WO2021100423A1 - Production method for optical layered product, adhesive application device, and production device for optical layered product - Google Patents

Production method for optical layered product, adhesive application device, and production device for optical layered product Download PDF

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WO2021100423A1
WO2021100423A1 PCT/JP2020/040368 JP2020040368W WO2021100423A1 WO 2021100423 A1 WO2021100423 A1 WO 2021100423A1 JP 2020040368 W JP2020040368 W JP 2020040368W WO 2021100423 A1 WO2021100423 A1 WO 2021100423A1
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adhesive
tank
film
coating
optical
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PCT/JP2020/040368
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French (fr)
Japanese (ja)
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山崎　達也
敏弘 小川
大地 植敷
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日東電工株式会社
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Priority to CN202080065851.8A priority Critical patent/CN114423598A/en
Priority to KR1020227000472A priority patent/KR20220016989A/en
Priority to JP2021558248A priority patent/JPWO2021100423A1/ja
Publication of WO2021100423A1 publication Critical patent/WO2021100423A1/en

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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
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/285—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyethers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • 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
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/55—Boron-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D163/00—Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D185/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing atoms other than silicon, sulfur, nitrogen, oxygen, and carbon; Coating compositions based on derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D4/00—Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00—Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40—Additives
    • C09D7/60—Additives non-macromolecular
    • C09D7/63—Additives non-macromolecular organic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/02—Non-macromolecular additives
    • C09J11/06—Non-macromolecular additives organic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J4/00—Adhesives based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond ; adhesives, based on monomers of macromolecular compounds of groups C09J183/00 - C09J183/16
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J7/00—Adhesives in the form of films or foils
    • C09J7/30—Adhesives in the form of films or foils characterised by the adhesive composition
    • 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
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • 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
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00—Optical elements other than lenses
    • G02B5/30—Polarising elements
    • G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
    • G02B5/305—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133528—Polarisers
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J201/00—Adhesives based on unspecified macromolecular compounds
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J201/00—Adhesives based on unspecified macromolecular compounds
    • C09J201/02—Adhesives based on unspecified macromolecular compounds characterised by the presence of specified groups, e.g. terminal or pendant functional groups
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J2301/00—Additional features of adhesives in the form of films or foils
    • C09J2301/40—Additional features of adhesives in the form of films or foils characterized by the presence of essential components
    • C09J2301/416—Additional features of adhesives in the form of films or foils characterized by the presence of essential components use of irradiation

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  • Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Optics & Photonics (AREA)
  • General Physics & Mathematics (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Nonlinear Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mathematical Physics (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Polarising Elements (AREA)

Abstract

[Problem] To provide a production method or the like for an optical layered product in which good adhesion is maintained, with a reduced running cost incurred for an adhesive and without a reduction in the manufacturing efficiency of the optical layered product. [Solution] The present invention comprises an adhesive application step for applying an actinic ray curable adhesive ad by using an adhesive application device 100 on at least a first optical film F1 or a second optical film F2, which are attached together to produce an optical layered product F. The adhesive application device comprises: an application machine 6 for applying an adhesive; a first tank 20 for storing the adhesive and supplying the adhesive to the application machine; and a second tank 30 that is for tightly sealing and storing the adhesive and supplying the adhesive to the first tank, and that has a larger storage amount of the adhesive than that of the first tank. In the adhesive application step, the adhesive is circulated between the first tank and the application machine, and when the amount of the adhesive stored in the first tank is not more than a predetermined value, the adhesive is supplied from the second tank to the first tank.

Description

光学積層体の製造方法、接着剤塗工装置及び光学積層体の製造装置Manufacturing method of optical laminate, adhesive coating equipment and manufacturing equipment of optical laminate
　本発明は、偏光子と保護フィルムとを接着剤を介して貼り合わせて偏光フィルムを製造するなど、第１光学フィルムと第２光学フィルムとを接着剤を介して貼り合わせて光学積層体を製造する方法、接着剤塗工装置及び光学積層体を製造する装置に関する。特に、本発明は、接着剤のランニングコストを抑制し且つ光学積層体の製造効率を損なうことなく、光学積層体における第１光学フィルムと第２光学フィルムとの間の良好な接着性を維持することが可能な光学積層体の製造方法、接着剤塗工装置及び光学積層体の製造装置に関する。 According to the present invention, a first optical film and a second optical film are bonded to each other via an adhesive to produce an optical laminate, for example, a polarizing element and a protective film are bonded to each other via an adhesive to produce a polarizing film. The present invention relates to an adhesive coating apparatus and an apparatus for producing an optical laminate. In particular, the present invention maintains good adhesiveness between the first optical film and the second optical film in the optical laminate without suppressing the running cost of the adhesive and impairing the production efficiency of the optical laminate. The present invention relates to a method for producing an optical laminate, an adhesive coating apparatus, and an apparatus for producing an optical laminate.
　従来、液晶表示装置や偏光サングラスなどの構成材料として、偏光子を含む偏光フィルムが使用されている。偏光フィルムは、例えば、ヨウ素などの二色性物質で染色した偏光子とこの偏光子を保護する保護フィルムとから構成されている。
　偏光フィルムは、例えば、特許文献１～３に記載のように、偏光子及び／又は保護フィルムに活性エネルギー線硬化型接着剤を塗工して、偏光子及び保護フィルムを貼り合わせ、偏光子と保護フィルムとの間の接着剤に活性エネルギー線を照射して接着剤を硬化させることで得られる。 Conventionally, a polarizing film containing a polarizing element has been used as a constituent material for a liquid crystal display device, polarized sunglasses, and the like. The polarizing film is composed of, for example, a polarizing element dyed with a dichroic substance such as iodine and a protective film that protects the polarizing element.
For the polarizing film, for example, as described in Patent Documents 1 to 3, a polarizing element and / or a protective film is coated with an active energy ray-curable adhesive, and the polarizing element and the protective film are bonded to the polarizing element. It is obtained by irradiating the adhesive between the protective film and the adhesive with active energy rays to cure the adhesive.
特開２０１７－１６０３１３号公報JP-A-2017-160313 特開２０１２－１４４６９０号公報Japanese Unexamined Patent Publication No. 2012-144690 国際公開第２０１７／１９９９７９号International Publication No. 2017/199979
　ここで、活性エネルギー線硬化型接着剤は、接着剤塗工装置によって、偏光子及び／又は保護フィルムに塗工される。一般的に、接着剤塗工装置は、グラビアコーター等の塗工機と、接着剤を貯留し塗工機に接着剤を供給するタンクとを備え、タンクと塗工機との間で接着剤を循環させている。
　このため、接着剤がタンク内に貯留されている間や、接着剤が循環している間に、接着剤が雰囲気中の水分を吸収したり、或いは、接着剤の溶媒成分が揮発したりして、接着剤の粘度が変化する。 Here, the active energy ray-curable adhesive is applied to the polarizer and / or the protective film by the adhesive coating device. Generally, an adhesive coating device includes a coating machine such as a gravure coater and a tank that stores the adhesive and supplies the adhesive to the coating machine, and an adhesive is provided between the tank and the coating machine. Is circulating.
Therefore, while the adhesive is stored in the tank or while the adhesive is circulating, the adhesive absorbs moisture in the atmosphere, or the solvent component of the adhesive volatilizes. As a result, the viscosity of the adhesive changes.
　接着剤の粘度が高すぎても低すぎても、偏光子と保護フィルムとの間の接着性が低下する。
　偏光フィルムには、安定した光学特性が求められるため、偏光子と保護フィルムとの間の良好な接着性を維持することが求められる。
　したがい、例えば、偏光フィルムと保護フィルムとの間の接着性が低下するタイミングを経験則的に把握し、タンク内に貯留された接着剤をこのタイミングまでに新品に交換する運用が行われている。
　しかしながら、タンク内に貯留された接着剤を交換する頻度が高いと、接着剤のランニングコストが高くなる。また、接着剤を交換する際には偏光フィルムの製造ラインを停止させる必要があるため、接着剤を交換する頻度が高いと、偏光フィルムの製造効率が損なわれる。 If the viscosity of the adhesive is too high or too low, the adhesiveness between the polarizer and the protective film will be reduced.
Since the polarizing film is required to have stable optical characteristics, it is required to maintain good adhesion between the polarizer and the protective film.
Therefore, for example, the timing at which the adhesiveness between the polarizing film and the protective film deteriorates is empirically grasped, and the adhesive stored in the tank is replaced with a new one by this timing. ..
However, if the adhesive stored in the tank is frequently replaced, the running cost of the adhesive increases. Further, since it is necessary to stop the production line of the polarizing film when the adhesive is replaced, if the adhesive is replaced frequently, the production efficiency of the polarizing film is impaired.
　なお、タンクと塗工機との間に、前記タンクよりも接着剤の貯留量が小さな補助タンクを設置する場合もある。そして、タンクから補助タンクに接着剤を供給し、補助タンクから塗工機に接着剤を供給する一方、塗工機で塗工されなかった接着剤をタンクに戻すことで、タンク、補助タンク及び塗工機間で接着剤を循環させる場合もある。一般的に、タンクは移動式とされており、接着剤を溶解する箇所から塗工機設置箇所まで運ばれて、古いタンクと交換される。これに対し、補助タンクは据え置き式とされるため、レベル計を設置して、補助タンク内に貯留されている接着剤の液面高さを測定することが可能である。したがい、補助タンクを設置する場合には、接着剤の枯渇を機械的に検知・防止可能である。
　しかしながら、上記の場合であっても、接着剤がタンク内や補助タンク内に貯留されている間や、接着剤が循環している間に、接着剤が雰囲気中の水分を吸収したり、或いは、接着剤の溶媒成分が揮発したりして、接着剤の粘度が変化する。このため、前述と同様に、接着剤のランニングコストが高くなったり、偏光フィルムの製造効率が損なわれるという問題が生じ得る。 In some cases, an auxiliary tank having a smaller amount of adhesive storage than the tank may be installed between the tank and the coating machine. Then, the adhesive is supplied from the tank to the auxiliary tank, and the adhesive is supplied from the auxiliary tank to the coating machine, while the adhesive that has not been applied by the coating machine is returned to the tank, so that the tank, the auxiliary tank and the auxiliary tank and the adhesive are supplied. In some cases, the adhesive is circulated between the coating machines. Generally, the tank is mobile and is carried from the place where the adhesive is melted to the place where the coating machine is installed and replaced with the old tank. On the other hand, since the auxiliary tank is a stationary type, it is possible to install a level meter and measure the liquid level height of the adhesive stored in the auxiliary tank. Therefore, when an auxiliary tank is installed, it is possible to mechanically detect and prevent the exhaustion of the adhesive.
