更有甚者，通过减少TAC层来实现将其整体厚度降低到80μm左右。考虑到支持强度收缩及信赖性等问题，减少TAC层的POL多使用在带增反膜的下偏光板中，这样可以将上、下偏光板的整体厚度降到160um左右。
具体请参阅图10所示，其中图示了现有的一种常见的偏光板结构。如图中所示，由于涉及使用的传统COP/TAC/CAT支撑层，其自身的厚度较厚，大概在10~50μm左右，从而使等现有偏光板的整体厚度较厚。
虽然偏光板的厚度在不断减薄，但业界对于偏光板厚度减薄需求，并未停止，还在不断探索能够减薄偏光板整体厚度的可实施方案。
 技术问题
本发明的的一个方面在于提供一种偏光板，其采用全新的结构设计，使得其整体厚度更薄，从而使得其所在的平面显示面板更为轻薄，进而满足业界的要求。
 技术解决方案
其中本发明采用的技术方案如下：
一种偏光板，包括聚乙烯醇层（PVA）和支撑层，其中所述支撑层与所述PVA层相接并对其进行支撑。其中所述支撑层是一种硬化胶涂层，其由热固化材质、光学胶以及UV固化胶中的至少一种材质构成。
本发明采用全新的偏光板结构设计，使用硬化胶涂层来替代现有常见的COP/TAC/CAT等支撑层，由其对所述聚乙烯醇层起到支撑保护作用。所述硬化胶涂层可以在实现现有COP/TAC/CAT支撑层相同功效的基础上，有效的缩减厚度，进而缩减所在偏光板的整体厚度。
具体的，其中所述硬化胶涂层可以选择热固化材料，例如改性聚氨酯系；也可以为光学胶；或者是UV固化胶，例如，改性聚氨酯丙稀酸酯系。
进一步的，在不同实施方式中，其中所述支撑层的厚度在5-20μm。
进一步的，其中涉及的所述聚乙烯醇（PVA）层，其也可以是由类似材料构成的等同变换结构层，例如，MSPVA层。给出的所述聚乙烯醇（PVA）层，仅为举例式说明，并无限定。
进一步的，在不同实施方式中，其中所述支撑层设置在所述聚乙烯醇层的上和/或下表面上。
进一步的，在不同实施方式中，其中所述支撑层包括两层分别设置在所述聚乙烯醇层的上下两侧，所述上侧支撑层上设置有保护膜，所述下侧支撑层下依次设置有压敏胶和离型膜。
进一步的，在不同实施方式中，其中所述支撑层设置在所述聚乙烯醇层上侧，其上设置有保护膜，所述聚乙烯醇层下依次设有压敏胶和离型膜。
进一步的，在不同实施方式中，其中所述支撑层包括两层分别设置在所述聚乙烯醇层的上下两侧，所述上侧支撑层上依次设置有增反膜和保护膜，所述下侧支撑层下依次设置有压敏胶和离型膜。
进一步的，在不同实施方式中，其中所述支撑层设置在所述聚乙烯醇层下侧，其下依次设置有压敏胶和离型膜，所述聚乙烯醇层上依次设置有增反膜和保护膜。
进一步的，在不同实施方式中，其中所述支撑层是在所述聚乙烯醇层拉伸后涂覆在所述聚乙烯醇层上。
进一步的，在不同实施方式中，其中所述支撑层是通过热固化或UV固化的方式固化在所述聚乙烯醇层上。
进一步的，在不同实施方式中，其中所述支撑层在涂覆的过程中同时进行其表面功能处理。例如，HC、AG、LR等等，但不限于。
进一步的，根据所需表面处理功能不同，所述支撑层可以添加不同物质，例如，SiO2颗粒等。进一步的，考虑到涉及使用材料的柔性，选择的所述支撑层的材料和厚度也应作相应调整。进一步的，所述聚乙烯醇层与压敏胶（PSA）接触侧和与增反膜（APF）接触侧可不做所述硬化胶涂层的涂覆，所述压敏胶/增反膜可以同样起到支撑作用。
本发明的又一方面是提供一种本发明涉及的所述偏光板的制造方法，由于所述偏光板采用了全新的结构设计，因而使得其涉及的制造方法中，使用了较少的制程以及较少的制备材料，从而降低了本发明涉及的所述偏光板的生产成本。
其采用的技术方案如下：
一种偏光板的制造方法，其包括以下步骤：
聚乙烯醇层染色步骤，将提供的聚乙烯醇（PVA）层浸入碘的水溶液进行染色，通过碘离子取代以实现不同波长光的吸收；
