WO2020091064A1 - 偏光性光学機能フィルム積層体及びこれに用いる偏光フィルム - Google Patents
偏光性光学機能フィルム積層体及びこれに用いる偏光フィルム Download PDFInfo
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- WO2020091064A1 WO2020091064A1 PCT/JP2019/043123 JP2019043123W WO2020091064A1 WO 2020091064 A1 WO2020091064 A1 WO 2020091064A1 JP 2019043123 W JP2019043123 W JP 2019043123W WO 2020091064 A1 WO2020091064 A1 WO 2020091064A1
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- film
- polarizing
- optical functional
- film laminate
- polarizing optical
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/38—Removing material by boring or cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
- B32B7/023—Optical properties
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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
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
- G02B1/11—Anti-reflection coatings
-
- 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
- G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
- G02B1/14—Protective coatings, e.g. hard coatings
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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
-
- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F9/00—Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements
Definitions
- the present invention is a polarizing optical functional film laminate, more specifically, a polarizing optical functional film laminate having a coating layer formed on a cut end face of a polarizer contained in the polarizing optical functional film laminate,
- the present invention relates to a polarizing film used for this.
- the image display device equipped with a polarizing film has a wide variety of uses, and therefore, it is often used for a long time in a high temperature and high humidity environment.
- a phenomenon occurs in which water flows in and out from the cut end surface of the polarizing film that has been exposed to water.
- a polarizer is of a type in which a stretched film made of a PVA-based resin material is impregnated with iodine to form a PVA-polyiodine ion complex so as to exhibit polarization performance.
- Patent Document 2 a method has been proposed in which the outer peripheral cut surface of a polarizing film cut into a desired shape is covered with a resin coating (Patent Document 2), but the method proposed in Patent Document 2 is proposed. Then, in order to form a film, it is necessary to apply a solution in which a resin is dissolved in a solvent to a cut surface of a polarizing film with a roll coater or the like, and to dry the manufacturing process, resulting in a long and complicated manufacturing process.
- Patent Document 3 Another problem that results in an increase in Further, in Patent Document 3, a protective layer disposed on both front and back surfaces of the polarizer is formed to be larger than the polarizer so that a groove-shaped gap is provided between the protective layers and the gap is filled with a sealing material.
- the manufacturing process is long and complicated.
- a coating is formed using a universal coating means such as a roll coater or a slot die coater on the cut end surface of the polarizing film whose outer periphery is cut into a non-linear shape including a curved line
- a universal coating means such as a roll coater or a slot die coater
- the gap between the liquid discharge part and the cut end face of the polarizing film needs to be kept uniform, but such gap adjustment is extremely difficult, and it is difficult to form a coating film with a uniform thickness on the cut end face. ..
- a spray coater for forming the resin film, but in this method, a solution in which a resin material is dissolved in an organic solvent is used as a coating liquid, and in this case, a multi-layer structure is used.
- the coating liquid penetrates between the layers of the polarizing film, and the coating liquid that has penetrated between the layers causes a problem that the interlayer adhesive force is reduced. Further, this method may cause a problem that the constituent substrate of the polarizing film is eroded by the diluting organic solvent contained in the coating liquid.
- the optical film generally has a surface protective film and a release liner which are peeled off at the time of mounting on a device on one side or both sides, and Patent Document 2 is provided at the cutting end of the optical film having such a constitution.
- Patent Document 2 is provided at the cutting end of the optical film having such a constitution.
- the cut end faces of the surface protective film and the release liner and the cut end face of the optical film are:
- the coating that covers the cut ends makes them fixed to each other, making it difficult to peel off the surface protective film and the release liner. Further, if the surface protective film and the release liner are forcibly peeled off, a problem arises that the coating film formed on the cut end portion falls off from the optical film. Further, there arises a problem that a part of the film that has fallen off causes contamination of foreign matter in the manufacturing process.
- Vapor deposition Vapor deposition, CVD (Chemical Vapor Deposition), and other so-called vacuum dry coating methods may be applied, but vapor deposition is mainly aimed at forming a metal component film, and in principle it is difficult to form an organic film.
- CVD it is possible to enclose an organic monomer in a reaction furnace and form a film by a plasma CVD method or the like, but it takes too much time to form a film having a thickness of 100 nm or more, and thus the productivity is low. , Is difficult to apply in reality.
- Patent Document 4 teaches that a protective film, which is originally formed of a material having low moisture permeability, is melted by the heat at the time of cutting, and the laser cut end surface of the polarizer is covered with the melt. Patent Document 4 states that according to this method, it is possible to improve the reliability of the processed end portion of the polarizing film in a high temperature and high humidity environment. According to this method, since the coating layer can be formed simultaneously with the laser cutting process, the outer peripheral coating step after the shape processing can be omitted.
- an optical laminate roll is prepared by winding a long optical laminate comprising a long optical film and protective sheets laminated on both sides of the optical film into a roll, and from this roll, A method has also been proposed in which the optical laminate is subjected to laser cutting processing while being fed out (Patent Document 5).
- Patent Document 5 among the protective sheets laminated on both sides of the optical film, the protective sheet located on the lower side can be made to function as the transport base material. In this case, it can be understood that the lower protective sheet is half-cut by laser irradiation.
- Patent Document 4 teaches that the protective film of the polarizer is formed of a resin material having a predetermined low water vapor transmission rate. However, even if such a material is used, when the polarizing film is laser cut, There is no guarantee that the resulting melt from the protective film will be quantitatively sufficient to form a coating covering the cut end surface of the polarizer, and a coating with a thickness sufficient to prevent the permeation of water from the cut end surface should be provided. It is difficult to form. As described above, with the above-mentioned methods that have been conventionally proposed, it is not possible to obtain a polarizing film that can satisfy the recent strict quality requirements for "depolarization" due to color loss from the cut end face of the polarizer.
- a polarizing film having at least a polarizing film having a protective film laminated on at least one side of a polarizer a sheet material which is a separate body from the polarizing optical functional film laminate and formed of a resin material is placed on one surface of the polarizing optical functional film laminate.
- a laser is irradiated in the thickness direction of the polarizing optical functional film laminate from the other surface of the polarizing optical functional film laminate opposite to the sheet material, and the irradiation position of the laser is the surface of the laminate.
- the laser irradiation is performed by cutting the polarizing optical functional film laminate into a predetermined shape by performing a laser cutting treatment of moving the film along a predetermined shape in the inside.
- the sheet material component existing in a part in the thickness direction is scattered as a droplet by laser energy, and at least a part of the droplet of the sheet material component is applied to the polarizer of the polarizing optical functional film laminate.
- a coating layer containing at least the components of the sheet material is formed so as to cover the laser-cut end surface of the polarizer so as to be deposited on the laser-cut end surface to be formed, and this phenomenon is utilized.
- the inventors have come up with the idea of forming a coating film on the cut end surface of the polarizing film to suppress the permeation of water.
- the coating film thus formed can enhance the function of protecting the cut end face of the polarizing film in a high temperature and high humidity environment and improve the reliability of the polarizing film.
- a polarizing optical functional film laminate has at least a polarizing film including a polarizer and a protective film laminated on at least one side of the polarizer, and has a predetermined shape formed by a cut end face.
- a polarizing optical functional film laminate, wherein at least a cutting end face of the polarizer among the cutting end faces includes a resin material component not included in the polarizing optical functional film laminate as a first resin component. The feature is that a layer is formed.
- the present invention it is possible to provide a polarizing optical functional film laminated body and a polarizing film used for the same, in which the problems on the cut end face in the above-mentioned conventional technique are improved.
- FIG. 1 is a schematic cross-sectional view showing an example of a polarizing optical function film laminate according to an embodiment of the present invention before cutting.
- FIG. 2 is a schematic cross-sectional view showing an example of a state when the polarizing optical functional film laminate of FIG. 1 is cut into a desired shape by laser irradiation.
- the schematic diagram of the laminated body cross section which showed the state of the laminated body with a sheet material during the cutting process by laser irradiation.
- FIG. 4 is an optical microscope image showing depolarization of a cut end face in a direction perpendicular to a light absorption axis of a polarizer under crossed Nicols transmission illumination, showing an example in which depolarization due to color loss does not occur.
- FIG. 1 is a schematic cross-sectional view showing an example of a polarizing optical function film laminate according to an embodiment of the present invention before cutting.
- FIG. 2 is a schematic cross-sectional view showing an example of a state when the polarizing
- FIG. 6 is an optical microscope image showing depolarization of a cut end face in a direction perpendicular to a light absorption axis of a polarizer under crossed Nicol transmitted illumination, showing an example in which depolarization due to color loss occurs.
- FIG. 8 is a cross-sectional SEM image showing an enlarged cut end portion of a polarizer in the image shown in FIG. 7.
- EDX image of the same location as in FIG. 9. Schematic of the laser shape processing apparatus which laser-cuts a long strip-shaped polarizing optical functional film laminated body by a roll-to-roll system. It is a figure which shows the example of a cutting processing layout at the time of manufacturing the product cut out in the smart phone shape from the large-sized polarizing film, and is a top view which shows the whole.
- FIG. 1 It is a figure which shows the example of a cutting process layout at the time of manufacturing the product cut out in the smart phone shape from the large-sized polarizing film, and is a top view which expands and shows a part. It is a figure which shows the example of a cutting processing layout at the time of manufacturing the product cut out in the automobile meter panel shape from the large-sized polarizing film, and is a top view which shows the whole. It is a figure which shows the example of a cutting processing layout at the time of manufacturing the product cut out in the automobile meter panel shape from the large-sized polarizing film, and is a top view which expands and shows a part.
- Example 1 the SEM image which observed the cut end surface from the molecular orientation direction.
- Example 2 the SEM image which observed the cut end surface from the molecular orientation direction.
- Compare example 1 the SEM image which observed the cut end surface from the molecular orientation direction.
- 3 is an image showing the analysis result by TOF-SIMS in Example 1.
- FIG. 5 is a diagram showing the elemental analysis result of the coating layer formed on the cut end surface in Example 1.
- 8 is an image showing the analysis result by TOF-SIMS in Example 6.
- FIG 9 is an image showing the analysis result by TOF-SIMS in Example 7.
- FIG. 1 shows an example of a polarizing optical functional film laminate according to an embodiment of the present invention in a state before cutting, more specifically, before forming a coating layer covering a cut end face of a polarizer.
- the state is shown in a schematic sectional view.
- the polarizing optical functional film laminate 1 includes at least the polarizing film 12, and further includes, but is not limited to, the surface treatment layer 13, the surface protective film 14, and the pollution control film 23 as optional elements. Can be included.
- a release liner 16 may be further attached to the polarizing optical functional film laminate 1 via the pressure-sensitive adhesive layer 15.
- the polarizing optical functional film laminate 1 provided with the pressure-sensitive adhesive layer 15 and the release liner 16 is indicated by reference numeral "1A", and the polarizing optical functional film laminate 1A will be described as an example.
- the polarizing film 12 is mainly composed of a polarizer 10 and a protective film 11 laminated on one or both main surfaces of the polarizer 10, as shown in FIG.
- Other optical functional films exhibiting optical functions such as a brightness enhancement film and a viewing angle compensation film may be further laminated.
- the laminate including these optical functional films constitutes the polarizing film 12.
- FIG. 1 shows an example in which the protective films 11a and 11b are laminated on both main surfaces of the polarizer 10, the protective film 11 may be laminated only on one main surface.
- the polarizer 10 is made of a resin film. Any appropriate resin can be used as this resin film, but a polyvinyl alcohol-based resin (hereinafter, referred to as PVA-based resin) is usually used.
- PVA-based resin examples include polyvinyl alcohol and ethylene-vinyl alcohol copolymer.
- the ethylene-vinyl alcohol copolymer can be obtained by saponifying an ethylene-vinyl acetate copolymer.