However, even in the above case, the adhesive absorbs moisture in the atmosphere or absorbs moisture in the atmosphere while the adhesive is stored in the tank or the auxiliary tank or while the adhesive is circulated. , The solvent component of the adhesive volatilizes, and the viscosity of the adhesive changes. Therefore, as described above, there may be a problem that the running cost of the adhesive is high and the production efficiency of the polarizing film is impaired.
　なお、上記の説明では、偏光子と保護フィルムとを接着剤を介して貼り合わせることで得られる偏光フィルムを例に挙げたが、上記の問題は偏光フィルムに限るものではなく、第１光学フィルムと第２光学フィルムとを接着剤を介して貼り合わせることで得られる光学積層体に共通する問題である。
　したがい、本発明は、接着剤のランニングコストを抑制し且つ光学積層体の製造効率を損なうことなく、光学積層体における第１光学フィルムと第２光学フィルムとの間の良好な接着性を維持することが可能な光学積層体の製造方法、接着剤塗工装置及び光学積層体の製造装置を提供することを課題とする。 In the above description, a polarizing film obtained by bonding a polarizing element and a protective film via an adhesive has been given as an example, but the above problem is not limited to the polarizing film, and the first optical film is not limited to the polarizing film. This is a problem common to optical laminates obtained by bonding the second optical film and the second optical film via an adhesive.
Therefore, the present invention maintains good adhesiveness between the first optical film and the second optical film in the optical laminate without suppressing the running cost of the adhesive and impairing the production efficiency of the optical laminate. It is an object of the present invention to provide a method for producing an optical laminate, an adhesive coating apparatus, and an apparatus for producing an optical laminate.
　前記課題を解決するため、本発明は、第１光学フィルム及び第２光学フィルムのうち少なくとも一方に、接着剤塗工装置によって活性エネルギー線硬化型接着剤を塗工する接着剤塗工工程と、前記第１光学フィルムと前記第２光学フィルムとを前記接着剤を介して貼り合わせ、前記接着剤に活性エネルギー線を照射して前記接着剤を硬化させることで、光学積層体を作製する光学積層体作製工程と、を含み、前記接着剤塗工装置は、前記接着剤を塗工する塗工機と、前記接着剤を貯留し、前記塗工機に前記接着剤を供給する第１タンクと、前記接着剤を密封して貯留し、前記第１タンクに前記接着剤を供給する、前記第１タンクよりも前記接着剤の貯留量が大きな第２タンクとを、備え、前記接着剤塗工工程において、前記第１タンクと前記塗工機との間で前記接着剤を循環させると共に、前記第１タンク内の前記接着剤の貯留量が所定値以下となった場合に、前記第２タンクから前記第１タンクに前記接着剤を供給する、光学積層体の製造方法を提供する。 In order to solve the above problems, the present invention comprises an adhesive coating step of applying an active energy ray-curable adhesive to at least one of a first optical film and a second optical film by an adhesive coating device. Optical lamination for producing an optical laminate by laminating the first optical film and the second optical film via the adhesive and irradiating the adhesive with active energy rays to cure the adhesive. The adhesive coating apparatus includes a body manufacturing step, a coating machine for applying the adhesive, and a first tank for storing the adhesive and supplying the adhesive to the coating machine. A second tank, which seals and stores the adhesive and supplies the adhesive to the first tank, has a larger storage amount of the adhesive than the first tank, and is provided with the adhesive coating. In the step, when the adhesive is circulated between the first tank and the coating machine and the amount of the adhesive stored in the first tank becomes a predetermined value or less, the second tank To provide a method for producing an optical laminate, which supplies the adhesive to the first tank.
　本発明においても、接着剤が第１タンク内に貯留されている間や、接着剤が第１タンクと塗工機との間で循環している間に、第１タンクと塗工機との間にある接着剤は、雰囲気中の水分を吸収したり、或いは、接着剤の溶媒成分が揮発したりする可能性がある。
　しかしながら、本発明によれば、第１タンク内に貯留されている接着剤が第１光学フィルム及び／又は第２光学フィルムに塗工されて、第１タンク内の接着剤の貯留量が所定値以下となった場合に、第２タンクから第１タンクに接着剤が供給されることになる。第２タンクでは、接着剤が密封されて貯留されているため、雰囲気中の水分を吸収し難く、溶媒成分も揮発し難い。また、塗工機で塗工されなかった接着剤は、第２タンクには戻らず第１タンクに戻るため、第２タンク内には、第１タンクと塗工機との間の循環使用によって雰囲気中の水分を吸収した接着剤や、溶媒成分の揮発した接着剤が混入しない。このため、新品に近い接着剤が第２タンクから第１タンクに供給され、この新品に近い接着剤が第１タンクと塗工機との間で新たに循環することになる。第２タンクにおける接着剤の貯留量は第１タンクよりも大きいため、第２タンク内の接着剤が無くなるまで、第２タンク内の接着剤を交換することなく、長期に亘って使用可能である。
　したがい、本発明によれば、接着剤のランニングコストを抑制し且つ光学積層体の製造効率を損なうことなく、光学積層体における第１光学フィルムと第２光学フィルムとの間の良好な接着性を維持することが可能である。 Also in the present invention, while the adhesive is stored in the first tank and the adhesive is circulated between the first tank and the coating machine, the first tank and the coating machine are used. The adhesive in between may absorb moisture in the atmosphere or the solvent component of the adhesive may volatilize.
However, according to the present invention, the adhesive stored in the first tank is applied to the first optical film and / or the second optical film, and the amount of the adhesive stored in the first tank is a predetermined value. When the following cases occur, the adhesive is supplied from the second tank to the first tank. In the second tank, since the adhesive is sealed and stored, it is difficult to absorb the moisture in the atmosphere and the solvent component is also difficult to volatilize. Further, since the adhesive that has not been applied by the coating machine does not return to the second tank but returns to the first tank, the adhesive used in the second tank by circulation between the first tank and the coating machine. Adhesives that have absorbed moisture in the atmosphere and adhesives that have volatilized solvent components do not get mixed in. Therefore, an adhesive close to new is supplied from the second tank to the first tank, and the adhesive close to new is newly circulated between the first tank and the coating machine. Since the amount of adhesive stored in the second tank is larger than that in the first tank, it can be used for a long period of time without replacing the adhesive in the second tank until the adhesive in the second tank is exhausted. ..
Therefore, according to the present invention, good adhesiveness between the first optical film and the second optical film in the optical laminate can be obtained without suppressing the running cost of the adhesive and impairing the production efficiency of the optical laminate. It is possible to maintain.
　なお、本発明において、「第１光学フィルム及び第２光学フィルムのうち少なくとも一方に、接着剤塗工装置によって活性エネルギー線硬化型接着剤を塗工する接着剤塗工工程」には、例えば、（１）第１光学フィルム及び第２光学フィルムの双方に、接着剤塗工装置によって活性エネルギー線硬化型接着剤を塗工する工程、（２）第１光学フィルムに、接着剤塗工装置によって活性エネルギー線硬化型接着剤を塗工し、第２光学フィルムに、本発明の接着剤塗工装置によって易接着組成物を塗工する工程、（３）第２光学フィルムに、接着剤塗工装置によって活性エネルギー線硬化型接着剤を塗工し、第１光学フィルムに、本発明の接着剤塗工装置によって易接着組成物を塗工する工程、の何れの工程も含まれる。 In the present invention, for example, in the "adhesive coating step of applying an active energy ray-curable adhesive to at least one of the first optical film and the second optical film by an adhesive coating device", for example. (1) A step of applying an active energy ray-curable adhesive to both the first optical film and the second optical film by an adhesive coating device, and (2) a step of applying an active energy ray-curable adhesive to the first optical film by an adhesive coating device. A step of applying an active energy ray-curable adhesive and applying an easy-adhesive composition to the second optical film by the adhesive coating apparatus of the present invention. (3) Adhesive coating to the second optical film. Any step of applying the active energy ray-curable adhesive by the apparatus and applying the easy-adhesive composition to the first optical film by the adhesive coating apparatus of the present invention is included.
　好ましくは、前記接着剤塗工工程において、前記接着剤の塗工開始時の２５℃での粘度が１ｍＰａ・ｓ～１００ｍＰａ・ｓである。
　上記の好ましい方法における粘度を維持できれば、第１光学フィルムと第２光学フィルムとの間の良好な接着性を維持し易い。 Preferably, in the adhesive coating step, the viscosity of the adhesive at the start of coating at 25 ° C. is 1 mPa · s to 100 mPa · s.
If the viscosity in the above preferred method can be maintained, it is easy to maintain good adhesiveness between the first optical film and the second optical film.
　好ましくは、前記接着剤塗工工程において、前記接着剤の塗工厚みが０．１μｍ～５μｍである。
　上記の好ましい方法のように薄い塗工厚みでは、塗工機としてグラビアコーターが好適に用いられ、グラビアコーターを用いると、第１光学フィルム及び／又は第２光学フィルムに塗工されずに余る（オーバーフローする）接着剤が生じ易い。このため、接着剤を循環使用することになり、本発明が好適に用いられる。 Preferably, in the adhesive coating step, the coating thickness of the adhesive is 0.1 μm to 5 μm.
With a thin coating thickness as in the preferred method above, a gravure coater is preferably used as the coating machine, and when the gravure coater is used, the first optical film and / or the second optical film is not coated (remaining). (Overflow) Adhesive is likely to occur. Therefore, the adhesive is circulated and used, and the present invention is preferably used.
　好ましくは、前記接着剤は、水酸基を含有する。
　接着剤が水酸基を含有すると、雰囲気中の水分を吸収し易い。したがい、水酸基を含有する接着剤の場合に、本発明が好適に用いられる。 Preferably, the adhesive contains a hydroxyl group.
When the adhesive contains a hydroxyl group, it easily absorbs moisture in the atmosphere. Therefore, the present invention is preferably used in the case of an adhesive containing a hydroxyl group.
　好ましくは、前記接着剤は、ＳＰ値が２９．０（ＭＪ／ｍ３）１／２以上３２．０（ＭＪ／ｍ３）１／２以下であるラジカル重合性化合物、又は、２１．０（ＭＪ／ｍ３）１／２以上２３．０（ＭＪ／ｍ３）１／２以下であるラジカル重合性化合物を含有する。
　接着剤のＳＰ値（溶解性パラメータ）が上記のような場合には、第１光学フィルムとして偏光子を用い、第２光学フィルムとして保護フィルムを用いた場合に、一般的に用いられる偏光子や保護フィルムの材料とＳＰ値が近くなり、接着性の向上に寄与する。また、ＳＰ値が比較的大きく、雰囲気中の水分を吸収し易いため、本発明が好適に用いられる。 Preferably, the adhesive is a radically polymerizable compound having an SP value of 29.0 (MJ / m 3 ) 1/2 or more and 32.0 (MJ / m 3 ) 1/2 or less, or 21.0 (21.0). containing MJ / m 3) 1/2 or more 23.0 (MJ / m 3) radically polymerizable compound is 1/2 or less.