聚乙烯醇层拉伸步骤，对染色后的所述聚乙烯醇层进行拉伸，拉伸长度为5~15倍，厚度控制在10~30μm；
聚乙烯醇层清洗和预烘干步骤，对拉伸后的所述聚乙烯醇层进行清洗，以及清洗后烘干处理；
支撑层涂布步骤，将染色烘干后的所述聚乙烯醇层进行硬化胶涂布，其中使用的材料包括热固化材质、光学胶以及UV固化胶中的至少一种材质，其涂布厚度在5-20μm；
硬化处理步骤，根据所述支撑层所选材料对涂布后的聚乙烯醇层进行热固化或是UV光照固化处理。
进一步的，在不同实施方式中，其中在所述拉伸步骤中，所述聚乙烯醇层是在硼酸和碘化钾的水溶液中进行拉伸的。
进一步的，在不同实施方式中，其中在所述清洗步骤中，所述聚乙烯醇层是通过水溶液进行清洗，并添加硫酸锌、氯化锌、碘化钾、氯化钾以及硼酸中的至少一种物质，以提高所述聚乙烯醇层的均匀性和材料强度，并对表面脏污进行清除。
进一步的，在不同实施方式中，其中在所述预烘干步骤中，所述清洗后的聚乙烯醇层的烘干温度在50~120度，持续时间0~60分钟。该过程注意不要过烘干，达到所述聚乙烯醇层表面干燥即可。
进一步的，在不同实施方式中，其还包括压敏胶（PSA）涂布步骤，其为向固化后的所述聚乙烯醇层和硬化胶涂层复合体涂布压敏胶，或者通过离型膜转印的方式进行。
进一步的，在不同实施方式中，其还包括增反膜贴覆（下偏光板）步骤，其制程工艺与现有制程类似，为避免不必要的重复，此处不再赘述。
 有益效果
本发明涉及的一种偏光板结构，其采用全新的结构设计，通过使用硬化胶涂层替代传统的COP/TAC/CAT支撑层，由所述硬化胶涂层起到同样的支撑保护作用，但其所需厚度较薄，使得所述偏光板的整体厚度更薄，从而使得其所在的显示面板更为轻薄，进而满足业界的要求。
另外，所述偏光板结构厚度的降低，同时也会给TFT-LCD模组堆叠预留了更多的空间，进而更能优化整机对亮度的需求。
进一步的，本发明涉及的所述偏光板的制造方法，由于所述偏光板采用了新的结构和材质，因而使得其制造工艺简化以及涉及制造材料减少，从而实现了所述偏光板的制造成本降低，进一步的提高了产品的竞争力。
 附图说明
图1是本发明涉及的一个实施方式提供的一种偏光板结构的结构示意图；
图2是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图3是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图4是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图5是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图6是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图7是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图8是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图9是本发明涉及的又一个实施方式提供的一种偏光板结构的结构示意图；
图10是现有技术中的偏光板结构的结构示意图。
 本发明的实施方式
以下将结合附图和实施例，对本发明涉及的一种偏光板及其制造方法的技术方案作进一步的详细描述。
本发明的一个实施方式提供了一种偏光板，包括聚乙烯醇（PVA）层和支撑层，其中所述支撑层与所述PVA层相接并对其进行支撑。其中所述支撑层是一种硬化胶涂层，其由热固化材质、光学胶以及UV固化胶中的至少一种材质构成，其厚度在5-20μm。
本发明采用全新的偏光板结构设计，使用硬化胶涂层来替代现有常见的COP/TAC/CAT等支撑层，由其对所述聚乙烯醇层起到支撑保护作用。所述硬化胶涂层可以在实现现有COP/TAC/CAT支撑层相同功效的基础上，有效的缩减厚度，进而缩减所在偏光板的整体厚度。