- the degree of saponification of the PVA-based resin is usually 85 mol% to 100 mol%, preferably 95.0 mol% or more, more preferably 99.0 mol% or more, and particularly preferably 99.93 mol% or more. ..
- the degree of saponification can be determined according to JIS K 6726-1994. By using the PVA-based resin having such a saponification degree, the polarizer 10 having excellent durability can be obtained.
- the PVA-based resin constituting the polarizer 10 may be subjected to various treatments such as swelling treatment, stretching treatment, dichroic substance, typically dyeing treatment with iodine, crosslinking treatment, washing treatment, and drying treatment, according to a commonly used method. It is applied and is ready for use as a polarizer. The number, order, time, etc. of each processing can be set appropriately.
- the PVA-based resin may be a thin film formed as a coating layer on another base material, and may be formed by subjecting the thin film to the above-mentioned treatments.
- the stretching direction in the stretching treatment corresponds to the absorption axis direction of the obtained polarizer. From the viewpoint of obtaining excellent polarization characteristics, the PVA-based resin is usually uniaxially stretched 3 to 7 times.
- the PVA-based resin film a film formed by an arbitrary method such as a casting method of casting a stock solution dissolved in water or an organic solvent to form a film, a casting method, an extrusion method, or the like can be appropriately used.
- the average degree of polymerization of the PVA resin can be appropriately selected according to the purpose.
- the average degree of polymerization is usually 1000 to 10000, preferably 1200 to 6000, and more preferably 2000 to 5000.
- the average degree of polymerization can be determined according to JIS K 6726-1994.
- the resin film forming the polarizer 10 is typically impregnated with a dichroic substance.
- the dichroic substance include iodine and organic dyes. These can be used alone or in combination of two or more. Iodine is preferably used as the dichroic substance.
- organic dyes examples include Red BR, Red LR, Red R, Pink LB, Rubin BL, Bordeaux GS, Sky Blue LG, Lemon Yellow, Blue BR, Blue 2R, Navy RY, Green LG, Violet LB, Violet B, Black. H, Black B, Black GSP, Yellow 3G, Yellow R, Orange LR, Orange 3R, Scarlet GL, Scarlet KGL, Congo Red, Brilliant Violet BK, Supra Blue G, Supra Blue GL, Supra Orange GL, Direct Sky Blue, Direct First orange S, first black, etc. can be used. These dichroic substances may be used alone or in combination of two or more.
- the thickness of the polarizer 10 can be set to any appropriate value.
- the thickness of a practically used polarizer is 5 ⁇ m to 30 ⁇ m.
- the polarizer 10 preferably has a characteristic of exhibiting absorption dichroism in the wavelength range of 380 nm to 780 nm.
- the single transmittance (Ts) of the polarizer 10 is generally 43% or more. The theoretical upper limit of the single transmittance is 50%, and the practical upper limit is 46%. Further, the single transmittance (Ts) is a Y value measured by a 2 degree visual field (C light source) based on JIS Z8701 and subjected to luminosity correction. For example, a spectrophotometer (J7, V7100) is used. Can be used to measure.
- the polarization degree of the polarizer 10 is generally 99.9% or more.
- Examples of materials for forming the protective films 11a and 11b include cellulosic resins such as diacetyl cellulose and triacetyl cellulose (TAC), (meth) acrylic resins, cycloolefin resins, olefin resins such as polypropylene, and polyethylene terephthalate. Examples thereof include ester-based resins such as resin-based resins, polyamide-based resins, polycarbonate-based resins, and copolymer resins of these.
- the expression “(meth) acrylic resin” means an acrylic resin and / or a methacrylic resin.
- the thickness of the protective films 11a and 11b is usually selected to be an arbitrary value within the range of 10 ⁇ m to 200 ⁇ m. The materials, thicknesses and the like may be the same or different between the protective film 11a and the protective film 11b.
- Each of the protective films 11a and 11b is typically laminated on each of the main surfaces of the polarizer 10 via an adhesive layer (not shown).
- Any appropriate adhesive can be used as the adhesive forming the adhesive layer.
- a water-based adhesive, a solvent-based adhesive, an active energy ray-curable adhesive, etc. are used.
- As the water-based adhesive it is preferable to use an adhesive containing a PVA-based resin.
- the protective films 11a and 11b may contain one or more kinds of appropriate additives. Examples of the additive include an ultraviolet absorber, an antioxidant, a lubricant, a plasticizer, a release agent, a coloring inhibitor, a flame retardant, a nucleating agent, an antistatic agent, a pigment and a coloring agent.
- FIG. 1 shows an example in which the surface treatment layer 13 is formed only on the protective film 11 a laminated on one main surface of the polarizer 10.
- the surface protective film 14 is a member that is releasably attached to the protective film 11a for the purpose of protecting the protective film 11a from scratches caused by contact or adhesion of foreign matter, and is composed of an adhesive layer 14a and a resin film 14b.
- the pressure-sensitive adhesive forming the pressure-sensitive adhesive layer 14a a material containing a polymer material of any one of acryl-based, rubber-based, urethane-based, silicone-based, and polyester-based as a main component is used, and the thickness is in the range of 1 to 100 ⁇ m. It can be appropriately selected.
- the resin film 14b examples include acrylic resins, olefin resins such as polyethylene and polypropylene, ester resins such as polyethylene terephthalate resin, and the like, and the thickness is preferably in the range of 5 ⁇ m to 100 ⁇ m.
- the surface protection film 14 is peeled off when the polarizing film is mounted on an optical display device. Therefore, the pressure-sensitive adhesive that constitutes the pressure-sensitive adhesive layer 14a preferably has a light pressure-sensitive adhesive force, and a preferable peeling force is 5 N / 20 mm or less.
- the release liner 16 is laminated on the surface of the polarizing film 12 on the side opposite to the surface protective film 14, that is, on the surface of the protective film 11b on the side opposite to the polarizer 10, with the adhesive layer 15 interposed therebetween.
- the main surface of the release liner 16 in contact with the pressure-sensitive adhesive layer 15 is subjected to a mold release treatment in order to obtain good release properties.
- the release liner 16 covers the adhesive layer 15 until the polarizing film 12 is attached to the optical display panel.
- the release liner 16 is peeled off from the protective film 11b leaving the pressure-sensitive adhesive layer 15 on the side of the polarization film 12 when the polarization film 12 is bonded to the optical display panel. It is attached to the optical display panel via.
- the peeling force of the release liner 16 with respect to the adhesive layer 15 is preferably 5 N / 20 mm or less.
- the release liner 16 is preferably composed of a resin film, and for example, an olefin resin such as polyethylene and polypropylene or an ester resin such as polyethylene terephthalate resin can be used, but the release liner 16 is not limited thereto.
- the thickness of the release liner 16 can be appropriately selected within the range of 1 ⁇ m to 100 ⁇ m.
- the release liner 16 is preferably formed of a material having low moisture permeability, and a preferable value of the moisture permeability of the material of the release liner 16 is 200 g / in a temperature of 40 ° C. and a humidity of 90% RH. m 2 ⁇ 24h or less, more preferably 150 g / m 2 ⁇ 24h or less.
- the pressure-sensitive adhesive forming the pressure-sensitive adhesive layer 15 it is possible to use a pressure-sensitive adhesive mainly containing any polymer material selected from the group consisting of acrylic, rubber, urethane, silicone, olefin, and polyester. it can. From the viewpoint of cost reduction, acrylic or rubber adhesives are preferable.
- the thickness of the pressure-sensitive adhesive layer 15 can be appropriately set within the range of 1 ⁇ m to 50 ⁇ m.
- the pollution control film 23 may be provided on the surface protection film 14.
- the pollution control film 23 includes at least a resin film base material 23a made of a resin material, and further includes an adhesive layer 23b arranged on one surface of the resin film base material 23a.
- the resin film substrate 23a is laminated on the surface protection film 14 via the adhesive layer 23b.
- a general resin film can be used as the resin film 23a, and for example, an acrylic resin, an olefin resin such as polyethylene and polypropylene, or an ester resin such as polyethylene terephthalate resin can be used.
- the resin film 23a preferably has a thickness in the range of 20 ⁇ m to 100 ⁇ m.
- the pressure-sensitive adhesive forming the pressure-sensitive adhesive layer 23b a material containing any of acrylic, rubber-based, urethane-based, silicone-based, and polyester-based polymer materials as a main component can be used.
- the thickness of the layer 23b can be appropriately selected within the range of 1 to 100 ⁇ m.
- the pressure-sensitive adhesive forming the pressure-sensitive adhesive layer 23b preferably has a light pressure-sensitive adhesive force to the surface protection film 14, and the pressure-sensitive adhesive force is equal to or smaller than the pressure-sensitive adhesive force of the surface protection film 14 used.
- the adhesive strength of the pressure-sensitive adhesive is larger than the adhesive strength of the surface protective film 14, the surface protective film 14 may be peeled off when the anti-contamination film 23 is peeled off, which is not preferable.
- the polarizing optical functional film laminate 1A is cut into a desired shape by laser cutting before the polarizing film 12 is attached to the optical display panel via the adhesive layer 15.
- the melt, fine particles or the like generated during the laser cutting process may be scattered and scattered, and the scattered components may contaminate the surface layer on the main surface of the polarizing film on the laser incident surface side.
- this pollution can be prevented or suppressed.
- the anti-contamination film in this way, it is possible to suppress burrs that may occur on the cut end surface.
- the layer or film located on the most front side in the laser irradiation direction, in the example of FIG. 1, the cut end surface of the resin film 14b forming the surface protection film 14. May have burrs “A” (see FIG. 5) in a state of protruding to the outside of the polarizing optical functional film laminate 1A.
- burrs are polarized. It is possible to suppress the thickness to 0 to 20 ⁇ m in the laminating direction of the optical function film laminate 1A.
- FIG. 2 shows an example of a state in which the polarizing optical functional film laminate 1A of FIG. 1 is cut into a desired shape by laser irradiation by the same method as in FIG.
- a laser By using a laser, not only the polarizing optical function film laminated body 1A can be easily cut into a predetermined shape, but also the polarized light contained in the polarizing optical function film laminated body 1A is accompanied by this cutting process.
- a coating layer can be formed on the cut end surface of the child 10.
- the surface of the polarizing film 12 facing the main surface on the side opposite to the laser incident surface is located outside the release liner 16 of the polarizing optical functional film laminate 1A in the present embodiment, for example.
- the sheet material 17 is arranged so as to face 16a.
- the polarizing optical functional film laminate 1A in which the sheet material 17 is arranged is referred to as a "laminate with a sheet material", and the whole is indicated by reference numeral "2".
- the sheet material 17 includes at least a resin film base material 17a made of a resin material, and further includes a pressure-sensitive adhesive layer 17b arranged on one surface of the resin film base material 17a.
- the resin film substrate 17a is releasably attached to the release liner 16 via the pressure-sensitive adhesive layer 17b, and is peeled from the release liner 16 after the cutting process.
- a general resin film can be used, and for example, an acrylic resin, an olefin resin such as polyethylene and polypropylene, or an ester resin such as polyethylene terephthalate resin is used. can do.
- the resin film substrate 17a preferably has a thickness in the range of 5 ⁇ m to 200 ⁇ m.
- the resin film base material 17a is formed of a material having low moisture permeability, and a preferable value of the moisture permeability of the material of the resin film base material 17a is under an atmosphere of a temperature of 40 ° C. and a humidity of 90% RH. And 200 g / m 2 ⁇ 24h or less, and more preferably 150 g / m 2 ⁇ 24h or less.