When the SP value (solubility parameter) of the adhesive is as described above, when a polarizer is used as the first optical film and a protective film is used as the second optical film, a polarizing element which is generally used or The SP value becomes close to that of the protective film material, which contributes to the improvement of adhesiveness. Further, since the SP value is relatively large and it is easy to absorb moisture in the atmosphere, the present invention is preferably used.
　好ましくは、前記接着剤は、水を含有する。
　接着剤が水を含有すると、第１光学フィルムとして偏光子を用いた場合、偏光子表面を水が膨潤、可塑化することにより、偏光子と接着剤との間の水素結合、イオン結合、共有結合などの各種物理、化学結合が形成されやすくなり、結果として接着性が向上する。 Preferably, the adhesive contains water.
When the adhesive contains water, when a polarizer is used as the first optical film, the water swells and plasticizes the surface of the polarizer, resulting in hydrogen bonds, ionic bonds, and sharing between the polarizer and the adhesive. Various physical and chemical bonds such as bonds are easily formed, and as a result, adhesiveness is improved.
　好ましくは、前記接着剤は、金属アルコキシド及び金属キレートからなる群より選択される少なくとも１種の有機金属化合物を含有する。
　接着剤が上記の有機金属化合物を含有すると、接着性・耐水性が向上する。 Preferably, the adhesive contains at least one organometallic compound selected from the group consisting of metal alkoxides and metal chelates.
When the adhesive contains the above-mentioned organometallic compound, the adhesiveness and water resistance are improved.
　好ましくは、前記接着剤は、カチオン重合性官能基を含有する。
　接着剤がカチオン重合性官能基（例えば、エポキシ基、オキセタニル基、オキセタン基、ビニルエーテル基、スピロオルトエステル基）を含有すると、第１光学フィルムとして偏光子を用いた場合、偏光子表面に存在する酸基と接着剤との間に、より強い相互作用が生じ、水分存在下でも簡単に剥離し難い層間接着性が発現する。 Preferably, the adhesive contains a cationically polymerizable functional group.
When the adhesive contains a cationically polymerizable functional group (for example, an epoxy group, an oxetanyl group, an oxetane group, a vinyl ether group, or a spirolothoester group), it is present on the surface of the polarizer when a polarizer is used as the first optical film. A stronger interaction occurs between the acid group and the adhesive, and interlayer adhesion that is difficult to easily peel off even in the presence of water is exhibited.
　本発明は、前記第１光学フィルムが偏光子であり、前記第２光学フィルムが保護フィルムであり、前記光学積層体が偏光フィルムである場合に、好適に用いられる。
　ただし、本発明はこれに限られるものではなく、第１光学フィルム及び第２光学フィルムの組み合わせとして、偏光子、保護フィルム、位相差フィルム、アンチグレアフィルム、輝度向上フィルム、視野角向上フィルム、透明導電性フィルムなど、種々の光学フィルムの組み合わせに適用可能である。 The present invention is preferably used when the first optical film is a polarizer, the second optical film is a protective film, and the optical laminate is a polarizing film.
However, the present invention is not limited to this, and as a combination of the first optical film and the second optical film, a polarizer, a protective film, a retardation film, an antiglare film, a brightness improving film, a viewing angle improving film, and transparent conductivity are used. It can be applied to various combinations of optical films such as sex films.
　また、前記課題を解決するため、本発明は、第１光学フィルム及び第２光学フィルムのうち少なくとも一方に、活性エネルギー線硬化型接着剤を塗工する接着剤塗工装置であって、前記接着剤を塗工する塗工機と、前記接着剤を貯留し、前記塗工機との間で前記接着剤を循環させながら前記塗工機に前記接着剤を供給する第１タンクと、前記接着剤を密封して貯留し、前記第１タンクに前記接着剤を供給する、前記第１タンクよりも前記接着剤の貯留量が大きな第２タンクと、前記第１タンク内の前記接着剤の貯留量が所定値以下となった場合に、前記第２タンクから前記第１タンクに前記接着剤を供給させる制御装置と、を備える接着剤塗工装置としても提供される。 Further, in order to solve the above problems, the present invention is an adhesive coating apparatus for applying an active energy ray-curable adhesive to at least one of a first optical film and a second optical film, and the adhesion is described above. A coating machine for coating an agent, a first tank for storing the adhesive and supplying the adhesive to the coating machine while circulating the adhesive between the coating machines, and the adhesion. A second tank in which the agent is sealed and stored and the adhesive is supplied to the first tank, and the amount of the adhesive stored is larger than that of the first tank, and storage of the adhesive in the first tank. It is also provided as an adhesive coating device including a control device for supplying the adhesive from the second tank to the first tank when the amount becomes a predetermined value or less.
　さらに、前記課題を解決するため、本発明は、前記接着剤塗工装置と、前記接着剤を介して貼り合わされた前記第１光学フィルム及び前記第２光学フィルム間の前記接着剤に活性エネルギー線を照射して硬化させる活性エネルギー線照射装置と、を備える光学積層体の製造装置としても提供される。 Further, in order to solve the above problems, the present invention presents an active energy ray to the adhesive between the adhesive coating device and the first optical film and the second optical film bonded via the adhesive. It is also provided as an apparatus for manufacturing an optical laminate including an active energy ray irradiation apparatus for irradiating and curing the film.
　本発明によれば、接着剤のランニングコストを抑制し且つ光学積層体の製造効率を損なうことなく、光学積層体における第１光学フィルムと第２光学フィルムとの間の良好な接着性を維持することが可能である。 According to the present invention, good adhesion between the first optical film and the second optical film in the optical laminate is maintained without suppressing the running cost of the adhesive and impairing the production efficiency of the optical laminate. It is possible.
本発明の一実施形態に係る光学積層体（偏光フィルム）の製造方法を適用する光学積層体（偏光フィルム）の製造装置の概略構成例を模式的に示す図である。It is a figure which shows typically the schematic structural example of the manufacturing apparatus of the optical laminated body (polarizing film) to which the manufacturing method of the optical laminated body (polarizing film) which concerns on one Embodiment of this invention is applied. 図１に示す接着剤塗工装置１００の具体的な構成例を模式的に示す図である。It is a figure which shows typically the specific structural example of the adhesive coating apparatus 100 shown in FIG. 図２に示す屈折率計２３で測定した接着剤の屈折率の変化と、測定した屈折率から演算した接着剤の水分率の変化との一例を示す図である。It is a figure which shows an example of the change of the refractive index of an adhesive measured by the refractive index meter 23 shown in FIG. 2, and the change of the moisture content of an adhesive calculated from the measured refractive index. 実施例１～４及び比較例１～４で得られた剥離力の測定結果を示す。The measurement results of the peeling force obtained in Examples 1 to 4 and Comparative Examples 1 to 4 are shown.
　以下、添付図面を参照しつつ、本発明の一実施形態に係る光学積層体の製造方法、接着剤塗工装置及び光学積層体の製造装置について、第１光学フィルムが偏光子であり、第２光学フィルムが保護フィルムであり、光学積層体が偏光フィルムである場合を例に挙げて説明する。したがい、本実施形態では、「光学積層体」を「偏光フィルム」と称し、「第１光学フィルム」を「偏光子」と称し、「第２光学フィルム」を「保護フィルム」と称する。
　なお、本明細書において、「下限値Ｘ～上限値Ｙ」で表される数値範囲は、下限値Ｘ以上上限値Ｙ以下を意味する。前記数値範囲が別個に複数記載されている場合、任意の下限値と任意の上限値とを選択して、「任意の下限値～任意の上限値」を設定できるものとする。
　また、各図は、参考的に表したものであり、各図に表された部材などの寸法、縮尺及び形状は、実際のものとは異なっている場合があることに留意されたい。 Hereinafter, with reference to the attached drawings, regarding the method for manufacturing an optical laminate, the adhesive coating device, and the device for manufacturing an optical laminate according to an embodiment of the present invention, the first optical film is a polarizer and the second The case where the optical film is a protective film and the optical laminate is a polarizing film will be described as an example. Therefore, in the present embodiment, the "optical laminate" is referred to as a "polarizing film", the "first optical film" is referred to as a "polarizer", and the "second optical film" is referred to as a "protective film".
In the present specification, the numerical range represented by "lower limit value X to upper limit value Y" means a lower limit value X or more and an upper limit value Y or less. When a plurality of the numerical values are described separately, it is possible to select an arbitrary lower limit value and an arbitrary upper limit value and set "arbitrary lower limit value to arbitrary upper limit value".
Also, please note that each figure is shown for reference only, and the dimensions, scale, and shape of the members shown in each figure may differ from the actual ones.
　図１は、本実施形態に係る偏光フィルムの製造方法を適用する偏光フィルムの製造装置の概略構成例を模式的に示す図である。図１に示す矢符は、各フィルムの搬送方向を意味する。
　本実施形態に係る偏光フィルムの製造装置は、接着剤塗工装置１００と、活性エネルギー線照射装置８と、を備える他、一般的な偏光フィルムの製造装置が備える従来公知の各種構成要素を備えている。
　なお、本発明に係る偏光フィルムの製造装置は、偏光子Ｆ１を製造した後、その偏光子Ｆ１に保護フィルムＦ２を連続的に接着する形式でもよく、或いは、偏光子Ｆ１を別途準備しておき、その偏光子Ｆ１に保護フィルムＦ２を接着する形式でもよい。前者の形式は、偏光子Ｆ１の製造から保護フィルムＦ２を接着して偏光フィルムＦを得るまでの一連の工程を１つの製造ライン上で行う形式であり、後者の形式は、偏光子Ｆ１の製造を１つの製造ライン上で行い、その偏光子Ｆ１に保護フィルムＦ２を接着して偏光フィルムＦを得る工程を別の製造ライン上で行う形式である。
　図１に示す製造装置は、偏光子Ｆ１の製造から少なくとも保護フィルムＦ２を接着して偏光フィルムＦを得るまでの一連の工程を１つの製造ライン上で行うロールツーロール形式である。 FIG. 1 is a diagram schematically showing a schematic configuration example of a polarizing film manufacturing apparatus to which the polarizing film manufacturing method according to the present embodiment is applied. The arrow marks shown in FIG. 1 mean the transport direction of each film.
The polarizing film manufacturing apparatus according to the present embodiment includes an adhesive coating apparatus 100, an active energy ray irradiation apparatus 8, and various conventionally known components included in a general polarizing film manufacturing apparatus. ing.