具体的，其中所述硬化胶涂层可以选择热固化材料，例如改性聚氨酯系；也可以为光学胶；或者是UV固化胶，例如，改性聚氨酯丙稀酸酯系。
进一步的，根据不同的具体需要，其中所述聚乙烯醇（PVA）层和所述支撑层之间的设置方式可以包括三种。
请参阅图1所示，第一种设置方式为所述支撑层20设置在所述聚乙烯醇（PVA）层10上。请参阅图2所示，第二种设置方式为所述支撑层20设置在所述聚乙烯醇（PVA）层10下。请参阅图3所示，第三种设置方式是所述聚乙烯醇（PVA）层10上、下均设置所述支撑层20。具体选择何种设置方式，则可随所述偏光板的具体结构来定，并无限定。
例如，请参阅图4、5所示，在本发明涉及的偏光板的两个实施方式中，其中所述聚乙烯醇层10与压敏胶（PSA）30接触侧和与增反膜（APF）40接触侧可不做所述支撑层20的涂覆，所述压敏胶30/增反膜40可以同样起到支撑作用。
进一步的，根据上述本发明的创作构思，本发明涉及的偏光板可以有以下几种具体结构。
请参阅图6所示，本发明的又一实施方式提供了一种偏光板，其包括保护膜60、支撑层20、聚乙烯醇层10、支撑层20、压敏胶30和离型膜50。
请参阅图7所示，本发明的又一实施方式提供了一种偏光板，其包括保护膜60、支撑层20、聚乙烯醇层10、压敏胶30和离型膜50。
请参阅图8所示，本发明的又一实施方式提供了一种偏光板，其包括保护膜60、增反膜40、支撑层20、聚乙烯醇层10、支撑层20、压敏胶30和离型膜50。
请参阅图9所示，本发明的又一实施方式提供了一种偏光板，其包括保护膜60、增反膜40、聚乙烯醇层10、支撑层20、压敏胶30和离型膜50。
以上揭示的这些偏光板的具体膜层结构，仅为对本发明创作构思的举例性说明，具体采用的膜层结构可根据实际需要进行增减，并无限定。
进一步的，根据所需表面处理功能不同，其中由所述硬化胶涂层构成的所述支撑层20可以添加不同物质，例如，SiO2颗粒等。进一步的，考虑到涉及使用材料的柔性，选择的所述硬化胶涂层的材料和厚度也应作相应调整。
进一步的，其中涉及的所述聚乙烯醇（PVA）层，其也可以是由类似材料构成的等同变换结构层，例如，MSPVA层。给出的所述聚乙烯醇（PVA）层，仅为举例式说明，并无限定。
本发明涉及的所述偏光板，其采用全新的结构设计，通过使用硬化胶涂层替代传统的COP/TAC/CAT支撑层，由其起到同样的支撑保护作用，使得其所在偏光板的整体厚度更薄，从而使得其所在的显示面板更为轻薄，进而满足业界的要求。另外，所述偏光板结构厚度的降低，同时也会给显示面板中的TFT-LCD模组堆叠预留了更多的空间，进而更能优化所述显示面板对亮度的需求。
本发明的又一方面是提供一种本发明涉及的所述偏光板的制造方法，由于所述偏光板采用了全新的结构设计，因而使得其涉及的制造方法中，使用了较少的制程以及较少的制备材料，从而降低了本发明涉及的所述偏光板的生产成本。
一种偏光板的制造方法，其包括聚乙烯醇层染色步骤、聚乙烯醇层拉伸步骤、聚乙烯醇层清洗和预烘干步骤、支撑层涂布步骤、硬化处理步骤、压敏胶（PSA）涂布步骤以及增反膜贴覆（下偏光板）步骤等。
其中在所述聚乙烯醇层染色步骤中，其为将提供的聚乙烯醇（PVA）层浸入碘的水溶液以进行染色，通过碘离子取代以实现不同波长光的吸收；
其中在所述聚乙烯醇层拉伸步骤中，其为对染色后的所述聚乙烯醇层进行拉伸，拉伸长度为5~15倍，厚度控制在10~30μm。其中所述聚乙烯醇层的拉伸是在硼酸和碘化钾的水溶液中进行的。
其中在所述聚乙烯醇层清洗和预烘干步骤中，其具体可分为前后两个步骤：清洗步骤和预烘干步骤。
在所述清洗步骤中，所述聚乙烯醇层是通过水溶液进行清洗，并添加硫酸锌、氯化锌、碘化钾、氯化钾以及硼酸中的至少一种物质，以提高所述聚乙烯醇层的均匀性和材料强度，并对表面脏污进行清除。