- the pressure-sensitive adhesive layer 17b is formed of a polymer material containing acrylic, urethane, silicone, rubber or polyester as a main component. Further, the pressure-sensitive adhesive layer 17b is preferably made of a pressure-sensitive adhesive having a light peeling pressure-sensitive adhesive force, and the peeling force of the pressure-sensitive adhesive layer 17b is the peeling force of the release liner 16 of the polarizing optical functional film laminate 1A. Is preferably equal to or smaller than. When the peeling force of the pressure-sensitive adhesive layer 17b of the sheet material 17 is larger than the peeling force of the release liner 16, the release liner 16 is also peeled off when the sheet material 17 is peeled after the laser cutting process. This may occur. The adhesive layer 17b is usually removed together with the resin film substrate 17a when the sheet material 17 is peeled off after the laser cutting process step.
- the laser is applied from the other surface of the polarizing optical functional film laminated body 1A located on the opposite side of the sheet material 17, to the surface on the side of the pollution control film 23 in the illustrated embodiment. Is irradiated in the thickness direction of the polarizing optical functional film laminate 1A.
- This “thickness direction” is sufficient as long as it is a direction that penetrates the layers constituting the polarizing optical functional film laminate 1 ⁇ / b> A, and is not necessarily a direction orthogonal to those layers.
- This cutting with a laser may be performed in a state where the polarizing optical functional film laminate 1A is singulated into a single plate state, but from the viewpoint of efficient production, as described in detail later, It is preferably carried out in the form of a strip film. Therefore, it is preferable that the laminate with sheet material 2 is formed in the form of a long strip film wound in a roll.
- FIG. 3 shows the state of the laminated body 2 with a sheet material during the cutting process by laser irradiation in a schematic view of the laminated body cross section.
- the cutting groove 2a is formed in the polarizing optical functional film laminate 1A of the laminate 2 with the sheet material over the entire thickness thereof including the release liner 16. Therefore, by moving the laser irradiation position along the predetermined shape within the plane of the polarizing optical functional film laminate 1A, the polarizing optical functional film laminate 1A can be cut into a desired shape.
- the cutting is performed by completely cutting the polarizing optical functional film laminate 1A forming the laminated body 2 with a sheet material in the thickness direction, and further cutting to a depth where a part of the sheet material is left.
- the laser cutting process be performed in a state where the laminated body 2 with a sheet material is placed on the suction type fixed stage 19 and held by suction force as shown in FIG.
- the cutting end face of the polarizing film 12 and especially the cutting end face of the polarizer 10 are covered with the coating layer 18a. , 18b can be formed.
- the "depolarization width" described below is reduced, in other words, it is possible to improve reliability in a high temperature and high humidity environment.
- FIG. 4A shows an example of a polarizing film in which depolarization due to color loss has not occurred
- FIG. 4B shows an example of a polarizing film in which depolarization has occurred by performing a reliability test in a high temperature and high humidity environment. ..
- the cut edge of the polarizing film 12 is indicated by reference numeral 12a, and color loss occurs in the region from the cut edge 12a to the width 12b.
- the width 12b of this region is the depolarization width.
- the protective films 11a and 11b constituting the polarizing film 12 and other adhesives (not shown) for adhering the polarizer 10 and the protective films 11a and 11b to each other generally have an infrared laser energy of a threshold value or more. It is made of a resin material that has the property of softening or melting. Therefore, at least the protective films 11a, 11b and the like adjacent to the cutting groove 2a can be melted by the thermal energy of the laser during the laser cutting process to form a melt. For the sake of convenience, FIG. 3 shows only the melt formed by the protective film 11a and the adhesive attached thereto.
- the melt contains a large amount of the components of the protective films 11a and 11b, and the melt flows along the laser cut end face of the polarizer 10 exposed by the cutting process to cover a part or all of the cut end face.
- Form layer 18a is formed on the cut end surface of the polarizing film 12, especially the cut end surface of the polarizer 10. Therefore, it is possible to improve reliability in a high temperature and high humidity environment.
- the region affected by the thermal energy of the laser and formed along the surface of the protective film 11 is preferably 200 ⁇ m or less from the cut end face, more preferably 100 ⁇ m or less, and particularly preferably 50 ⁇ m or less. This is because if the thickness exceeds 200 ⁇ m, the fused region may be projected from the frame portion of the display panel in a state where the polarizing film 12 is bonded to the display panel, and the appearance quality may be deteriorated.
- the component of the sheet material 17 first resin component
- the components of the adhesive layer 15 and the release liner 16 second resin component
- the coating layer 18b containing other components are formed.
- a desired effect can be expected depending on the water blocking property (hydrophobicity or moisture permeability) of the formed coating layer 18b.
- the moisture barrier property (hydrophobicity or moisture permeability) of the formed coating layer even in the same thickness, a high temperature and high humidity environment can be obtained.
- the degree of influence on the reliability of the cut end of the polarizing film 12 below changes, the formation of such a coating layer 18b on the cut end face results in at least physical removal of moisture.
- a predetermined effect of blocking infiltration can be expected. Therefore, according to the present embodiment, in the shape processing of the polarizing optical functional film laminate 1A, at the same time as the laser cutting processing, in addition to the coating layer 18a, on the cutting end surface of the polarizing film 12, especially the cutting end surface of the polarizer 10.
- the coating layer 18b can be formed, and the reliability can be improved in a high temperature and high humidity environment.
- the width of the cutting groove 2a formed on the sheet material 17 is appropriately determined in the range of 5 ⁇ m to 300 ⁇ m, and the depth of the cutting groove 2a is 5 ⁇ m to 200 ⁇ m. It is preferable to appropriately determine in the range.
- the thickness of the coating layer 18b formed on the cut end surface of the polarizing film 12, more specifically, the length in the direction orthogonal to the cut end surface of the polarizing film 12 is preferably 10 ⁇ m or less. If the thickness of the coating layer 18b exceeds 10 ⁇ m, the dimensional accuracy of the product may be affected, and a defect may occur when the coating layer 18b is mounted on the target display panel, and peeling occurs when the coating layer 18b is mounted on the display panel. This is because it is unfavorable because it may affect the releasability of the surface protective film. ..
- the component (first resin component) of the pressure-sensitive adhesive layer 17b of the sheet material 17 constitutes a part or all of the component of the coating layer 18b formed on the cut end surface of the polarizing film 12.
- the thickness of the pressure-sensitive adhesive layer 17b is preferably in the range of 1 ⁇ m to 100 ⁇ m, more preferably in the range of 5 ⁇ m to 50 ⁇ m.
- the thickness of the pressure-sensitive adhesive layer 17b is less than 1 ⁇ m, a sufficient pressure-sensitive adhesive force cannot be obtained, and peeling may occur during transportation, and when the thickness of the pressure-sensitive adhesive layer 17b is more than 100 ⁇ m, the sheet This is because the total thickness of the laminated body with material 2 becomes too thick and the handling property deteriorates.
- the adhesive layer 17b is made of a silicone-based or rubber-based one having hydrophobicity as a main component. It is particularly preferable that it has an alkyl group such as a methyl group or an ethyl group, or a hydrophobic group such as a phenyl group. Furthermore, it is desirable that the pressure-sensitive adhesive layer 17b is formed of a material having a low moisture permeability, and a preferable value of the moisture permeability of the material of the pressure-sensitive adhesive layer 17b is under an atmosphere of a temperature of 40 ° C. and a humidity of 90% RH.
- the components of the adhesive layer 17b are the same as those described above. It is not limited. Further, when the laser penetrates the pressure-sensitive adhesive layer 17b of the sheet material 17 and reaches the resin film base material 17a, the components of the resin film base material 17a (first resin component) as well as the components of the pressure-sensitive adhesive layer 17b are also included.
- the resin film substrate 17a The thickness is preferably in the range of 10 ⁇ m to 150 ⁇ m.
- the coating layer 18a contains a large amount of the melt of the protective films 11a and 11b.
- the coating layer 18b at least the component (first resin component) of the sheet material 17, which is a component other than the polarizing optical functional film laminate 1, 1A, is also included. It is considered that a large amount of the components (the second resin component) of the pressure-sensitive adhesive layer 15 and the release liner 16, which are the components.
- the coating layer 18a and the coating layer 18b can theoretically be relatively clearly distinguished as shown in the schematic view of FIG. 3, it is practically difficult to clearly distinguish them. Is.
- both the coating layer 18a and the coating layer 18b respectively, at least the components of the protective film 11a, 11b and the component that is melted and scattered from the sheet material 17, Furthermore, the release liner 16 and the adhesive layer 15 and the like contain components that are melted and scattered. In other words, the components of the coating layer 18a and the coating layer 18b are in a mixed or mixed state, so that the components of the coating layer 18a and the coating layer 18b cannot be clearly distinguished, and it is necessary to do so. Absent.
- FIG. 3 merely shows a conceptual diagram for facilitating the explanation.
- the components contained in the coating layers 18a and 18b were analyzed by TOF-SIMS (time-of-flight secondary ion mass spectrometry) or energy dispersive X-ray analysis. Are analyzed by.
- FIG. 5 shows an SEM image of a cut cross section of the laser-cut laminated body 2 as an example of the present invention.
- FIG. 6A shows the effect obtained by the laminate 2 with a sheet material according to one embodiment of the present invention by “depolarization width” in comparison with the effect obtained by the end mill according to the conventional art shown in FIG. 6B.
- FIG. 6A shows an example of a depolarization width achieved by Example 4 described later
- FIG. 6B shows an example of a depolarization width achieved by Comparative Example 3 described later.
- the coating layer (18a) was melted and scattered from the release liner 16 and the sheet material 17.
- the coating layer (18a) contributes to the improvement of the quality reliability of the cut end surface of the polarizer 10 in a high temperature and high humidity environment.
- the pressure-sensitive adhesive layer 15 is not always necessary, and even when the pressure-sensitive adhesive layer 15 is provided, the pressure-sensitive adhesive for the laser used is Depending on the thermal characteristics such as reactivity and fluidity during heating, the coating layer (18a) may not include the components of the melt from the adhesive layer 15. However, the components of the coating layer 18a and the components of the coating layer 18b are in a mixed or mixed state. Therefore, even in such a case, the quality reliability of the cut end face of the polarizer 10 can be improved. ..
- FIG. 7 is a cross-sectional SEM image in the vicinity of a polarizing film of a laminate with a sheet material according to one example of the present invention (corresponding to Example 1 described later) processed by laser cutting, and more specifically, molecular orientation of a polarizer.
- a cross-sectional SEM image of a cut end face in a direction perpendicular to the (light absorption axis) is shown in FIG. 8, an EDX (energy dispersive X-ray analysis) image of the same portion as FIG. 7, and an image shown in FIG.
- FIG. 10 shows an EDX image at the same position as in FIG.
- the thickness of the polarizer 10 at the cut end face in the direction perpendicular to the light absorption axis direction of the polarizer 10 is as shown in FIG.
- bulging (10a) occurs as compared with the thickness other than the vicinity of the cut end face, and the thickness increases 1.1 to 2.5 times.
- the PVA-based resin containing iodine is thermally stressed by the laser energy, so that the PVA-based resin is contracted in the optical absorption axis direction which is the stretching direction of the PVA-based resin, and as a result, the PVA-based resin is compressed in the optical absorption axis direction. It is considered that this is due to expansion in the thickness direction. Along with this phenomenon, the softened or melted protective film 11 and the pressure-sensitive adhesive flow into the space formed by compression, so that the coating layer (18a) is easily formed. Such a phenomenon is not observed at the cut end surface parallel to the light absorption axis direction of the polarizer 10.
- the laser light source for example, an infrared laser including a CO 2 laser light source having an oscillation wavelength of laser light in the infrared region of 9 to 11 ⁇ m is preferably used from the viewpoint of high productivity.
- the infrared laser can easily obtain a power of several tens of W, and further efficiently heats the film and the pressure-sensitive adhesive layer constituting the polarizing optical functional film laminate 1A by molecular vibration associated with infrared absorption, It is possible to cause etching accompanying the phase transition of a substance.
- a near infrared (NIR) light source a visible light (Vis) light source, and an ultraviolet (UV) light source can be used as long as they are pulse laser light sources.