The polarizing film manufacturing apparatus according to the present invention may be in the form of continuously adhering the protective film F2 to the polarizing element F1 after manufacturing the polarizing element F1, or the polarizing element F1 may be prepared separately. , The protective film F2 may be adhered to the polarizer F1. The former type is a type in which a series of steps from the production of the polarizing element F1 to the adhesion of the protective film F2 to obtain the polarizing film F is performed on one production line, and the latter type is the production of the polarizer F1. Is performed on one production line, and the step of adhering the protective film F2 to the polarizing element F1 to obtain the polarizing film F is performed on another production line.
The manufacturing apparatus shown in FIG. 1 is a roll-to-roll type in which a series of steps from manufacturing the polarizer F1 to at least adhering the protective film F2 to obtain the polarizing film F is performed on one production line.
　図１に示す製造設備を用いて偏光フィルムＦを製造するにあたっては、まず、繰出ローラ１に巻回された原反フィルムＦ０を繰り出し、処理槽２（例えば、原反フィルムＦ０の搬送方向上流側から順に、膨潤処理槽、染色処理槽、架橋処理槽、延伸処理槽、洗浄処理槽から構成される）内の処理浴に浸漬して、ヨウ素や二色性染料等の二色性物質で染色すると共に一軸延伸する。次いで、オーブン３で乾燥させることで、偏光子Ｆ１を得る。偏光子Ｆ１は、特定の１つの方向のみに振動する光（偏光）を透過し、それ以外の方向に振動する光を遮断する性質を有する光学素子である。本実施形態の偏光子Ｆ１は、柔軟なフィルム状である。 In manufacturing the polarizing film F using the manufacturing equipment shown in FIG. 1, first, the raw film F0 wound around the feeding roller 1 is fed, and the processing tank 2 (for example, the upstream side in the transport direction of the raw film F0) is fed. Immerse in a treatment bath (consisting of a swelling treatment tank, a dyeing treatment tank, a cross-linking treatment tank, a stretching treatment tank, and a cleaning treatment tank) and dye with a dichroic substance such as iodine or a dichroic dye. And uniaxially stretch. Then, it is dried in the oven 3 to obtain the polarizer F1. The polarizer F1 is an optical element having a property of transmitting light (polarized light) that vibrates in only one specific direction and blocking light that vibrates in the other direction. The polarizer F1 of the present embodiment is in the form of a flexible film.
　原反フィルムＦ０は、長尺帯状である。本明細書において、長尺帯状は、長手方向の長さが短手方向（長手方向と直交する方向）の長さよりも十分に大きい長方形状を意味する。長尺帯状の長手方向の長さは、例えば、１０ｍ以上であり、好ましくは５０ｍ以上である。
　原反フィルムＦ０としては、特に限定されないが、二色性物質による染色性に優れていることから、好ましくは、親水性ポリマーフィルム（例えば、ポリビニルアルコール系フィルムなど）を含むフィルムが用いられ、より好ましくは、親水性ポリマーフィルムが用いられる。親水性ポリマーフィルムを含むフィルムとしては、親水性ポリマーフィルムと非親水性ポリマーフィルムとが積層されたフィルムが挙げられる。この場合、非親水性ポリマーフィルムの表面及び／又は裏面に親水性ポリマーフィルムが積層されていることが好ましい。この場合、非親水性ポリマーフィルムの表面及び／又は裏面に積層される親水性ポリマーフィルムは、厚み数μｍ程度の薄い膜状であってもよい。 The raw film F0 has a long strip shape. In the present specification, the long strip shape means a rectangular shape whose length in the longitudinal direction is sufficiently larger than the length in the lateral direction (direction orthogonal to the longitudinal direction). The length of the long strip in the longitudinal direction is, for example, 10 m or more, preferably 50 m or more.
The raw film F0 is not particularly limited, but a film containing a hydrophilic polymer film (for example, a polyvinyl alcohol-based film) is preferably used because it is excellent in dyeability with a bicolor substance. Preferably, a hydrophilic polymer film is used. Examples of the film containing the hydrophilic polymer film include a film in which a hydrophilic polymer film and a non-hydrophilic polymer film are laminated. In this case, it is preferable that the hydrophilic polymer film is laminated on the front surface and / or the back surface of the non-hydrophilic polymer film. In this case, the hydrophilic polymer film laminated on the front surface and / or the back surface of the non-hydrophilic polymer film may be in the form of a thin film having a thickness of about several μm.
　親水性ポリマーフィルムとしては、特に限定されず、従来公知のフィルムを使用できる。具体的には、親水性ポリマーフィルムとしては、例えば、ポリビニルアルコール（ＰＶＡ）系フィルム、部分ホルマール化ＰＶＡ系フィルム、ポリエチレンテレフタレート（ＰＥＴ）フィルム、エチレン・酢酸ビニル共重合体系フィルム、これらの部分ケン化フィルムなどが挙げられる。また、これらの他にも、ＰＶＡの脱水処理物やポリ塩化ビニルの脱塩酸処理物などのポリエン配向フィルム、延伸配向されたポリビニレン系フィルムなども使用できる。これらの中でも、特に二色性物質による染色性に優れることから、ＰＶＡ系ポリマーフィルムが好ましい。
　ＰＶＡ系ポリマーフィルムの原料ポリマーとしては、例えば、酢酸ビニルを重合した後にケン化したポリマー、酢酸ビニルに対して少量の不飽和カルボン酸や不飽和スルホン酸等の共重合可能なモノマーを共重合したポリマー、などが挙げられる。ＰＶＡ系ポリマーの重合度は、特に限定されないが、水に対する溶解度の点等から、５００～１００００が好ましく、より好ましくは、１０００～６０００である。また、ＰＶＡ系ポリマーのケン化度は、７５モル％以上が好ましく、より好ましくは、９８モル％～１００モル％である。
　未処理の原反フィルムＦ０の厚みは、特に限定されないが、例えば、１５μｍ～１１０μｍである。 The hydrophilic polymer film is not particularly limited, and conventionally known films can be used. Specifically, examples of the hydrophilic polymer film include polyvinyl alcohol (PVA) -based film, partially formalized PVA-based film, polyethylene terephthalate (PET) film, ethylene / vinyl acetate copolymer film, and partial saponification of these. Examples include films. In addition to these, polyene-oriented films such as a dehydrated product of PVA and a dehydrochlorinated product of polyvinyl chloride, a stretch-oriented polyvinylene-based film, and the like can also be used. Among these, a PVA-based polymer film is particularly preferable because it is excellent in dyeability with a dichroic substance.
As the raw material polymer of the PVA-based polymer film, for example, a polymer obtained by polymerizing vinyl acetate and then saponified, or a copolymerizable monomer such as a small amount of unsaturated carboxylic acid or unsaturated sulfonic acid is copolymerized with vinyl acetate. Polymers, etc. may be mentioned. The degree of polymerization of the PVA-based polymer is not particularly limited, but is preferably 500 to 10000, more preferably 1000 to 6000, from the viewpoint of solubility in water and the like. The degree of saponification of the PVA-based polymer is preferably 75 mol% or more, more preferably 98 mol% to 100 mol%.
The thickness of the untreated raw film F0 is not particularly limited, but is, for example, 15 μm to 110 μm.
　処理槽２が、原反フィルムＦ０の搬送方向上流側から順に、膨潤処理槽、染色処理槽、架橋処理槽、延伸処理槽、洗浄処理槽から構成される場合（図示せず）、各槽は、例えば、以下に述べる構成を有する。 When the treatment tank 2 is composed of a swelling treatment tank, a dyeing treatment tank, a cross-linking treatment tank, a stretching treatment tank, and a cleaning treatment tank in this order from the upstream side in the transport direction of the raw film F0 (not shown), each tank is For example, it has the configuration described below.
　＜膨潤処理槽＞
　膨潤処理槽は、膨潤処理液が収容された処理槽である。膨潤処理液は、原反フィルムＦ０を膨潤させる。膨潤処理液としては、例えば、水を使用することができる。さらに、水に、グリセリンやヨウ化カリウムなどのヨウ素化合物を適量加えた水を膨潤処理液としてもよい。グリセリンを添加する場合、その濃度は５重量％以下が好ましく、ヨウ化カリウムなどのヨウ素化合物を添加する場合、その濃度は１０重量％以下が好ましい。 <Swelling treatment tank>
The swelling treatment tank is a treatment tank in which the swelling treatment liquid is stored. The swelling treatment liquid swells the raw film F0. As the swelling treatment liquid, for example, water can be used. Further, water obtained by adding an appropriate amount of an iodine compound such as glycerin or potassium iodide to water may be used as the swelling treatment liquid. When glycerin is added, the concentration is preferably 5% by weight or less, and when an iodine compound such as potassium iodide is added, the concentration is preferably 10% by weight or less.
　＜染色処理槽＞
　染色処理槽は、染色処理液が収容された処理槽である。染色処理液は、原反フィルムＦ０を染色する。染色処理液としては、有効成分として二色性物質を含む溶液が挙げられる。二色性物質としては、ヨウ素、有機染料などが挙げられる。好ましくは、染色処理液として、ヨウ素を溶媒に溶解させた溶液を使用できる。溶媒としては、水が一般的に使用されるが、水と相溶性のある有機溶媒が更に添加されてもよい。染色処理液中のヨウ素の濃度としては、特に限定されないが、０．０１重量％～１０重量％であることが好ましく、０．０２重量％～７重量％の範囲がより好ましく、０．０２５重量％～５重量％であることがさらに好ましい。染色効率をより一層向上させるために、必要に応じて、染色処理液にヨウ素化合物を添加してもよい。ヨウ素化合物は、分子内にヨウ素とヨウ素以外の元素とを含む化合物であり、例えば、ヨウ化カリウム、ヨウ化リチウム、ヨウ化ナトリウム、ヨウ化亜鉛、ヨウ化アルミニウム、ヨウ化鉛、ヨウ化銅、ヨウ化バリウム、ヨウ化カルシウム、ヨウ化錫、ヨウ化チタンなどが挙げられる。 <Dyeing tank>
The dyeing treatment tank is a treatment tank containing a dyeing treatment liquid. The dyeing solution dyes the raw film F0. Examples of the dyeing solution include a solution containing a dichroic substance as an active ingredient. Examples of the dichroic substance include iodine and organic dyes. Preferably, as the dyeing treatment liquid, a solution in which iodine is dissolved in a solvent can be used. Water is generally used as the solvent, but an organic solvent compatible with water may be further added. The concentration of iodine in the dyeing solution is not particularly limited, but is preferably 0.01% by weight to 10% by weight, more preferably 0.02% by weight to 7% by weight, and 0.025% by weight. It is more preferably% to 5% by weight. If necessary, an iodine compound may be added to the dyeing solution in order to further improve the dyeing efficiency. The iodine compound is a compound containing iodine and an element other than iodine in the molecule, and is, for example, potassium iodide, lithium iodide, sodium iodide, zinc iodide, aluminum iodide, lead iodide, copper iodide, etc. Examples thereof include barium iodide, calcium iodide, tin iodide, and titanium iodide.