而在所述预烘干步骤中，所述清洗后的聚乙烯醇层的烘干温度在50~120度，持续时间0~60分钟；该过程注意不要对所述聚乙烯醇层过烘干，达到其表面干燥即可。
其中在所述支撑层涂布步骤中，其为将染色烘干后的所述聚乙烯醇层进行硬化胶涂布，其中使用的材料是由热固化材质、光学胶以及UV固化胶中的至少一种材质构成，其涂布厚度在5-20μm。
其中在所述硬化处理步骤中，其为根据所述支撑层所选材料对涂布后的聚乙烯醇层进行热固化或是UV光照固化处理。
其中在所述压敏胶（PSA）涂布步骤中，其为向固化后的所述聚乙烯醇复合体涂布压敏胶，或者通过离型膜转印的方式进行。
其中所述增反膜贴覆（下偏光板）步骤，其制程工艺与现有制程类似，为避免不必要的重复，此处不再赘述。
本发明涉及的所述偏光板的制造方法，由于所述偏光板采用了新的结构和材质，因而使得其制造工艺简化以及涉及制造材料减少，从而实现了本发明涉及的所述偏光板的制造成本降低，进一步的提高了产品的竞争力。
本发明的技术范围不仅仅局限于上述说明中的内容，本领域技术人员可以在不脱离本发明技术思想的前提下，对上述实施例进行多种变形和修改，而这些变形和修改均应当属于本发明的范围内。

Claims (10)

  1. 一种偏光板，包括聚乙烯醇层和支撑层，其中所述支撑层与所述聚乙烯醇层相接并对其进行支撑；
    其中所述支撑层是一种硬化胶涂层，其由热固化材质、光学胶以及UV固化胶中的至少一种材质构成。
  2. 根据权利要求1所述的一种偏光板，其中所述支撑层的厚度在5-20μm。
  3. 根据权利要求1所述的一种偏光板，其中所述支撑层设置在所述聚乙烯醇层的上和/或下表面上。
  4. 根据权利要求1所述的一种偏光板，其中所述支撑层包括两层分别设置在所述聚乙烯醇层的上下两侧，所述上侧支撑层上设置有保护膜，所述下侧支撑层下依次设置有压敏胶和离型膜。
  5. 根据权利要求1所述的一种偏光板，其中所述支撑层设置在所述聚乙烯醇层上侧，其上设置有保护膜，所述聚乙烯醇层下依次设置有压敏胶和离型膜。
  6. 根据权利要求1所述的一种偏光板，其中所述支撑层包括两层分别设置在所述聚乙烯醇层的上下两侧，所述上侧支撑层上依次设置有增反膜和保护膜，所述下侧支撑层下依次设置有压敏胶和离型膜。
  7. 根据权利要求1所述的一种偏光板，其中所述支撑层设置在所述聚乙烯醇层下侧，其下依次设置有压敏胶和离型膜，所述聚乙烯醇层上依次设置有增反膜和保护膜。
  8. 一种用于制备根据权利要求1所述的一种偏光板的制备方法，包括以下步骤：
    聚乙烯醇层染色步骤，将提供的聚乙烯醇层浸入碘的水溶液进行染色，通过碘离子取代以实现不同波长光的吸收；
    聚乙烯醇层拉伸步骤，对染色后的所述聚乙烯醇层进行拉伸，拉伸长度为5~15倍，厚度控制在10~30μm；
    聚乙烯醇层清洗和预烘干步骤，对拉伸后的所述聚乙烯醇层进行清洗，以及清洗后烘干处理；
    支撑层涂布步骤，将染色烘干后的所述聚乙烯醇层进行硬化胶涂布，其中使用的材料包括热固化材质、光学胶以及UV固化胶中的至少一种材质，其涂布厚度在5-20μm；
    硬化处理步骤，根据所述支撑层所选材料对涂布后的聚乙烯醇层进行热固化或是UV光照固化处理。
  9. 根据权利要求8所述的一种偏光板的制备方法，其中在所述拉伸步骤中，所述聚乙烯醇层是在硼酸和碘化钾的水溶液中进行拉伸的。
  10. 根据权利要求8所述的一种偏光板的制备方法，其中在所述清洗和预烘干步骤中的清洗步骤中，所述聚乙烯醇层是通过水溶液进行清洗，并添加硫酸锌、氯化锌、碘化钾、氯化钾以及硼酸中的至少一种物质，以提高所述聚乙烯醇层的均匀性和材料强度，并对表面脏污进行清除。
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