- the oscillation wavelength of laser light is 1064 nm, 532 nm, 355 nm, 349 nm or 266 nm (Nd: YAG, Nd: YLF, or YVO4) A second harmonic), an excimer laser light source having a laser light oscillation wavelength of 351 nm, 248 nm, 222 nm, 193 nm or 157 nm, and an F2 laser light source having a laser light oscillation wavelength of 157 nm.
- a pulse wave is preferable to a continuous wave (CW) from the viewpoint of suppressing heat damage to the polarizing film.
- the pulse width can be appropriately set within the range of 10 femtoseconds (10 ⁇ 14 seconds) to 1 millisecond (10 ⁇ 3 seconds). It is also possible to set and process two or more types of pulse widths.
- the repetition frequency which is the time interval of pulses, is preferably 1 to 1,000 kHz, and more preferably 10 to 500 kHz.
- Gaussian beam is preferable because it shows good condensing property, can be made into a small spot, and can be expected to improve productivity. It may be shaped into a flat top beam using a diffractive optical element, an aspherical lens or the like.
- the laser beam may be irradiated once along the target shape, or may be irradiated multiple times to achieve a desired cutting depth. Further, it is possible to appropriately adjust the processing conditions for the first and second processings within the above-mentioned condition range.
- a polarizing optical function By using a general scanning device such as a stage drive system such as an XY precision stage, an optical scanning system such as a galvano scanner and a polygon scanner, or a combination thereof (multi-axis synchronous control), a polarizing optical function to be a workpiece.
- a general scanning device such as a stage drive system such as an XY precision stage, an optical scanning system such as a galvano scanner and a polygon scanner, or a combination thereof (multi-axis synchronous control), a polarizing optical function to be a workpiece.
- the laser irradiation While changing the relative position of the film laminated body 1A and the laser beam at a predetermined speed, the laser irradiation is controlled to be on / off by using a mechanical shutter mechanism, an AOM (acousto-optical element), or the like, thereby obtaining a desired shape. It becomes possible to process it.
- the scanning speed of laser irradiation achieves a desired etching depth that can completely cut the polarizing optical functional film laminate 1A in the thickness direction and further form a cutting groove in the sheet material 17 to a sufficient depth. It may be set as appropriate.
- the laser beam preferably has a focused spot diameter that can be processed with a cutting width of 500 ⁇ m or less, and more preferably has a focused spot diameter that can be processed with a cutting width of 300 ⁇ m or less.
- the spot diameter is defined as the point where the intensity is reduced to 1 / e 2 as compared with the peak intensity value
- the focused spot diameter is preferably 200 ⁇ m or less, more preferably 100 ⁇ m or less.
- a beam expanding unit for adjusting the beam diameter may be arranged in the optical path of the objective lens from the emission end of the laser oscillator to obtain the desired focused spot diameter and cutting width.
- the laser power may be appropriately set according to the thickness and properties of the polarizing optical functional film laminate 1A to be processed.
- the laser power is in the range of 5 to 300 W. It is preferable to set to, and it is more preferable to set to the range of 20 to 200W.
- -It is possible to irradiate two or more types of lasers at the same time, and it is also possible to irradiate two or more types of lasers sequentially.
- the laser cutting process for the polarizing functional optical film laminate 1A may be performed while continuously feeding the polarizing optical functional film laminate 1A wound in a roll, or may be cut in advance to a predetermined length. You may perform it to 1 A of polarizing functional optical film laminated bodies separated by this.
- the polarizing optical functional film laminate 1A is continuously or intermittently supplied by a so-called roll-to-roll method, and in the meanwhile, desired
- an optical element such as a laser light source and a lens or a mirror is placed and fixed on the XY biaxial movable stage, and the XY biaxial movable stage is driven, so that the XY2 of the laser light irradiated to the polarizing film is obtained. Change the position on the dimensional plane.
- the long strip-shaped film laminate may be stopped from being conveyed or may be synchronously processed according to the feed speed and position while being continuously conveyed.
- the suction-fixing stage for holding the laminate with sheet material 2 during processing may or may not be provided. It is preferable to provide a dust collecting mechanism in the vicinity of the laser irradiation part for the purpose of suppressing the adhesion of scattered particles, which do not contribute to the formation of the coating layer during processing, to the product.
- a desired amount of the sheet material-derived material that is scattered from the sheet material by the laser energy received during laser cutting processing and adheres to the cut end surface of the polarizing film can be obtained. It can be a value. Therefore, at the same time as the laser cutting process, a coating layer that contributes to reliability improvement in a high temperature and high humidity environment can be formed on the cut end surface of the polarizing film to obtain the depolarization preventing effect.
- FIG. 11 is a schematic diagram showing an example of a laser cutting device 30 that can be used in a method of continuously performing laser cutting processing by a roll-to-roll method.
- a laminated body 31 in which a surface protective film 34, a polarizing film 32, and a release liner 36 are laminated in the same configuration as the polarizing optical function film laminated body 1A shown in FIG. 1 is formed in a long strip shape. It is used as it is.
- the long strip-shaped laminated body 31 is rolled and formed into a roll 31a, and the roll 31a is rotatably supported by a roll supporting portion (not shown).
- the sheet material 37 having the same configuration as the sheet material 17 is used in a state of being formed in a long strip shape.
- the long strip-shaped sheet material 37 is rolled and formed into a roll 37a, and the roll 37a is rotatably supported by a roll supporting portion (not shown).
- the stacked body 31 and the sheet material 37 fed from the rolls 31a and 37a are fed to the nip of the pair of overlapping rollers 40 in a state of being overlapped with each other.
- the laminated body 31 and the sheet material 37 are laminated by the superposing roller 40 to form a laminated body 41 with a sheet material, which is sent to the nip of the second superposing roller 42 in the next stage.
- the anti-contamination film 43 is fed to the second stacking roller 42 on the side of the laminated body 41 with the sheet material that overlaps the surface protection film 34.
- the anti-contamination film 43 is supplied in the form of a roll, and is rotatably supported by a roll support portion (not shown).
- the second superimposing roller 42 attaches the pollution control film 43 onto the surface protection film 34 of the sheet material-attached laminate 41, and the sheet material-attached laminate 41 to which the contamination prevention film 43 is attached is moved to the next stage.
- a laser irradiation device 45 capable of XY biaxial movement is arranged between the second overlapping roller 42 and the guide roller 44.
- the laser irradiation device 45 irradiates the laminated body 41 with the sheet material with laser light from the upper side of the pollution control film 43, and moves XY biaxially during that time to move the contamination prevention film 43 and the laminated body 41 with the sheet material.
- a cutting groove 46 is formed as shown in the lower sectional view in FIG. Laser cutting of a desired pattern is performed by the cutting groove 46. As shown in the lower sectional view of FIG. 11, the cutting groove 46 cuts the pollution control film 43 and the laminated body 41 with the sheet material in the thickness direction, and reaches a certain depth in the thickness direction of the sheet material 37. .. Due to the cutting groove 46, a cutting portion 47 having a predetermined pattern is formed in the pollution control film 43 and the sheet material-attached laminate 41.
- the pollution control film recovery tape 49 formed of an adhesive tape has its adhesive surface
- the anti-contamination film 43 is pressed against the anti-contamination film 43, and the anti-contamination film 43 is collected from the upper surface of the laminate 41.
- other unnecessary portions unnecessary materials
- the sheet material peeling portion 51 is provided with a wedge-shaped peeling plate 51a, and the used sheet material after the laser cutting process is peeled off from the laminate 31 which is a product portion in the peeling plate 51a.
- the remaining laminated body 31 is sent to the product collecting unit 52 and collected as a product.
- the laminated body 31 that has reached the product collecting unit 52 may be wound into a roll here to form a product roll.
- FIG. 11 shows a configuration in which the unnecessary material and the pollution control film are collected separately, but the invention is not limited to this, and it is possible to collect them at the same time.
- the polarizing film 12 included in the polarizing optical functional film laminate of the present invention is a liquid crystal display device including an automobile meter display unit, a smart watch, goggles, a smartphone, a notebook computer, and a note pad, and further an organic EL display. Since it is used for many devices such as an optical display device such as a device or an optical display panel such as a plasma display panel (PDP), as illustrated in FIGS. 12A to 14, not only a rectangular shape but also a curved shape. It is cut into various shapes, such as shapes with edges and holes.
- FIGS. 13A and 13B are views showing a cutting processing layout example in the case of manufacturing a product cut out from a large-sized polarizing film into a smartphone shape.
- FIG. 12A is a plan view showing the whole
- FIG. 13A and 13B are enlarged plan views showing a part thereof
- FIGS. 13A and 13B are views showing a cutting processing layout example in the case of manufacturing a product cut out from a large-sized polarizing film into an automobile meter panel shape.
- FIG. 13B is a plan view showing the whole
- FIG. 13B is a plan view showing a part of the enlarged view
- FIG. 14 is a photograph showing a plurality of examples of polarizing films cut out in a smartphone shape. Therefore, the present invention is applicable to cutting of all of these shapes.
- a laser for cutting it is possible to perform processing having a curved portion with a small radius of curvature (R), and it is possible to handle cutting with a radius of curvature R of 2 mm or less
- a polarizing film used for an automobile meter panel may have a structure in which a through hole is formed for fixing a meter needle, and it is required to form a through hole having a diameter of 0.5 mm to 100 mm, for example.
- the laser cutting process of the polarizing film 12 is not limited to the above-mentioned shape, and can be applied to various shapes.
- this laser cutting processing method is also applicable to a step of slit-cutting a long strip-shaped film laminate including a polarizing film in a longitudinal direction by a laser, and a cut end face of the slit-cut long strip-shaped film laminate is cut.
- the coating layer according to the present invention can be formed. This coating layer makes it possible to suppress the deterioration of the cut end surface of the long strip film laminate due to the infiltration of water from the cut end face of the laminate during storage and transportation of the long strip film laminate. ..
- this laser cutting method is a roll-to-roll method for transporting a long strip-shaped film laminate including a polarizing film, while transporting at a predetermined transport amount and then stopping in the transport direction.
- Example 1 (Polarizing optical functional film laminate) A polymer film having a thickness of 30 ⁇ m, which contains a PVA-based resin as a main component, is sequentially immersed in 5 baths of [1] to [5] below while applying tension that allows stretching in the longitudinal direction of the film, and a stretching ratio of 6 times ( It was stretched with a polymer film manufactured by Kuraray Co., Ltd.). The stretched film was dried to obtain a polarizer 10 having a thickness of 12 ⁇ m.
- Swelling bath pure water at 30 ° C.
- Dyeing bath aqueous solution at 30 ° C.
- First crosslinking bath containing potassium iodide and boric acid, 40 C. aqueous solution
- Second crosslinking bath 60 ° C. aqueous solution containing potassium iodide and boric acid
- Washing bath potassium iodide containing 25 C aqueous solution
- a PVA-based adhesive is applied to one side of the above-described polarizer so that the thickness after drying is 100 nm, and long TAC films having a thickness of 25 ⁇ m are attached to each other so that their longitudinal directions are aligned with each other, and thus the protective film 11a is formed.
- a PVA-based adhesive was applied to the other side of the above-described polarizer so that the thickness after drying was 100 nm, and a long TAC film having a thickness of 25 ⁇ m was attached so that the longitudinal directions thereof were aligned with each other.
- the protective film 11b was used.
- the polarizing film 12 was produced as described above.
- a hard coat layer is formed on the main surface of the one TAC film 11a opposite to the polarizer so as to have a thickness after drying of 7 ⁇ m to form a surface treatment layer 13, and a surface treatment layer 13 is further formed thereon.
- the protective film 14 was formed.
- the surface protection film 14 is composed of a polyethylene terephthalate substrate (thickness 38 ⁇ m) and an acrylic adhesive (thickness 23 ⁇ m).