　＜架橋処理槽＞
　架橋処理槽は、架橋処理液が収容された処理槽である。架橋処理液は、染色された原反フィルムＦ０を架橋する。架橋処理液としては、有効成分としてホウ素化合物を含む溶液を使用できる。例えば、架橋処理液としては、ホウ素化合物を溶媒に溶解させた溶液が使用できる。溶媒としては、水が一般的に使用されるが、水と相溶性のある有機溶媒が更に添加されてもよい。ホウ素化合物としては、ホウ酸、ホウ砂などが挙げられる。架橋処理液中のホウ素化合物の濃度としては、特に限定されないが、１重量％～１０重量％であることが好ましく、２重量％～７重量％がより好ましく、２重量％～６重量％であることがさらに好ましい。さらに、均一な光学特性を有する偏光子が得られることから、必要に応じて、架橋処理液にヨウ素化合物を添加してもよい。 <Crosslink processing tank>
The cross-linking treatment tank is a treatment tank containing a cross-linking treatment liquid. The cross-linking treatment liquid cross-links the dyed raw film F0. As the cross-linking treatment liquid, a solution containing a boron compound as an active ingredient can be used. For example, as the cross-linking treatment liquid, a solution in which a boron compound is dissolved in a solvent can be used. Water is generally used as the solvent, but an organic solvent compatible with water may be further added. Examples of the boron compound include boric acid and borax. The concentration of the boron compound in the cross-linking treatment liquid is not particularly limited, but is preferably 1% by weight to 10% by weight, more preferably 2% by weight to 7% by weight, and 2% by weight to 6% by weight. Is even more preferable. Further, since a polarizer having uniform optical characteristics can be obtained, an iodine compound may be added to the cross-linking treatment liquid, if necessary.
　＜延伸処理槽＞
　延伸処理槽は、延伸処理液が収容された処理槽である。
　延伸処理液は、特に限定されないが、例えば、有効成分としてホウ素化合物を含む溶液を使用できる。延伸処理液としては、例えば、ホウ素化合物、及び必要に応じて、各種金属塩、亜鉛化合物などを溶媒に溶解させた溶液が使用できる。溶媒としては、水が一般的に使用されるが、水と相溶性のある有機溶媒が更に添加されてもよい。延伸処理液中のホウ素化合物の濃度としては、特に限定されないが、１重量％～１０重量％であることが好ましく、２重量％～７重量％がより好ましい。フィルムに吸着させたヨウ素の溶出を抑制する観点から、必要に応じて、延伸処理液に、ヨウ素化合物を添加してもよい。 <Stretching tank>
The stretching treatment tank is a treatment tank containing the stretching treatment liquid.
The stretching treatment liquid is not particularly limited, but for example, a solution containing a boron compound as an active ingredient can be used. As the stretching treatment liquid, for example, a solution in which a boron compound and, if necessary, various metal salts, zinc compounds and the like are dissolved in a solvent can be used. Water is generally used as the solvent, but an organic solvent compatible with water may be further added. The concentration of the boron compound in the stretching treatment liquid is not particularly limited, but is preferably 1% by weight to 10% by weight, more preferably 2% by weight to 7% by weight. From the viewpoint of suppressing the elution of iodine adsorbed on the film, an iodine compound may be added to the stretching treatment liquid, if necessary.
　＜洗浄処理槽＞
　洗浄処理槽は、洗浄処理液が収容された処理槽である。洗浄処理液は、延伸後の原反フィルムＦ０を洗浄する。洗浄処理液は、原反フィルムＦ０に付着した染色処理液や架橋処理液などの処理液を洗浄するための処理液である。洗浄処理液としては、代表的には、イオン交換水、蒸留水、純水などの水が用いられる。 <Washing tank>
The cleaning treatment tank is a treatment tank in which the cleaning treatment liquid is stored. The cleaning treatment liquid cleans the raw film F0 after stretching. The cleaning treatment liquid is a treatment liquid for cleaning the treatment liquid such as the dyeing treatment liquid and the cross-linking treatment liquid adhering to the raw film F0. As the cleaning treatment liquid, water such as ion-exchanged water, distilled water, and pure water is typically used.
　オーブン３は、以上に説明した処理槽２を構成する洗浄処理槽の下流側に設けられている。オーブン３は、処理後のフィルムを乾燥するために設けられている。
　なお、以上に説明した例では、処理槽２は、膨潤処理槽、染色処理槽、架橋処理槽、延伸処理槽及び洗浄処理槽を有するが、これらのうちの１つ又は２つの処理槽を省略してもよい。他方、処理槽２は、調整処理槽（図示せず）を更に有していてもよい。調整処理槽は、調整処理液が収容された処理槽である。この調整処理槽は、架橋処理槽と延伸処理槽との間、又は、延伸処理槽と洗浄処理槽との間に設けられる。調整処理液は、フィルムの色相調整などのための溶液であり、有効成分としてヨウ素化合物を含む溶液を使用できる。
　洗浄後の原反フィルムＦ０をオーブン３で乾燥させて得られるフィルムが、偏光子Ｆ１である。 The oven 3 is provided on the downstream side of the cleaning treatment tank constituting the treatment tank 2 described above. The oven 3 is provided to dry the treated film.
In the example described above, the treatment tank 2 has a swelling treatment tank, a dyeing treatment tank, a cross-linking treatment tank, a stretching treatment tank, and a cleaning treatment tank, but one or two of these treatment tanks is omitted. You may. On the other hand, the treatment tank 2 may further have an adjustment treatment tank (not shown). The adjustment treatment tank is a treatment tank in which the adjustment treatment liquid is stored. This adjustment treatment tank is provided between the cross-linking treatment tank and the stretching treatment tank, or between the stretching treatment tank and the cleaning treatment tank. The adjusting treatment liquid is a solution for adjusting the hue of the film, and a solution containing an iodine compound as an active ingredient can be used.
The film obtained by drying the washed raw film F0 in the oven 3 is the polarizer F1.
　次いで、図１に示すように、偏光子Ｆ１の両面に接着剤塗工装置１００で活性エネルギー線硬化型接着剤を塗工する（本発明の接着剤塗工工程に相当）。また、繰出ローラ５から繰り出された保護フィルムＦ２の片面に接着剤塗工装置１００で活性エネルギー線硬化型接着剤を塗工する。そして、貼り合わせローラ７によって、接着剤が塗工された保護フィルムＦ２を、接着剤が塗工された偏光子Ｆ１の両面に貼り合わせる。
　接着剤の塗工厚みは、特に限定されないが、あまりに小さいと、フィルムの接着強度が低下し、あまりに大きいと、偏光フィルムＦの厚みが相対的に大きくなりすぎる。かかる観点から、偏光子Ｆ１及び保護フィルムＦ２への接着剤の塗工厚みは、それぞれ独立して、０．１μｍ～５μｍであることが好ましい。
　また、塗工開始時の接着剤の粘度は、特に限定されないが、あまりに小さい又は大きいと、塗工開始時から接着剤の接着性の低下を生じる。かかる観点から、接着剤は、塗工開始時の２５℃での粘度が１ｍＰａ・ｓ～１００ｍＰａ・ｓに調整されていることが好ましく、塗工開始時の２５℃での粘度が１０ｍＰａ・ｓ～５０ｍＰａ・ｓに調整されていることがより好ましく、１５ｍＰａ・ｓ～４５ｍＰａ・ｓに調整されていることが特に好ましい。
　接着剤塗工装置１００の具体的な構成や、接着剤塗工装置１００で塗工する接着剤の種類については、後述する。 Next, as shown in FIG. 1, an active energy ray-curable adhesive is applied to both surfaces of the polarizer F1 with an adhesive coating device 100 (corresponding to the adhesive coating step of the present invention). Further, the active energy ray-curable adhesive is applied to one side of the protective film F2 fed from the feeding roller 5 by the adhesive coating device 100. Then, the protective film F2 coated with the adhesive is bonded to both sides of the polarizing element F1 coated with the adhesive by the bonding roller 7.
The coating thickness of the adhesive is not particularly limited, but if it is too small, the adhesive strength of the film is lowered, and if it is too large, the thickness of the polarizing film F becomes relatively large. From this point of view, the coating thickness of the adhesive on the polarizer F1 and the protective film F2 is preferably 0.1 μm to 5 μm, respectively.
The viscosity of the adhesive at the start of coating is not particularly limited, but if it is too small or too large, the adhesiveness of the adhesive will decrease from the start of coating. From this point of view, it is preferable that the viscosity of the adhesive at 25 ° C. at the start of coating is adjusted to 1 mPa · s to 100 mPa · s, and the viscosity at 25 ° C. at the start of coating is 10 mPa · s ~. It is more preferably adjusted to 50 mPa · s, and particularly preferably adjusted to 15 mPa · s to 45 mPa · s.
The specific configuration of the adhesive coating device 100 and the types of adhesives coated by the adhesive coating device 100 will be described later.
　保護フィルムＦ２は、長尺帯状である。また、保護フィルムＦ２は、偏光子Ｆ１よりも親水性が低い（疎水性を有する）フィルムである。保護フィルムＦ２としては、透明性、機械的強度、熱安定性、水分遮断性、等方性などに優れるものが好ましい。例えば、ポリエチレンテレフタレートやポリエチレンナフタレートなどのポリエステル系ポリマー、ジアセチルセルロースやトリアセチルセルロースなどのセルロース系ポリマー、ポリメチルメタクリレートなどのアクリル系ポリマー、ポリスチレンやアクリロニトリル・スチレン共重合体（ＡＳ樹脂）などのスチレン系ポリマー、ポリカーボネート系ポリマーなどが挙げられる。また、ポリエチレン、ポリプロピレン、シクロ系又はノルボルネン構造を有するポリオレフィン、エチレン・プロピレン共重合体の如きポリオレフィン系ポリマー、塩化ビニル系ポリマー、ナイロンや芳香族ポリアミドなどのアミド系ポリマー、イミド系ポリマー、スルホン系ポリマー、ポリエーテルスルホン系ポリマー、ポリエーテルエーテルケトン系ポリマー、ポリフェニレンスルフィド系ポリマー、ビニルアルコール系ポリマー、塩化ビニリデン系ポリマー、ビニルブチラール系ポリマー、アリレート系ポリマー、ポリオキシメチレン系ポリマー、エポキシ系ポリマー、又は上記ポリマーのブレンド物なども保護フィルムＦ２を形成するポリマーの例として挙げられる。保護フィルムＦ２中には任意の適切な添加剤が１種類以上含まれていてもよい。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。保護フィルムＦ２中の上記熱可塑性樹脂の含有量は、好ましくは５０～１００重量％、より好ましくは５０～９９重量％、さらに好ましくは６０～９８重量％、特に好ましくは７０～９７重量％である。保護フィルムＦ２中の上記熱可塑性樹脂の含有量が５０重量％以下の場合、熱可塑性樹脂が本来有する高透明性などが十分に発現できないおそれがある。 The protective film F2 has a long strip shape. Further, the protective film F2 is a film having lower hydrophilicity (having hydrophobicity) than the polarizer F1. The protective film F2 preferably has excellent transparency, mechanical strength, thermal stability, moisture blocking property, isotropic property, and the like. For example, polyester polymers such as polyethylene terephthalate and polyethylene naphthalate, cellulose polymers such as diacetyl cellulose and triacetyl cellulose, acrylic polymers such as polymethyl methacrylate, and styrene such as polystyrene and acrylonitrile-styrene copolymer (AS resin). Examples thereof include based polymers and polystyrene polymers. In addition, polyethylene, polypropylene, polyolefins having a cyclo- or norbornene structure, polyolefin-based polymers such as ethylene / propylene copolymers, vinyl chloride-based polymers, amide-based polymers such as nylon and aromatic polyamide, imide-based polymers, and sulfone-based polymers. , Polyether sulfone polymer, polyether ether ketone polymer, polyphenylene sulfide polymer, vinyl alcohol polymer, vinylidene chloride polymer, vinyl butyral polymer, allylate polymer, polyoxymethylene polymer, epoxy polymer, or the above. Polymer blends and the like are also examples of polymers that form the protective film F2. The protective film F2 may contain one or more of any suitable additives. Examples of the additive include an ultraviolet absorber, an antioxidant, a lubricant, a plasticizer, a mold release agent, an antioxidant, a flame retardant, a nucleating agent, an antistatic agent, a pigment, a coloring agent and the like. The content of the thermoplastic resin in the protective film F2 is preferably 50 to 100% by weight, more preferably 50 to 99% by weight, still more preferably 60 to 98% by weight, and particularly preferably 70 to 97% by weight. .. When the content of the thermoplastic resin in the protective film F2 is 50% by weight or less, the high transparency inherent in the thermoplastic resin may not be sufficiently exhibited.
　また、保護フィルムＦ２としては、特開２００１－３４３５２９号公報に記載のポリマーフィルム、例えば、（Ａ）側鎖に置換及び／又は非置換イミド基を有する熱可塑性樹脂と、側鎖に置換及び／又は非置換フェニル並びにニトリル基を有する熱可塑性樹脂とを含有する樹脂組成物が挙げられる。具体例としては、イソブチレンとＮ－メチルマレイミドからなる交互共重合体とアクリロニトリル・スチレン共重合体とを含有する樹脂組成物のフィルムが挙げられる。フィルムとしては、樹脂組成物の混合押出品などからなるフィルムを用いることができる。これらのフィルムは位相差が小さく、光弾性係数が小さいため偏光フィルムＦの歪みによるムラなどの不具合を解消することができ、また透湿度が小さいため、加湿耐久性に優れる。 Further, the protective film F2 includes a polymer film described in JP-A-2001-343529, for example, (A) a thermoplastic resin having a substituted and / or unsubstituted imide group in the side chain, and substituted and / in the side chain. Alternatively, a resin composition containing an unsubstituted phenyl and a thermoplastic resin having a nitrile group can be mentioned. Specific examples include a film of a resin composition containing an alternating copolymer composed of isobutylene and N-methylmaleimide and an acrylonitrile / styrene copolymer. As the film, a film made of a mixed extruded product of the resin composition or the like can be used. Since these films have a small phase difference and a small photoelastic coefficient, problems such as unevenness due to distortion of the polarizing film F can be eliminated, and since the moisture permeability is small, they are excellent in humidification durability.
　次いで、図１に示すように、活性エネルギー線照射装置８から偏光子Ｆ１及び保護フィルムＦ２間の接着剤に活性エネルギー線を照射して硬化させた後、オーブン９で乾燥させる。活性エネルギー線は、活性エネルギー線硬化型接着剤の硬化性に応じて適宜選択される。活性エネルギー線としては、電子線、紫外線、可視光線などが挙げられる。最後に、両面に保護フィルムＦ２が貼り合わせられた偏光子Ｆ１の片面に、繰出ローラ１０から繰り出された長尺帯状の表面保護フィルムＦ３を貼り合わせローラ１１によって貼り合わせることで、長尺帯状の偏光フィルムＦが得られる。得られた偏光フィルムＦは、巻取ローラ１２で巻き取られる。
　偏光子Ｆ１と保護フィルムＦ２とを接着剤を介して貼り合わせ、接着剤に活性エネルギー線を照射して接着剤を硬化させることで偏光フィルムＦを作製する工程が、本発明の光学積層体作製工程に相当する。 Next, as shown in FIG. 1, the adhesive between the polarizer F1 and the protective film F2 is irradiated with the active energy ray from the active energy ray irradiation device 8 to be cured, and then dried in the oven 9. The active energy ray is appropriately selected according to the curability of the active energy ray-curable adhesive. Examples of the active energy ray include an electron beam, ultraviolet rays, and visible light. Finally, a long strip-shaped surface protective film F3 unwound from the feeding roller 10 is bonded to one side of the polarizing element F1 to which the protective film F2 is bonded on both sides by the bonding roller 11 to form a long strip. The polarizing film F is obtained. The obtained polarizing film F is wound by the winding roller 12.
The process of producing a polarizing film F by adhering a polarizing element F1 and a protective film F2 via an adhesive and irradiating the adhesive with active energy rays to cure the adhesive is the process of producing the optical laminate of the present invention. Corresponds to the process.
　なお、図１に示す例では、偏光子Ｆ１及び保護フィルムＦ２の双方に活性エネルギー線硬化型接着剤を塗工しているが、偏光子Ｆ１の両面にのみ接着剤を塗工することも可能である。この場合、図１に示す計４台の接着剤塗工装置１００のうち、図１の下側（フィルムの搬送方向下流側）２台の接着剤塗工装置１００は不要である。また、保護フィルムＦ２の片面にのみ接着剤を塗工することも可能である。この場合、図１に示す計４台の接着剤塗工装置１００のうち、図１の上側（フィルムの搬送方向上流側）２台の接着剤塗工装置１００は不要である。さらに、図１に示す例では、偏光子Ｆ１の両面に保護フィルムＦ２を貼り合わせているため、接着剤塗工装置１００を図１の左右に一対配置し、活性エネルギー線照射装置８を左右に一対配置しているが、偏光子Ｆ１の片面にのみ保護フィルムＦ２を貼り合わせる場合には、接着剤塗工装置１００及び活性エネルギー線照射装置８は、図１の左右何れかに１台配置するだけでよい。 In the example shown in FIG. 1, the active energy ray-curable adhesive is applied to both the polarizer F1 and the protective film F2, but it is also possible to apply the adhesive only to both sides of the polarizer F1. Is. In this case, out of the total of four adhesive coating devices 100 shown in FIG. 1, the two adhesive coating devices 100 on the lower side (downstream side in the film transport direction) of FIG. 1 are unnecessary. It is also possible to apply the adhesive only to one side of the protective film F2. In this case, out of the total of four adhesive coating devices 100 shown in FIG. 1, the two adhesive coating devices 100 on the upper side (upstream side in the film transport direction) of FIG. 1 are unnecessary. Further, in the example shown in FIG. 1, since the protective films F2 are attached to both sides of the polarizer F1, a pair of adhesive coating devices 100 are arranged on the left and right sides of FIG. 1, and the active energy ray irradiation devices 8 are placed on the left and right sides. Although a pair is arranged, when the protective film F2 is attached only to one side of the polarizer F1, one adhesive coating device 100 and one active energy ray irradiating device 8 are arranged on either the left or right side of FIG. Just need it.
　図２は、接着剤塗工装置１００の具体的な構成例を模式的に示す図である。図２は、各構成要素の内部を適宜透視した状態で図示している。
　図２に示すように、本実施形態の接着剤塗工装置１００は、接着剤ａｄを偏光子Ｆ１又は保護フィルムＦ２（図２では図示省略）に塗工する塗工機６と、接着剤ａｄを貯留し、塗工機６との間で接着剤ａｄを循環させながら塗工機６に接着剤ａｄを供給する第１タンク２０と、接着剤ａｄを密封して貯留し、第１タンク２０に接着剤ａｄを供給する、第１タンク２０よりも接着剤ａｄの貯留量が大きな第２タンク３０と、第１タンク２０内の接着剤ａｄの貯留量が所定値以下となった場合に、第２タンク３０から第１タンク２０に接着剤ａｄを供給させる制御装置４０と、を備えている。 FIG. 2 is a diagram schematically showing a specific configuration example of the adhesive coating device 100. FIG. 2 shows a state in which the inside of each component is appropriately seen through.
As shown in FIG. 2, the adhesive coating device 100 of the present embodiment includes an coating machine 6 for applying the adhesive ad to the polarizer F1 or the protective film F2 (not shown in FIG. 2) and the adhesive ad. The first tank 20 for supplying the adhesive ad to the coating machine 6 while circulating the adhesive ad with the coating machine 6 and the first tank 20 for sealing and storing the adhesive ad. When the amount of adhesive ad stored in the second tank 30 is larger than that of the first tank 20, and the amount of adhesive ad stored in the first tank 20 is equal to or less than a predetermined value. A control device 40 for supplying the adhesive ad from the second tank 30 to the first tank 20 is provided.
　塗工機６としては、グラビアコータが好適に用いられる。グラビアコータは、表面に複数のセル（供給された接着剤ａｄが入る凹部）が形成されたグラビアロールを有し、このグラビアロール６１が偏光子Ｆ１又は保護フィルムＦ２に接触することにより、セル内の接着剤ａｄが偏光子Ｆ１又は保護フィルムＦ２の片面に転写される。このようにして、グラビアロールから偏光子Ｆ１又は保護フィルムＦ２の片面に、それぞれ接着剤ａｄがベタ状に塗工される。 A gravure coater is preferably used as the coating machine 6. The gravure coater has a gravure roll in which a plurality of cells (recesses into which the supplied adhesive ad enters) are formed on the surface, and the gravure roll 61 comes into contact with the polarizer F1 or the protective film F2 in the cell. Adhesive ad is transferred to one side of the polarizer F1 or the protective film F2. In this way, the adhesive ad is applied solidly from the gravure roll to one side of the polarizer F1 or the protective film F2.