- An acrylic adhesive having a thickness of 12 ⁇ m is applied to the main surface of the other TAC film 11b opposite to the polarizer to form an adhesive layer 15, and a release liner made of polyethylene terephthalate is further formed thereon. 16 were stuck together.
- the pollution control film 23 / surface protection film 14 / hard coat 13 / TAC film 11a / PVA adhesive / polarizer 10 / PVA adhesive / TAC film 11b / pressure-sensitive acrylic pressure-sensitive adhesive layer 15 / peeling A polarizing optical functional film laminate 1A having a structure of the liner 16 and a total thickness of about 180 ⁇ m was obtained.
- laser A CO 2 laser (J-3 manufactured by Coherent Co., wavelength 9.4 ⁇ m, Gaussian beam, pulse oscillation) was used as the laser oscillator, and the theoretical spot diameter was defined by the objective lens (the spot diameter was defined as the intensity of 1 / e 2 of the peak value). ) Is about 90 ⁇ m, and the XY stage and galvano scanner are used together, and the desired processing shape is scanned once with a laser power of 65 W, a repetition frequency of 30 kHz, and a scanning speed of 500 mm / s. It was cut into a rectangular shape with dimensions of 80 mm ⁇ 50 mm.
- a sheet material 17 composed of a silicone-based pressure-sensitive adhesive layer 17b (thickness: 75 ⁇ m) and a polyethylene terephthalate substrate 17a (manufactured by Mitsubishi Chemical Corporation, T100-75S, thickness: 75 ⁇ m) is inserted through the above-mentioned silicone-based pressure-sensitive adhesive layer 17b. It was attached to the main surface 16a of the release liner 16 of the above-mentioned polarizing optical function film laminate 1A.
- the sheet material 17 and the polarizing optical functional film laminate 1A to which the anti-contamination film 43 was attached were laser-cut into a desired shape.
- the polarizing optical functional film laminate 1A is fully cut along with the silicone-based adhesive layer 17b of the sheet material 17 over the entire thickness, while the polyethylene terephthalate substrate 17a is not completely cut. It was confirmed that the cutting process was performed in the half-cut state.
- the pollution control film 43 was peeled off, and the height of the burr formed on the cut end surface of the surface protection film 14 was measured, and it was confirmed to be 3 ⁇ m, which is a sufficiently low value.
- the thickness of the polarizer at the cut end face in the direction perpendicular to the stretching direction of the polarizer 10, that is, in the direction perpendicular to the alignment direction of PVA-based molecules is 1 compared with the thickness of the polarizer other than the vicinity of the cut end face. It was .8 times.
- the sheet material 17 and the anti-contamination film 43 are peeled off from the sample of the polarizing film that has been laser-cut into a rectangular shape, the cut surface is embedded with an epoxy resin, and the cut cross section is FE-SEM (scanning electron microscope, Japan). SEM images were acquired by observing with JSM-7001F manufactured by Denshi Co., Ltd. (FIGS. 7 and 9). Further, the state of the cut end face of the polarizer 10, in other words, the state of the coating layer was observed from the molecular orientation direction using the same FE-SEM to obtain an SEM image (FIG. 15A). This FIG.
- FIG. 15A is an SEM image in Example 1, and corresponds to the SEM image seen from the direction of arrow “C” in FIG. 9.
- FIG. 15B shows similar SEM images in Example 2
- FIGS. 15C and 15D show similar SEM images in Comparative Examples 1 and 2, respectively.
- the cut end surface of the polarizer 10 is surely covered with the coating layers 18a and 18b.
- FIGS. 8 and 10 are EDX images processed by software so that when the coating layers 18a and 18b contain silicon, the silicon is displayed brightly and brightly.
- the coating layer 18b formed on the cut end face of the polarizing film contains silicon (Si element) derived from the silicone-based pressure-sensitive adhesive layer 17b forming the sheet material 17. .. Further, the coating layer 18b had a thickness of about 2 to 5 ⁇ m.
- TOF- was used for the location corresponding to the location in FIG. 9 by using the time-of-flight secondary ion mass spectrometer of ULVAC-PHI, Inc. Analysis by SIMS was performed. More, obtained by analysis, C-derived PET 8 H 5 O 4 - ( m / z 165) (m / z represents the mass-to-charge ratio) in view of the ionic strength of the mapping data did.
- FIG. 16 shows an image showing the analysis result. From this image, it was confirmed that a film of polyethylene terephthalate (PET) was formed not only on the coating layer 18b but also on the coating layer 18a.
- PET polyethylene terephthalate
- a cutting groove 17-1a having a width of 40 ⁇ m and a depth of about 100 ⁇ m formed by cutting with laser energy was confirmed. This indicates that at least the component of the sheet material 17 scattered from the cutting groove 17-1a adheres to the cut end surface of the polarizing film 12 and forms the coating layers 18a and 18b (FIG. 17). ..
- FIG. 18 is a graph showing the results of component analysis of the materials contained in the coating layers 18a and 18b in Example 1. More specifically, it is a graph showing the EDX elemental analysis result of the portion indicated by the arrow “B” in FIG. 10, where the horizontal axis shows the X-ray energy (keV) and the vertical axis shows the X-ray count number. As shown in this figure, in this example, carbon (C) and oxygen (O) were detected in addition to silicon (Si) from the coating layers 18a and 18b. As can be seen from this, the coating layers 18a and 18b formed on the cut end surface of the polarizer 10 include at least the polarizing film 12, the adhesive layer 15, the release liner 16, the organic component derived from the sheet material, and the sheet material. It can be seen that the layer is formed by mixing with silicon (Si) derived from the adhesive layer 17b.
- the surface protective film 14 and the release liner 16 were peeled from the sample of the manufactured rectangular polarizing optical functional film laminate 1A, and they were attached to the glass plate so that the surface of the pressure-sensitive adhesive layer 15 was in contact.
- the sample was put in an oven set to an environment of a temperature of 65 ° C. and a humidity of 90% to perform a reliability test.
- the condition of the reliability test was to hold the sample in an oven in the above environment for 240 hours (10 days) and observe depolarization due to color loss of the polarizing film 12 on the processed end face in a high temperature and high humidity environment.
- the depolarization width of the cut end surface (alignment parallel surface) parallel to the light absorption axis of the polarizer was 135 ⁇ m, and the depolarization width of the cut end surface (alignment division cross section) perpendicular to the light absorption axis was 183 ⁇ m. It was It can be seen that the depolarization width can be suppressed as compared with the comparative example described later.
- Example 2 In the sheet material 17, the acrylic pressure-sensitive adhesive layer (thickness 23 ⁇ m) was used as the pressure-sensitive adhesive layer 17 b, the polyethylene terephthalate substrate (thickness 38 ⁇ m) was used as the resin film substrate 17 a, and the laser power was changed to 55 W. Except for the above, evaluation of depolarization due to laser cutting and color loss of the polarizer 10 was performed under the same conditions as in Example 1.
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer 10 was 153 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 216 ⁇ m.
- the depolarization width could be suppressed as compared with the comparative example described later.
- Example 3 In the sheet material 17, a rubber-based pressure-sensitive adhesive layer (thickness 10 ⁇ m) was used as the pressure-sensitive adhesive layer 17 b, a polyethylene terephthalate substrate (thickness 38 ⁇ m) was used as the resin film substrate 17 a, and the laser power was changed to 55 W. Except for the above, evaluation of depolarization due to laser cutting and color loss of the polarizer 10 was performed under the same conditions as in Example 1.
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 120 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 191 ⁇ m.
- the depolarization width could be suppressed as compared with the comparative example described later.
- Example 4 The same conditions as in Example 2 except that the thickness of the polarizer 10 was set to 5 ⁇ m, the protective film 11b was removed, a base material in which the thickness of the silicone adhesive layer was 20 ⁇ m was used, and the laser power was changed to 35 W. Then, evaluation of depolarization caused by laser cutting and color loss of the polarizer 10 was performed. Note that FIG. 5 corresponds to the SEM image obtained by removing the anti-contamination film from the configuration of Example 4.
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 113 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 103 ⁇ m.
- the depolarization width could be suppressed as compared with Comparative Example 3 described later.
- Example 1 Except that the polarizing optical functional film laminate 1A described in Example 1, which does not use the sheet material and the pollution control film 23, is cut into a predetermined shape using an end mill, that is, a rectangular shape having a size of 80 mm ⁇ 50 mm. The evaluation was performed under the same conditions as in Example 1.
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 182 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 251 ⁇ m.
- the depolarization width was larger than in Examples 1 and 2.
- Example 2 Under the same conditions as in Example 1 except that the sheet material was not used and the laser power was changed to 55 W, the laser cutting process and the depolarization caused by the color loss of the polarizer 10 were evaluated. In this case, it was confirmed that the polarizing optical functional film laminate 1A was fully cut, while the release liner 16 was not completely cut, but was cut into a half-cut state.
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 170 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 231 ⁇ m.
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer 10 was 129 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 177 ⁇ m.
- the depolarization width was larger than that in Example 4.
- Example 5 Due to the laser cutting process and color loss of the polarizer 10 under the same conditions as in Example 1 except that the pollution control film 23 was not used, and the laser power was changed to 43 W and the repetition frequency was 15 kHz. Depolarization evaluation was performed. As a result, the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 122 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 195 ⁇ m. The depolarization width could be suppressed as compared with the comparative example described later.
- Example 6 The TOF-SIMS analysis was performed under the same conditions as in Example 2 except that the pollution control film 23 was not used, the laser power was changed to 39 W, and the repetition frequency was 15 kHz. Also, depolarization caused by color loss of the polarizer 10 was evaluated.
- FIG. 19 is an image showing the analysis result by TOF-SIMS. From this figure, it was confirmed that a film of polyethylene terephthalate (PET) was formed not only on the coating layer 18b but also on the coating layer 18a.
- PET polyethylene terephthalate
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 132 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 214 ⁇ m.
- the depolarization width could be suppressed as compared with the comparative example described later.
- Example 7 Analysis by TOF-SIMS was performed under the same conditions as in Example 2 except that the pollution control film 23 was not used, the laser power was changed to 20 W, the repetition frequency was 15 kHz, and the number of scans was 2. Further, evaluation of depolarization caused by laser cutting and color loss of the polarizer 10 was performed.
- FIG. 20 is an image showing the analysis result by TOF-SIMS. From this figure, it was confirmed that a film of polyethylene terephthalate (PET) was formed not only on the coating layer 18b but also on the coating layer 18a.
- PET polyethylene terephthalate
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 133 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 233 ⁇ m.
- the depolarization width could be suppressed as compared with the comparative example described later. Further, it was revealed that by lowering the laser power and increasing the number of scans, the result is comparable to the case where the laser power is strong and the number of scans is small.
- Example 4 Analysis was performed by TOF-SIMS under the same conditions as in Example 5 except that the sheet material was not used and the laser power was changed to 20 W. Also, due to laser cutting and color loss of the polarizer 10. The depolarization evaluation was performed. In this case, it was confirmed that the release liner 16 of the polarizing optical functional film laminate 1A was not completely cut, but cut into a half-cut state.
- FIG. 21 is an image showing the analysis result by TOF-SIMS. From this figure, it was confirmed that no polyethylene terephthalate (PET) film was formed on the coating layers 18a and 18b.
- PET polyethylene terephthalate
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 158 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 235 ⁇ m.
- the depolarization width was larger than that in Example 5.
- FIG. 22 is an image showing the analysis result by TOF-SIMS. From this figure, it was confirmed that no polyethylene terephthalate (PET) film was formed on the coating layers 18a and 18b.
- PET polyethylene terephthalate
- the depolarization width of the cut end surface parallel to the light absorption axis of the polarizer was 163 ⁇ m, and the depolarization width of the cut end surface perpendicular to the light absorption axis was 268 ⁇ m.