　本実施形態の接着剤塗工装置１００は、供給管２１、ポンプ２２、屈折率計２３及び排出管２４を更に備えている。
　第１タンク２０内に貯留されている接着剤ａｄは、供給管２１に取り付けられたポンプ２２によって、下端が第１タンク２０内に挿入されて接着剤ａｄに浸漬された供給管２１を通じて吸い上げられ、塗工機６に供給される。供給管２１には、屈折率計２３が取り付けられており、供給管２１中を流れる接着剤ａｄの屈折率が屈折率計２３によって連続的に測定される。屈折率計２３としては、従来公知の屈折率計を種々適用可能であり、例えば、全反射臨界角からスネルの法則を用いて屈折率を導出する方法を測定原理とするＡＴＡＧＯ社製のプロセス屈折計「ＰＲＭ－１００α」を用いることができる。 The adhesive coating device 100 of the present embodiment further includes a supply pipe 21, a pump 22, a refractive index meter 23, and a discharge pipe 24.
The adhesive ad stored in the first tank 20 is sucked up by the pump 22 attached to the supply pipe 21 through the supply pipe 21 whose lower end is inserted into the first tank 20 and immersed in the adhesive ad. , Is supplied to the coating machine 6. A refractive index meter 23 is attached to the supply pipe 21, and the refractive index of the adhesive ad flowing through the supply pipe 21 is continuously measured by the refractive index meter 23. As the refractive index meter 23, various conventionally known refractometers can be applied. For example, a process refraction manufactured by ATAGO whose measurement principle is a method of deriving a refractive index from the total reflection critical angle using Snell's law. A total "PRM-100α" can be used.
　一方、塗工機６で偏光子Ｆ１又は保護フィルムＦ２に塗工されなかった接着剤ａｄは、下端が第１タンク２０内に挿入された排出管２４を通じて第１タンク２０内に戻る。
　以上のようにして、接着剤ａｄは、第１タンク２０と塗工機６との間で循環しながら使用される。 On the other hand, the adhesive ad, which has not been applied to the polarizer F1 or the protective film F2 by the coating machine 6, returns to the inside of the first tank 20 through the discharge pipe 24 whose lower end is inserted into the first tank 20.
As described above, the adhesive ad is used while circulating between the first tank 20 and the coating machine 6.
　本実施形態の接着剤塗工装置１００は、袋体３１、結束バンド３２、第１供給管３３、重り３４、継手３５、第２供給管３６及び蓋体３７を更に備えている。
　第２タンク３０内には、内部に接着剤ａｄが収容されて上端部が結束バンド３２で縛られた袋体３１が収容されている。これにより、第２タンク３０内には、接着剤ａｄが密封されて貯留される。袋体３１内には、ゴム製ホース等の可撓性を有する第１供給管３３が挿入されている。第１供給管３３の下端が袋体３１の底面近傍に位置するように、第１供給管３３の下端には重り３４が取り付けられている。第１供給管３３は、袋体３１の上端部及び結束バンド３２内を通り、その上端が継手３５に接続されている。この継手３５には、ゴム製ホース等の可撓性を有する第２供給管３６も接続されており、継手３５を介して、第１供給管３３と第２供給管３６とが連通している。第２タンク３０内（袋体３１内）に貯留されている接着剤ａｄは、第２供給管３６に取り付けられたポンプ４２によって、第１供給管３３の下端から、第１供給管３３、継手３５及び第２供給管３６を通じて吸い上げられ、第２供給管３６の下端から排出されて、第１タンク２０に供給される。 The adhesive coating device 100 of the present embodiment further includes a bag body 31, a binding band 32, a first supply pipe 33, a weight 34, a joint 35, a second supply pipe 36, and a lid 37.
Inside the second tank 30, the adhesive ad is housed and the bag body 31 whose upper end is bound by the binding band 32 is housed. As a result, the adhesive ad is sealed and stored in the second tank 30. A flexible first supply pipe 33 such as a rubber hose is inserted in the bag 31. A weight 34 is attached to the lower end of the first supply pipe 33 so that the lower end of the first supply pipe 33 is located near the bottom surface of the bag 31. The first supply pipe 33 passes through the upper end portion of the bag body 31 and the binding band 32, and the upper end thereof is connected to the joint 35. A flexible second supply pipe 36 such as a rubber hose is also connected to the joint 35, and the first supply pipe 33 and the second supply pipe 36 communicate with each other via the joint 35. .. The adhesive ad stored in the second tank 30 (inside the bag 31) is connected to the first supply pipe 33 from the lower end of the first supply pipe 33 by the pump 42 attached to the second supply pipe 36. It is sucked up through the 35 and the second supply pipe 36, discharged from the lower end of the second supply pipe 36, and supplied to the first tank 20.
　第２タンク３０内（袋体３１内）の接着剤ａｄの貯留量は、第１タンク２０内の接着剤ａｄの貯留量よりも大きい。例えば、第２タンク３０内の接着剤ａｄの貯留量が１８０リットルであるのに対し、第１タンク２０内の接着剤ａｄの貯留量は３０リットル以下である。第１タンク２０内の接着剤ａｄの貯留量に対し、第２タンク３０内の接着剤ａｄの貯留量は、２～５０倍程度であることが好ましい。 The amount of adhesive ad stored in the second tank 30 (inside the bag 31) is larger than the amount of adhesive ad stored in the first tank 20. For example, the storage amount of the adhesive ad in the second tank 30 is 180 liters, while the storage amount of the adhesive ad in the first tank 20 is 30 liters or less. The amount of the adhesive ad stored in the second tank 30 is preferably about 2 to 50 times the amount of the adhesive ad stored in the first tank 20.
　なお、第２タンク３０から第１タンク２０に接着剤ａｄを供給する際には、図２に示すように、第２タンク３０の上端開口を閉塞するための蓋体３７を開いて、継手３５に第２供給管３６を接続することになる。一方、第２タンク３０内で接着剤ａｄを調製する際には、継手３５から第２供給管３６を取り外し、蓋体３７を閉じればよい。この際、蓋体３７の下面に目止め（図示せず）を設け、継手３５の第２供給管３６との接続箇所にこの目止めで栓をすれば、第２タンク３０内における接着剤ａｄの密封状態を維持可能である。 When supplying the adhesive ad from the second tank 30 to the first tank 20, as shown in FIG. 2, the lid 37 for closing the upper end opening of the second tank 30 is opened to open the joint 35. The second supply pipe 36 will be connected to. On the other hand, when preparing the adhesive ad in the second tank 30, the second supply pipe 36 may be removed from the joint 35 and the lid 37 may be closed. At this time, if a seal (not shown) is provided on the lower surface of the lid 37 and the joint 35 is plugged with the seal at the connection point with the second supply pipe 36, the adhesive ad in the second tank 30 is ad. It is possible to maintain the sealed state of.
　本実施形態の制御装置４０は、コンピュータやＰＬＣ（Programmable Logic Controller）から構成される制御装置本体４１と、ポンプ４２と、レベル計４３と、を具備する。レベル計４３としては、従来公知のレベル計（液面計）を種々適用可能であり、例えば、ガイドパルス方式を測定原理とするキーエンス社製のガイドパルス式レベルセンサ「ＦＬ－００１」を用いることができる。
　制御装置本体４１には、レベル計４３で測定した第１タンク２０内に貯留されている接着剤ａｄの液面高さ測定値が入力される。制御装置本体４１は、入力された液面高さ測定値が予め設定したしきい値以下となった場合（すなわち、第１タンク２０内の接着剤ａｄの貯留量が所定値以下となった場合）に、ポンプ４２に対し、ポンプ４２を駆動する制御信号を送信する。これにより、ポンプ４２が駆動し、第２タンク３０内（袋体３１内）に貯留されている接着剤ａｄが、第１供給管３３の下端から、第１供給管３３、継手３５及び第２供給管３６を通じて吸い上げられ、第２供給管３６の下端から排出されて、第１タンク２０に供給される。
　以上のようにして、制御装置４０は、第１タンク２０内の接着剤ａｄの貯留量が所定値以下となった場合に、第２タンク３０から第１タンク２０に接着剤ａｄを供給させる。 The control device 40 of the present embodiment includes a control device main body 41 composed of a computer and a PLC (Programmable Logic Controller), a pump 42, and a level meter 43. As the level meter 43, various conventionally known level meters (liquid level meters) can be applied. For example, a guide pulse type level sensor "FL-001" manufactured by KEYENCE Co., Ltd., which uses a guide pulse method as a measurement principle, is used. Can be done.
The liquid level height measurement value of the adhesive ad stored in the first tank 20 measured by the level meter 43 is input to the control device main body 41. When the input liquid level height measurement value of the control device main body 41 is equal to or less than a preset threshold value (that is, when the amount of adhesive ad stored in the first tank 20 is equal to or less than a predetermined value). ), A control signal for driving the pump 42 is transmitted to the pump 42. As a result, the pump 42 is driven, and the adhesive ad stored in the second tank 30 (inside the bag 31) is released from the lower end of the first supply pipe 33 to the first supply pipe 33, the joint 35, and the second. It is sucked up through the supply pipe 36, discharged from the lower end of the second supply pipe 36, and supplied to the first tank 20.
As described above, the control device 40 causes the second tank 30 to supply the adhesive ad to the first tank 20 when the amount of the adhesive ad stored in the first tank 20 becomes equal to or less than a predetermined value.
　以上に説明した構成を有する接着剤塗工装置１００で塗工する接着剤ａｄとしては、活性エネルギー線硬化型接着剤が用いられる。つまり、接着剤塗工装置１００の第２タンク３０内には、未硬化の活性エネルギー線硬化型接着剤が調製されて貯留されている。
　活性エネルギー線硬化型接着剤としては、従来公知のものを使用できる。活性エネルギー線硬化型接着剤は、一般に、活性エネルギー線硬化性成分及び重合開始剤を含み、必要に応じて、各種の添加剤を含む。
　活性エネルギー線硬化性成分は、電子線硬化性、紫外線硬化性、可視光線硬化性に大別できる。また、活性エネルギー線硬化性成分は、硬化のメカニズムの観点では、ラジカル重合性化合物とカチオン重合性化合物とに大別できる。 As the adhesive ad to be coated by the adhesive coating apparatus 100 having the configuration described above, an active energy ray-curable adhesive is used. That is, an uncured active energy ray-curable adhesive is prepared and stored in the second tank 30 of the adhesive coating apparatus 100.
As the active energy ray-curable adhesive, conventionally known ones can be used. The active energy ray-curable adhesive generally contains an active energy ray-curable component and a polymerization initiator, and optionally contains various additives.
The active energy ray-curable component can be roughly classified into electron beam curability, ultraviolet curability, and visible light curability. Further, the active energy ray-curable component can be roughly classified into a radical-polymerizable compound and a cationically polymerizable compound from the viewpoint of the curing mechanism.