- the depolarization width was larger than that in Example 6.
- FIG. 23 is an image showing the analysis result by TOF-SIMS. From this figure, it was confirmed that a film of polyethylene terephthalate (PET) was formed not only on the coating layer 18b but also on the coating layer 18a. As a result, it was found that a film of polyethylene terephthalate (PET) was formed on the coating layers 18a and 18b even when the pollution control film 23 and the like were not present.
- PET polyethylene terephthalate
- FIG. 24 is an image showing the analysis result by TOF-SIMS. From this figure, it was confirmed that no polyethylene terephthalate (PET) film was formed not only on the coating layer 18b but also on the coating layer 18a. As a result, it was found that when the release liner and the sheet material were not used, the polyethylene terephthalate (PET) film was not formed on the coating layers 18a and 18b even if the anti-contamination film 23 and the like were present.
- PET polyethylene terephthalate
- the coating layers 18a and 18b include at least the component of the sheet material 17, that is, the component of the pressure-sensitive adhesive layer 17b, and / or the PET component of the resin film substrate 17a. Therefore, by appropriately selecting the components of these sheet materials, particularly for the pressure-sensitive adhesive layer 17b, it is possible to effectively prevent water from entering the polarizer 10 from the outside through the cut end face, Prevention of color loss, in other words, reduction of depolarization width can be expected.
- the polarizing optical functional film laminate 1 constitutes the polarizing optical functional film laminate 1A including the pressure-sensitive adhesive layer 15 and the release liner 16, depending on the components of the pressure-sensitive adhesive layer 15, further
- the coating layers 18a and 18b can be made thicker and the entry of water can be prevented more effectively.
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Abstract
Description
インクジェットプリンティング又はディスペンサ方式のような、切断加工形状に沿った滴下コーティング方法も存在するが、この種の方法によっても、被膜の薄型化が困難であり、かつ被膜形成に伴う偏光フィルム表層への飛沫汚染などの問題が生じる為、技術的に適用困難である。
なお、光学フィルムは、片側もしくは両側に、デバイスへの実装に際して剥離される表面保護フィルム及び剥離ライナーを有する事が一般的であり、このような構成の光学フィルムの切断加工端部に特許文献2に教示される被膜を形成すると、表面保護フィルム及び剥離ライナーの切断端面にも被膜が同時に形成されることになるため、表面保護フィルム及び剥離ライナーの切断端面と、光学フィルムの切断端面とが、切断端部を被覆する被膜によって互いに固定された状態になり、表面保護フィルム及び剥離ライナーを剥離させることが困難になる。また、表面保護フィルム及び剥離ライナーを無理に剥がそうとすると、切断加工端部に形成した被膜が光学フィルムから脱落する問題を生じる。さらに、脱落した被膜の一部が製造工程における異物汚染の原因になるという問題が生じる。
このように、従来提案された上述の手法では、偏光子切断端面からの色抜けによる「偏光解消」に対する近年の厳しい品質要求を満足できる偏光フィルムを得ることはできなかった。
本発明の一態様による偏光性光学機能フィルム積層体は、偏光子と該偏光子の少なくとも片側に積層された保護フィルムとを含む偏光フィルムを少なくとも有し、切断端面により形成される所定形状を有する偏光性光学機能フィルム積層体であって、前記切断端面のうち少なくとも前記偏光子の切断端面には、偏光性光学機能フィルム積層体には含まれない樹脂材料の成分を第1樹脂成分として含む被覆層が形成されていることを特徴として有する。
図1に、本発明の一実施形態による偏光性光学機能フィルム積層体の一例を、切断加工を行う前の状態で、更に詳細には、偏光子の切断端面を覆う被覆層を形成する前の状態で概略断面図で示す。偏光性光学機能フィルム積層体1は、偏光フィルム12を少なくとも含み、更に、これらに限定されるわけではないが、表面処理層13、表面保護フィルム14、及び、汚染対策フィルム23を任意の要素として含むことができる。
偏光性光学機能フィルム積層体1には更に、粘着剤層15を介して剥離ライナー16を貼り合わせてもよい。以下、粘着剤層15と剥離ライナー16を設けた偏光性光学機能フィルム積層体1を、符号「1A」で示し、この偏光性光学機能フィルム積層体1Aを例として説明を行う。
保護フィルム11a、11bの厚みは、通常は10μm~200μmの範囲内で任意の値に選定される。
尚、これら材料及び厚み等は、保護フィルム11aと保護フィルム11bとの間で、同じものとされていてもよいし、異なるものとされていてもよい。
保護フィルム11a、11bには、任意の適切な添加剤が1種以上含まれていても良い。添加剤としては、例えば、紫外線吸収剤、酸化防止剤、滑剤、可塑剤、離型剤、着色防止剤、難燃剤、核剤、帯電防止剤、顔料、着色剤などが挙げられる。
粘着剤層14aを構成する粘着剤は、アクリル系、ゴム系、ウレタン系、シリコーン系及びポリエステル系のいずれかの高分子材料を主成分とする材料が用いられ、1~100μmの範囲で厚みを適宜選択することができる。
樹脂フィルム14bとしては、アクリル系樹脂、ポリエチレン及びポリプロピレン等のオレフィン系樹脂、ポリエチレンテレフタレート系樹脂等のエステル系樹脂等が挙げられ、厚みは5μm~100μmの範囲とすることが好ましい。
図2に、図1の偏光性光学機能フィルム積層体1Aをレーザー照射により所望形状に切断加工する際の状態の一例を、図1と同様の方法で示す。レーザーを用いることにより、偏光性光学機能フィルム積層体1Aを所定の形状に容易に切断することができるだけでなく、更に、この切断加工に伴って、偏光性光学機能フィルム積層体1Aに含まれる偏光子10の切断端面に被覆層を形成することができる。切断加工に際しては、偏光フィルム12の、レーザー入射面とは反対側の主面に対向させて、例えば、本実施形態では、偏光性光学機能フィルム積層体1Aの剥離ライナー16の外側に位置する面16aに対向させてシート材17を配置する。以下、シート材17が配置された偏光性光学機能フィルム積層体1Aを、「シート材付き積層体」と呼び、全体を符号「2」で示す。
樹脂フィルム基材17aを構成する樹脂フィルムとしては、一般的な樹脂フィルムを使用でき、例えば、アクリル系樹脂、ポリエチレン及びポリプロピレン等のオレフィン系樹脂、又はポリエチレンテレフタレート系樹脂等のエステル系樹脂等を使用することができる。樹脂フィルム基材17aは、5μm~200μmの範囲の厚みを有することが好ましい。また、樹脂フィルム基材17aは、透湿度が低い材料から形成されることが望ましく、樹脂フィルム基材17aの材料の透湿度の好ましい値は、温度40℃、湿度90%RHの雰囲気のもとで、200g/m2・24h以下であり、150g/m2・24h以下がより好ましい。
偏光フィルム12の主要構成要素である偏光子10は、高温高湿環境のもとで長時間放置されると、熱負荷のかかった偏光フィルムの切断端面から水分が出入りし、このため、偏光子10に含まれるポリヨウ素イオン錯体が変質して流動性を帯び偏光子10から抜けていく脱色現象を生じる。その結果、偏光子10の端部において、偏光機能が消失するという、品質に関連する課題が生じる。この偏光機能が消失することを偏光解消と言い、切断端面から偏光解消した領域の幅を偏光解消幅と呼ぶ。図4A、図4Bに、偏光子の光吸収軸に対し直角方向の切断端面をクロスニコルの透過照明のもとで平面視した偏光解消幅を示す光学顕微鏡画像を示す。図4Aは、色抜けによる偏光解消を生じていない偏光フィルムの例を示し、一方、図4Bは、高温高湿環境で信頼性試験を実施したことによって偏光解消を生じた偏光フィルムの例を示す。図4Bにおいて、偏光フィルム12の切断端縁は、符号12aで示されており、該切断端縁12aから幅12bの領域において、色抜けを生じている。この領域の幅12bが偏光解消幅である。
偏光フィルム12を構成する保護フィルム11a、11b、その他、偏光子10と保護フィルム11a、11bとを接着する接着剤(図示せず)は、一般的に、閾値以上の赤外線レーザーエネルギーを投入することで軟化若しくは溶融する性質を示す樹脂材料から構成されている。このため、少なくとも切断溝2aに隣接する保護フィルム11a、11b等は、レーザー切断加工時にレーザーの熱エネルギーによって溶融して、溶融物を形成し得る。便宜上、図3には、保護フィルム11aとこれに付随する接着剤によって形成された溶融物のみを示している。この溶融物には、保護フィルム11a、11bの成分が多く含まれると考えられ、切断加工によって露出する偏光子10のレーザー切断端面に沿って流れて、切断端面の一部又は全部を被覆する被覆層18aを形成する。従って、本実施形態によれば、偏光性光学機能フィルム積層体1Aの形状加工において、レーザー切断加工と同時に、偏光フィルム12の切断端面、取り分け、偏光子10の切断端面に、被覆層18aを形成することができ、高温高湿環境における信頼性向上を図ることが可能となる。
レーザーが偏光性光学機能フィルム積層体1Aを厚み方向に貫通してシート材17に到達した場合、レーザーの熱エネルギーによって、偏光性光学機能フィルム積層体1、1Aには含まれないが、その厚み方向の一部に存在する少なくともシート材17の成分(第1樹脂成分)が、また、偏光性光学機能フィルム積層体1には含まれないが、その厚み方向の一部に存在し得る粘着剤層15及び剥離ライナー16の成分(第2樹脂成分)が、更に、偏光性光学機能フィルム積層体1に含まれ得るその他の成分が、飛沫となって飛散させられ、この飛沫の少なくとも一部は偏光子10に形成されるレーザー切断端面に堆積する。この結果、少なくともシート材17の成分(第1樹脂成分)を、場合によっては、粘着剤層15及び剥離ライナー16の成分(第2樹脂成分)を、更に、その他の成分を含む被覆層18bが形成され、形成される被覆層18bの水分遮断性(疎水性又は透湿度)によっては、所望の効果が期待できる。また、形成される被覆層の成分又は性状とは無関係に、更に詳細には、形成される被覆層の水分遮断性(疎水性又は透湿度)によって、同じ厚みであっても、高温高湿環境下における偏光フィルム12の切断加工端部の信頼性に及ぼす影響の度合は変わってくるにもかかわらず、切断端面にこのような被覆層18bが形成されることにより、少なくとも、物理的に水分の浸入を遮断する所定の効果が期待できる。従って、本実施形態によれば、偏光性光学機能フィルム積層体1Aの形状加工において、レーザー切断加工と同時に、偏光フィルム12の切断端面、取り分け、偏光子10の切断端面に、被覆層18aに加えて、被覆層18bを形成することができ、高温高湿環境における信頼性向上を図ることが可能となる。
更に、レーザーが、シート材17の粘着剤層17bを貫通して、樹脂フィルム基材17aにまで達する場合は、粘着剤層17bの成分とともに樹脂フィルム基材17aの成分(第1樹脂成分)も、偏光フィルム12の切断端面に形成される被覆層18bの成分の一部を構成することになるため、この観点から、また、取り扱い中の破損を防止する等観点から、樹脂フィルム基材17aの厚みは、10μm~150μmの範囲が好ましい。
上の記載から明らかなように、被覆層18aには、保護フィルム11a、11bの溶融物が多く含まれると考えられる。
一方、被覆層18bには、偏光性光学機能フィルム積層体1、1A以外の成分である、少なくともシート材17の成分(第1樹脂成分)が、また、偏光性光学機能フィルム積層体1以外の成分である、粘着剤層15及び剥離ライナー16の成分(第2樹脂成分)が多く含まれると考えられる。
このように、被覆層18aと被覆層18bは、理論的には、図3の模式図に示すように比較的明確に区別することができるものの、実際上、それらを明確に区別することは困難である。なぜなら、例えば、用いるレーザーに対する粘着剤の反応性及び加熱時の流動性といった熱的特性等によって、被覆層の状態は容易に変化してしまうからである。後述する実施例等の記載からも明らかなように、実際のところ、被覆層18aと被覆層18bは双方ともに、それぞれ、少なくとも保護フィルム11a、11bの成分及びシート材17から溶融飛散した成分を、更に、剥離ライナー16、粘着剤層15等から溶融飛散した成分を含むものとなっている。言い換えれば、被覆層18aの成分と被覆層18bの成分は混合又は混和した状態にあり、従って、被覆層18aの成分と被覆層18bを明確に区別することはできないし、そのようにする必要もない。なぜなら、被覆層18aと被覆層18bは双方ともに、偏光性光学機能フィルム積層体等の形状加工において、レーザー切断加工と同時に、偏光フィルムの切断端面に形成されて、高温高湿環境における信頼性向上に寄与し得るからである。従って、図3は、説明を容易にするための単なる概念図を示すものである。尚、後の記載から明らかなように、実施例等では、被覆層18a、18bに含まれる成分を、TOF-SIMS(飛行時間型二次イオン質量分析法)、又は、エネルギー分散型X線分析によって分析している。
図5に示した画像からは必ずしも明らかではないが、実施例等に示したTOF-SIMSによる分析結果等を考慮すると、被覆層(18a)には、剥離ライナー16及びシート材17から溶融飛散した成分が含まれると考えられる。よって、図6A及び図6Bの比較結果からも明らかなように、この被覆層(18a)は、高温高湿環境における偏光子10の切断端面の品質信頼性の向上に貢献するものである。
尚、粘着剤層15を設けた例を示したが、粘着剤層15は必ずしも必要なものではなく、また、粘着剤層15が設けられている場合であっても、用いるレーザーに対する粘着剤の反応性及び加熱時の流動性といった熱的特性によっては、被覆層(18a)に、この粘着剤層15からの溶融物の成分が含まれない場合もある。しかしながら、被覆層18aの成分と被覆層18bの成分は混合又は混和した状態にあり、従って、そのような場合であっても、偏光子10の切断端面の品質信頼性の向上を図ることができる。
ヨウ素を含むPVA系樹脂で構成された偏光子10が、レーザー切断されると、該偏光子10の光吸収軸方向に対して垂直方向の切断端面においては、偏光子10の厚みが、図7~図10に示すように、切断端面近傍以外の厚みと比べて膨れ(10a)を生じ、厚みが1.1倍~2.5倍に増加する。これは、レーザーエネルギーによってヨウ素を含むPVA系樹脂が熱応力を受けることで、PVA系樹脂の延伸方向である光吸収軸方向に収縮し、その結果、PVA系樹脂が光吸収軸方向に圧縮されて、厚み方向に膨張するためと考えられる。この現象に伴って、圧縮によってできた空間に、軟化若しくは溶融した保護フィルム11及び粘着剤が流れ込むことで、被覆層(18a)が形成され易くなる。偏光子10の光吸収軸方向に平行な切断端面においては、このような現象は見られない。
レーザー光源としては、例えば、レーザー光の発振波長が赤外域の9~11μmであるCO2レーザー光源を含む赤外線レーザーを用いることが高生産性の観点で好ましい。赤外線レーザーは、数10W級のパワーを容易に得ることができ、さらに偏光性光学機能フィルム積層体1Aを構成するフィルム及び粘着剤層を赤外線吸収に伴う分子振動によって効率的に発熱させることで、物質の相転移に伴うエッチングを起こすことが可能である。
偏光性機能光学フィルム積層体1Aに対するレーザー切断加工は、ロール状に巻き回された偏光性光学機能フィルム積層体1Aを連続的に繰り出しながら行ってもよいし、また、予め所定長さに切断することによって個片化された偏光性機能光学フィルム積層体1Aに対して行ってもよい。
加工中に発生する被覆層の形成に寄与しない飛散物の製品への付着を抑制する目的で、レーザー照射部近傍に集塵機構を設けることが好ましい。
本発明によれば、シート材の厚みを適宜設定することで、レーザー切断加工に際して受けるレーザーエネルギーにより該シート材から飛散させられて偏光フィルムの切断端面に付着するシート材起因材料の量を所望の値にすることが可能である。したがって、レーザー切断加工と同時に、高温高湿環境における信頼性向上に寄与する被覆層を、偏光フィルムの切断端面に形成して、偏光解消防止効果を得ることができる。
ロール31a及びロール37aから繰り出された積層体31及びシート材37は、互いに重ね合わされた状態で、一対の重ね合せローラ40のニップに送り込まれる。積層体31及びシート材37は、重ね合せローラ40により積層されて、シート材付き積層体41となり、次段の第二重ね合せローラ42のニップに送り込まれる。第二重ね合せローラ42には、シート材付き積層体41の表面保護フィルム34に重なる側に、汚染対策フィルム43が送り込まれる。汚染対策フィルム43は、ロールの形態で供給され、図示しないロール支持部に回転自在に支持される。第二重ね合せローラ42は、シート材付き積層体41の表面保護フィルム34の上に汚染対策フィルム43を貼り合わせ、該汚染対策フィルム43が貼り合わせられたシート材付き積層体41を、次段の案内ローラ44の下側に送り込むように作用する。
第二重ね合せローラ42と案内ローラ44との間に、X-Y2軸移動可能なレーザー照射装置45が配置される。レーザー照射装置45は、汚染対策フィルム43の上側からシート材付き積層体41にレーザー光を照射し、その間に、X-Y2軸移動して、汚染対策フィルム43及びシート材付き積層体41に、図11において下側の断面図に示すように切断溝46を形成する。この切断溝46により、所望パターンのレーザー切断加工が遂行される。図11の下側断面図に示すように、切断溝46は、汚染対策フィルム43とシート材付き積層体41を厚み方向に切断し、シート材37の厚さ方向に或る程度の深さまで達する。この切断溝46により、汚染対策フィルム43及びシート材付き積層体41には所定パターンの切断部47が形成される。
汚染対策フィルム43が貼り合わせられたシート材付き積層体41が、一対の汚染対策フィルム回収用ローラ48を通過する際、粘着テープにより構成される汚染対策フィルム回収用テープ49は、その粘着面を汚染対策フィルム43に押し付けられ、積層体41の上面から汚染対策フィルム43が回収される。その後、案内ローラ44を通過したシート材付き積層体41は、切断溝46で区画される製品部分をシート材37に残しつつその他の不要となる部分(不要材)が巻き取られ回収される。その後、製品部分が残ったシート材付き積層体41は、一対の案内ローラ50を経て、シート材剥離部51に送られる。シート材剥離部51には、楔状の剥離板51aが備えられており、この剥離板51aにおいて、レーザー切断加工後の用済シート材が製品部分となる積層体31から剥がされる。残った積層体31は、製品収集部52に送られて、製品として収集される。製品収集部52に到達した積層体31は、ここでロール状に巻回されて、製品ロールとされても良い。図11では、不要材と汚染対策フィルムを分けて回収した構成を示しているが、これに限定されることはなく、同時に回収する事も可能である。
本発明の偏光性光学機能フィルム積層体に含まれている偏光フィルム12は、自動車のメーター表示部、スマートウォッチ、ゴーグル、スマートフォン、ノートパソコン、及びノートパッドを含む液晶表示装置、さらには有機EL表示装置等の光学表示デバイスまたはプラズマディスプレイパネル(PDP)等の光学的表示パネルといった多くの装置に利用されるため、図12A乃至図14に例示されているように、矩形形状のみならず、曲線状縁部や穴をもった形状のように、様々な形状に切断加工される。ここで、図12A、図12Bは、大判の偏光フィルムからスマートフォン形状に切り出された製品を製造する場合の切断加工レイアウト例を示す図であって、図12Aは全体を示す平面図、図12Bはその一部を拡大して示す平面図、図13A、図13Bは、大判の偏光フィルムから自動車メーターパネル形状に切り出された製品を製造する場合の切断加工レイアウト例を示す図であって、図13Aは全体を示す平面図、図13Bはその一部を拡大して示す平面図、図14は、スマートフォン形状に切り出された偏光フィルムの例を、複数枚並べて示す写真である。したがって、本発明は、それらすべての形状の切断加工に適用可能である。切断にレーザーを用いることで、曲率半径(R)の小さい曲線部を有する加工も可能となり、曲率半径Rが2mm以下の切断にも対応可能である。
以下、実施例等を参照しつつ本発明を具体的に説明する。しかしながら、以下に説明する実施例は、あくまで本発明の理解を助け、本発明が実施可能であることを示すために提示されるものであって、本発明は、これら実施例に限定されるものではない。
(偏光性光学機能フィルム積層体)
PVA系樹脂を主成分とする厚み30μmの高分子フィルムを、下記[1]~[5]の5浴に順次、フィルム長手方向に延伸可能な張力を付与しながら浸漬し、延伸倍率6倍(株式会社クラレ社製の高分子フィルム)で延伸した。この延伸フィルムを乾燥させて、厚み12μmの偏光子10を得た。
<条件>
[1]膨潤浴:30℃の純水
[2]染色浴:ヨウ素とヨウ化カリウムとを含む、30℃の水溶液
[3]第1の架橋浴:ヨウ化カリウムとホウ酸とを含む、40℃の水溶液
[4]第2の架橋浴:ヨウ化カリウムとホウ酸とを含む、60℃の水溶液
[5]洗浄浴:ヨウ化カリウムを含む、25℃の水溶液
以上により、偏光フィルム12を作製した。
レーザー発振器は、CO2レーザー(コヒレント社製J-3、波長9.4μm、ガウシアンビーム、パルス発振)を用い、対物レンズによって理論スポット径(ピーク値の1/e2の強度でスポット径を規定)が約90μmとなるように集光して、X―Yステージ及びガルバノスキャナを併用の上、所望の加工形状をレーザーパワー65W、繰り返し周波数30kHz、スキャン速度500mm/sで、1回スキャンして80mm×50mmの寸法の矩形形状に切断加工した。
シリコーン系粘着剤層17b(厚み75μm)及びポリエチレンテレフタレート基材17a(三菱ケミカル社製、T100-75S、厚み75μm)で構成されたシート材17を、上述のシリコーン系粘着剤層17bを介して、上述の偏光性光学機能フィルム積層体1Aの剥離ライナー16の主面16aに貼付した。
上記「レーザー」の項に記載したレーザー諸条件にて、シート材17及び汚染対策フィルム43が貼付された偏光性光学機能フィルム積層体1Aに対し、所望形状のレーザー切断加工を実施した。このレーザー切断加工により、偏光性光学機能フィルム積層体1Aは、シート材17のシリコーン系粘着剤層17bとともに厚み全体にわたりフルカットされ、一方、ポリエチレンテレフタレート基材17aは完全には切断されることなく、ハーフカット状態に切断加工がなされたことが確認された。
矩形形状にレーザー切断加工した偏光フィルムの試料から、シート材17及び汚染対策フィルム43を剥離し、切断面をエポキシ樹脂で包埋し、切断断面の状態をFE-SEM(走査型電子顕微鏡、日本電子株式会社製、JSM-7001F)で観察して、SEM画像を取得した(図7及び図9)。
また、偏光子10の切断端面の状態、言い換えれば、被覆層の状態を、同FE-SEMを用いて分子配向方向から観察してSEM画像を取得した(図15A)。この図15Aは、実施例1におけるSEM画像であって、図9の矢印「C」の方向から見たSEM画像に相当する。比較を容易にするため、図15Bに、実施例2における同様のSEM画像を、更に、図15C及び図15Dにそれぞれ、比較例1及び2における同様のSEM画像を示す。
これらの画像から分かるように、偏光子10の切断端面は、被覆層18a、18bによって確実に覆われている。
作製した矩形形状の偏光性光学機能フィルム積層体1Aの試料から表面保護フィルム14及び剥離ライナー16を剥離して、ガラス板に粘着剤層15の面が接触するように貼り合わせた。この状態で、試料を、温度65℃、湿度90%の環境に設定したオーブン内に入れて信頼性試験を行った。信頼性試験の条件は、上記環境のオーブン内に試料を240時間(10日間)保持し、高温高湿環境における加工端面における偏光フィルム12の色抜けによる偏光解消を観測するものであった。
前述の信頼性試験を経たサンプルを、光学顕微鏡(クロスニコル、透過照明)を用いて観測し、図4A、図4Bに関連して前述した定義に基づく、レーザー切断加工された切断端部からの偏光解消幅を測定した。
シート材17において、粘着剤層17bとしてアクリル系粘着剤層(厚み23μm)を使用し、樹脂フィルム基材17aとしてポリエチレンテレフタレート基材(厚み38μm)を使用したこと、及び、レーザーパワーを55Wに変更したこと以外は、実施例1と同じ条件で、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。
シート材17において、粘着剤層17bとしてゴム系粘着剤層(厚み10μm)を使用し、樹脂フィルム基材17aとしてポリエチレンテレフタレート基材(厚み38μm)を使用したこと、及び、レーザーパワーを55Wに変更したこと以外は、実施例1と同じ条件で、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。
偏光子10の厚みを5μmとし、保護フィルム11bを取り除いて、シリコーン系粘着剤層の厚みを20μmとした基材を用いること、レーザーパワーを35Wに変更したこと以外は、実施例2と同じ条件で、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。尚、図5は、実施例4の構成から汚染対策フィルムを取り除いたSEM画像に相当する。
シート材と汚染対策フィルム23を用いていない、実施例1記載の偏光性光学機能フィルム積層体1Aを、エンドミルを用いて、所定形状、即ち、80mm×50mmの寸法の矩形形状に切断加工した以外、実施例1と同じ条件で評価を行った。
シート材を用いないこと、及びレーザーパワーを55Wに変更したこと以外は、実施例1と同じ条件で、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。この場合、偏光性光学機能フィルム積層体1Aはフルカットされ、一方、剥離ライナー16は完全には切断されることなく、ハーフカット状態に切断加工がなされたことが確認された。
シート材と汚染対策フィルム23を用いていない、実施例4記載の偏光性光学機能フィルム積層体1Aを、比較例1と同じ条件でエンドミル加工し、得られた形状加工サンプルの評価を行った。
汚染対策フィルム23を用いないこと、及び、レーザーパワーを43Wに変更し、繰り返し周波数を15kHzとしたこと以外は、実施例1と同じ条件で、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。
その結果、偏光子の光吸収軸と平行な切断端面の偏光解消幅は122μmであり、光吸収軸と垂直な切断端面の偏光解消幅は195μmであった。後述の比較例と比べて、偏光解消幅を抑制することができた。
汚染対策フィルム23を用いないこと、及び、レーザーパワーを39Wに変更し、繰り返し周波数を15kHzとしたこと以外は、実施例2と同じ条件で、TOF-SIMSによる分析を行い、また、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。
図19は、TOF-SIMSによる分析結果を示す画像である。この図から、被覆層18bに限らず、被覆層18aにも、ポリエチレンテレフタレート(PET)の膜が形成されていることが確認された。
また、偏光子の光吸収軸と平行な切断端面の偏光解消幅は132μmであり、光吸収軸と垂直な切断端面の偏光解消幅は214μmであった。後述の比較例と比べて、偏光解消幅を抑制することができた。
汚染対策フィルム23を用いないこと、及び、レーザーパワーを20Wに変更し、繰り返し周波数を15kHzとし、スキャン回数を2回としたこと以外は、実施例2と同じ条件で、TOF-SIMSによる分析を行い、また、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。
図20は、TOF-SIMSによる分析結果を示す画像である。この図から、被覆層18bに限らず、被覆層18aにも、ポリエチレンテレフタレート(PET)の膜が形成されていることが確認された。
また、偏光子の光吸収軸と平行な切断端面の偏光解消幅は133μmであり、光吸収軸と垂直な切断端面の偏光解消幅は233μmであった。後述の比較例と比べて、偏光解消幅を抑制することができた。
また、レーザーパワーを弱くしてスキャンの回数を増やすことにより、レーザーパワーが強く、スキャンの回数が少ない場合と、遜色無い結果が得られることが明らかとなった。
シート材を用いないこと、及び、レーザーパワーを20Wに変更したこと以外は、実施例5と同じ条件で、TOF-SIMSによる分析を行い、また、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。この場合、偏光性光学機能フィルム積層体1Aの剥離ライナー16は完全には切断されることなく、ハーフカット状態に切断加工がなされたことが確認された。
図21は、TOF-SIMSによる分析結果を示す画像である。この図から、被覆層18a、18bには、ポリエチレンテレフタレート(PET)の膜が形成されていないことが確認された。
また、偏光子の光吸収軸と平行な切断端面の偏光解消幅は158μmであり、光吸収軸と垂直な切断端面の偏光解消幅は235μmであった。実施例5と比べて、偏光解消幅は大きくなった。
シート材を用いないこと、及び、レーザーパワーを27Wに変更したこと以外は、実施例6と同じ条件で、TOF-SIMSによる分析を行い、また、レーザー切断加工及び偏光子10の色抜けに起因する偏光解消の評価を実施した。
このレーザー切断加工では、偏光性光学機能フィルム積層体1Aは完全に切断され、フルカット状態に切断加工がなされたことが確認された。ここでは、シート材を設けていないことから、レーザーは、照射方向に完全に抜けた状態となった。
図22は、TOF-SIMSによる分析結果を示す画像である。この図から、被覆層18a、18bには、ポリエチレンテレフタレート(PET)の膜が形成されていないことが確認された。
また、偏光子の光吸収軸と平行な切断端面の偏光解消幅は163μmであり、光吸収軸と垂直な切断端面の偏光解消幅は268μmであった。実施例6と比べて、偏光解消幅は大きくなった。
汚染対策フィルム23及び表面保護フィルム14を用いないこと以外は、実施例1と同じ条件で、TOF-SIMSによる分析を行った。
図23は、TOF-SIMSによる分析結果を示す画像である。この図から、被覆層18bに限らず、被覆層18aにも、ポリエチレンテレフタレート(PET)の膜が形成されていることが確認された。
この結果、汚染対策フィルム23等が存在しない場合にも、被覆層18a、18bには、ポリエチレンテレフタレート(PET)の膜が形成されることが分かった。
剥離ライナー16とシート材17を用いないこと以外は、実施例1と同じ条件で、TOF-SIMSによる分析を行った。レーザー切断加工によって、偏光性光学機能フィルム積層体1及び粘着剤層15はフルカットした。
図24は、TOF-SIMSによる分析結果を示す画像である。この図から、被覆層18bに限らず、被覆層18aにも、ポリエチレンテレフタレート(PET)の膜が形成されていないことが確認された。
この結果、剥離ライナーとシート材を用いない場合には、汚染対策フィルム23等が存在しても、被覆層18a、18bには、ポリエチレンテレフタレート(PET)の膜が形成されないことが分かった。
被覆層18a、18bには、少なくとも、シート材17の成分、即ち、粘着剤層17bの成分、及び/又は、樹脂フィルム基材17aのPET成分が含まれる。従って、これらシート材の成分によって、特に粘着剤層17bについてはその成分を適当に選択することによって、切断端面を通じて外部から偏光子10へ水分が浸入してしまうことを効果的に防止して、色抜けの防止、言い換えれば、偏光解消幅の減少が期待できる。
また、偏光性光学機能フィルム積層体1が、粘着剤層15及び剥離ライナー16を含む偏光性光学機能フィルム積層体1Aを構成するものである場合には、粘着剤層15の成分によって、更には、剥離ライナー16由来のPET成分によって、被覆層18a、18bをより厚くして、水分の侵入を更に効果的に防止することができる。
Claims (13)
- 偏光子と該偏光子の少なくとも片側に積層された保護フィルムとを含む偏光フィルムを少なくとも有し、切断端面により形成される所定形状を有する偏光性光学機能フィルム積層体であって、前記切断端面のうち少なくとも前記偏光子の切断端面には、偏光性光学機能フィルム積層体には含まれない樹脂材料の成分を第1樹脂成分として含む被覆層が形成されていることを特徴とする偏光性光学機能フィルム積層体。
- 請求項1に記載した偏光性光学機能フィルム積層体であって、前記偏光性光学機能フィルム積層体の一方の面に粘着剤層を介して剥離ライナーが剥離可能に貼り合わされており、前記被覆層は、前記第1樹脂成分の他に、前記粘着剤層及び/又は前記剥離ライナーの成分を第2樹脂成分として含むことを特徴とする偏光性光学機能フィルム積層体。
- 請求項1又は2に記載の偏光性光学機能フィルム積層体であって、前記被覆層が、温度が40℃、湿度が90%RHの雰囲気のもとにおける透湿度が200g/m2・24h以下である材料を含むことを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至3のいずれかに記載の偏光性光学機能フィルム積層体であって、前記被覆層が、アクリル系、ゴム系、ウレタン系、シリコーン系、オレフィン系、またはポリエステル系の群から成るいずれかの高分子材料を含むことを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至4のいずれかに記載の偏光性光学機能フィルム積層体であって、前記被覆層が、前記保護フィルムの成分、及び/又は、前記偏光子と前記保護フィルムを接着する接着剤の成分を含むことを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至5のいずれかに記載の偏光性光学機能フィルム積層体であって、前記保護フィルムが、ジアセチルセルロース、トリアセチルセルロース(TAC)等のセルロース系樹脂、(メタ)アクリル系樹脂、シクロオレフィン系樹脂、ポリプロピレン等のオレフィン系樹脂、ポリエチレンテレフタレート系樹脂等のエステル系樹脂、ポリアミド系樹脂、ポリカーボネート系樹脂を含むことを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至6のいずれかに記載の偏光性光学機能フィルム積層体であって、前記偏光フィルムの一方の面に積層された表面保護フィルムの切断端面が、0以上20μm以下のバリを有することを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至7のいずれかに記載の偏光性光学機能フィルム積層体であって、前記偏光フィルムの一方の面に、ハードコート処理、反射防止処理及びアンチグレアを目的とした表面処理層が積層されていることを特徴とする請求項1乃至7のいずれかに記載の偏光性光学機能フィルム積層体。
- 請求項1乃至8のいずれかに記載の偏光性光学機能フィルム積層体であって、前記切断端面の少なくとも一部は、前記偏光子の光吸収軸方向と交差する方向に延びており、前記切断端面における前記偏光子の厚みが、前記切断端面近傍以外の偏光子の厚みと比べて1.1倍以上2.5倍以下であることを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至9のいずれかに記載の偏光性光学機能フィルム積層体が自動車のメーター表示部、スマートウォッチ、ゴーグル、スマートフォン、ノートパッド及びノートパソコンを含む液晶表示装置、有機EL表示装置またはプラズマディスプレイパネル(PDP)に搭載されていることを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至10のいずれかに記載の偏光性光学機能フィルム積層体であって、前記被覆層は厚みが10μm以下であることを特徴とする偏光性光学機能フィルム積層体。
- 請求項1乃至11のいずれかに記載の偏光性光学機能フィルム積層体に用いる前記偏光フィルム。
- 請求項12に記載の偏光フィルムであって、前記偏光フィルムは長尺状に巻回されていることを特徴とする偏光フィルム。
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WO2022054295A1 (ja) * | 2020-09-14 | 2022-03-17 | 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 |
WO2023080065A1 (ja) * | 2021-11-08 | 2023-05-11 | 日東電工株式会社 | 粘着剤層を有する積層フィルムの製造方法 |
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