　ラジカル重合性化合物としては、（メタ）アクリロイル基、ビニル基などの炭素－炭素二重結合のラジカル重合性の官能基を有する化合物が挙げられる。また、単官能ラジカル重合性化合物又は二官能以上の多官能ラジカル重合性化合物のいずれも用いることができる。また、これらラジカル重合性化合物は、１種単独で又は２種以上を併用してもよい。ラジカル重合性化合物としては、（メタ）アクリロイル基を有する化合物が好ましく、例えば、（メタ）アクリルアミド基を有する（メタ）アクリルアミド誘導体、（メタ）アクリロイルオキシ基を有する（メタ）アクリレートなどが挙げられる。
　活性エネルギー線硬化型接着剤としてラジカル重合性化合物を用いる場合の重合開始剤は、活性エネルギー線に応じて適宜に選択される。紫外線又は可視光線により接着剤を硬化させる場合には、紫外線開裂又は可視光線開裂の重合開始剤が用いられる。このような重合開始剤としては、例えば、ベンゾフェノン系化合物、芳香族ケトン化合物、アセトフェノン系化合物、芳香族ケタール系化合物、芳香族スルホニルクロリド系化合物、チオキサントン系化合物などが挙げられる。 Examples of the radically polymerizable compound include compounds having a radically polymerizable functional group of a carbon-carbon double bond such as a (meth) acryloyl group and a vinyl group. Moreover, either a monofunctional radical polymerizable compound or a bifunctional or higher functional radical polymerizable compound can be used. Further, these radically polymerizable compounds may be used alone or in combination of two or more. The radically polymerizable compound is preferably a compound having a (meth) acryloyl group, and examples thereof include a (meth) acrylamide derivative having a (meth) acrylamide group and a (meth) acrylate having a (meth) acryloyloxy group.
When a radically polymerizable compound is used as the active energy ray-curable adhesive, the polymerization initiator is appropriately selected according to the active energy ray. When the adhesive is cured by ultraviolet rays or visible light, an ultraviolet cleaving or visible light cleaving polymerization initiator is used. Examples of such a polymerization initiator include benzophenone compounds, aromatic ketone compounds, acetophenone compounds, aromatic ketal compounds, aromatic sulfonyl chloride compounds, and thioxanthone compounds.
　カチオン重合性化合物としては、分子内にカチオン重合性官能基を１つ有する単官能カチオン重合性化合物、分子内にカチオン重合性官能基を２つ以上有する多官能カチオン重合性化合物などが挙げられる。カチオン重合性官能基としては、エポキシ基、オキセタニル基、オキセタン基、ビニルエーテル基、スピロオルトエステル基などが挙げられる。エポキシ基を有するカチオン重合性化合物としては、脂肪族エポキシ化合物、脂環式エポキシ化合物、芳香族エポキシ化合物などが挙げられる。オキセタニル基を有するカチオン重合性化合物としては、３－エチル－３－ヒドロキシメチルオキセタン、１，４－ビス［（３－エチル－３－オキセタニル）メトキシメチル］ベンゼン、３－エチル－３－（フェノキシメチル）オキセタンなどが挙げられる。ビニルエーテル基を有するカチオン重合性化合物としては、２－ヒドロキシエチルビニルエーテル、ジエチレングリコールモノビニルエーテル、４－ヒドロキシブチルビニルエーテルなどが挙げられる。
　活性エネルギー線硬化型接着剤としてカチオン重合性化合物を用いる場合、カチオン重合開始剤が配合される。このカチオン重合開始剤は、可視光線、紫外線、電子線などの活性エネルギー線の照射によって、カチオン種又はルイス酸を発生し、カチオン重合性化合物のエポキシ基などと重合反応を開始する。カチオン重合開始剤としては、光酸発生剤と光塩基発生剤とを使用することができる。 Examples of the cationically polymerizable compound include a monofunctional cationically polymerizable compound having one cationically polymerizable functional group in the molecule, a polyfunctional cationically polymerizable compound having two or more cationically polymerizable functional groups in the molecule, and the like. Examples of the cationically polymerizable functional group include an epoxy group, an oxetanyl group, an oxetane group, a vinyl ether group, a spiroorthoester group and the like. Examples of the cationically polymerizable compound having an epoxy group include an aliphatic epoxy compound, an alicyclic epoxy compound, and an aromatic epoxy compound. Examples of the cationically polymerizable compound having an oxetanyl group include 3-ethyl-3-hydroxymethyloxetane, 1,4-bis [(3-ethyl-3-oxetanyl) methoxymethyl] benzene, and 3-ethyl-3- (phenoxymethyl). ) Oxetane and the like. Examples of the cationically polymerizable compound having a vinyl ether group include 2-hydroxyethyl vinyl ether, diethylene glycol monovinyl ether, and 4-hydroxybutyl vinyl ether.
When a cationically polymerizable compound is used as the active energy ray-curable adhesive, a cationic polymerization initiator is blended. This cationic polymerization initiator generates a cationic species or Lewis acid by irradiation with active energy rays such as visible light, ultraviolet rays, and electron beams, and initiates a polymerization reaction with an epoxy group of a cationically polymerizable compound. As the cationic polymerization initiator, a photoacid generator and a photobase generator can be used.
　本発明においては、３８０ｎｍ～４５０ｎｍの可視光線を含む光で硬化する活性エネルギー線硬化型接着剤を用いることもできる。この場合、ラジカル重合性化合物と重合開始剤とを含む活性エネルギー線硬化型接着剤を用いることが好ましい。
　このような活性エネルギー線硬化型接着剤は、例えば、特開２０１８－０９２１８６号公報に開示されており、本発明の活性エネルギー線硬化型接着剤として、上記公報に記載の活性エネルギー線硬化型接着剤を用いることができる。本明細書においては、紙面の都合上、上記公報の記載を転記することを省略するが、上記公報の接着剤に関する記載を本明細書にそのまま取り込めるものとする。 In the present invention, an active energy ray-curable adhesive that cures with light containing visible light of 380 nm to 450 nm can also be used. In this case, it is preferable to use an active energy ray-curable adhesive containing a radically polymerizable compound and a polymerization initiator.
Such an active energy ray-curable adhesive is disclosed in, for example, Japanese Patent Application Laid-Open No. 2018-092186, and as the active energy ray-curable adhesive of the present invention, the active energy ray-curable adhesive described in the above publication. Agents can be used. In this specification, for the convenience of space, the description of the above publication is omitted, but the description of the adhesive of the above publication can be incorporated into the present specification as it is.
　また、本発明においては、接着剤ａｄとして、水酸基を含有する活性エネルギー線硬化型接着剤を用いることもできる。このような活性エネルギー線硬化型接着剤としては、例えば、特許文献１の段落０１５２及び表１に記載の実施例１の接着剤を用いることができる。本明細書においては、紙面の都合上、上記特許文献１の記載を転記することを省略するが、上記特許文献１の接着剤に関する記載を本明細書にそのまま取り込めるものとする。 Further, in the present invention, an active energy ray-curable adhesive containing a hydroxyl group can also be used as the adhesive ad. As such an active energy ray-curable adhesive, for example, the adhesive of Example 1 described in paragraph 0152 and Table 1 of Patent Document 1 can be used. In the present specification, the description of the above-mentioned Patent Document 1 is omitted due to space limitations, but the description of the adhesive of the above-mentioned Patent Document 1 can be incorporated into the present specification as it is.
　また、本発明においては、接着剤ａｄとして、ＳＰ値が２９．０（ＭＪ／ｍ３）１／２以上３２．０（ＭＪ／ｍ３）１／２以下であるラジカル重合性化合物、又は、２１．０（ＭＪ／ｍ３）１／２以上２３．０（ＭＪ／ｍ３）１／２以下であるラジカル重合性化合物を含有する活性エネルギー線硬化型接着剤を用いることもできる。このような活性エネルギー線硬化型接着剤としては、例えば、特許文献２の段落００１５等に記載のラジカル重合性化合物（Ａ）やラジカル重合性化合物（Ｃ）を含有する活性エネルギー線硬化型接着剤を用いることができる。本明細書においては、紙面の都合上、上記特許文献２の記載を転記することを省略するが、上記特許文献２の接着剤に関する記載を本明細書にそのまま取り込めるものとする。 Further, in the present invention, the adhesive ad is a radically polymerizable compound having an SP value of 29.0 (MJ / m 3 ) 1/2 or more and 32.0 (MJ / m 3 ) 1/2 or less, or An active energy ray-curable adhesive containing a radically polymerizable compound of 21.0 (MJ / m 3 ) 1/2 or more and 23.0 (MJ / m 3 ) 1/2 or less can also be used. As such an active energy ray-curable adhesive, for example, an active energy ray-curable adhesive containing a radically polymerizable compound (A) or a radically polymerizable compound (C) described in paragraph 0015 of Patent Document 2 or the like. Can be used. In the present specification, the description of the above-mentioned Patent Document 2 is omitted due to space limitations, but the description of the adhesive of the above-mentioned Patent Document 2 can be incorporated into the present specification as it is.
　また、本発明においては、接着剤ａｄとして、水を含有する活性エネルギー線硬化型接着剤を用いることもできる。このような活性エネルギー線硬化型接着剤としては、例えば、従来公知の活性エネルギー線硬化型接着剤と特許文献３の表３に記載の実施例１６の接着剤（易接着組成物）との組み合わせを用いることができる。本明細書においては、紙面の都合上、上記特許文献３の記載を転記することを省略するが、上記特許文献３の接着剤に関する記載を本明細書にそのまま取り込めるものとする。 Further, in the present invention, an active energy ray-curable adhesive containing water can also be used as the adhesive ad. As such an active energy ray-curable adhesive, for example, a combination of a conventionally known active energy ray-curable adhesive and the adhesive (easy-adhesive composition) of Example 16 described in Table 3 of Patent Document 3 is used. Can be used. In the present specification, the description of the above-mentioned Patent Document 3 is omitted due to space limitations, but the description of the adhesive of the above-mentioned Patent Document 3 can be incorporated into the present specification as it is.
　さらに、本発明においては、接着剤ａｄとして、金属アルコキシド及び金属キレートからなる群より選択される少なくとも１種の有機金属化合物を含有する活性エネルギー線硬化型接着剤を用いることもできる。このような活性エネルギー線硬化型接着剤としては、例えば、特許文献１の段落０１５２及び表１に記載の実施例１の接着剤を用いることができる。 Further, in the present invention, as the adhesive ad, an active energy ray-curable adhesive containing at least one organometallic compound selected from the group consisting of a metal alkoxide and a metal chelate can also be used. As such an active energy ray-curable adhesive, for example, the adhesive of Example 1 described in paragraph 0152 and Table 1 of Patent Document 1 can be used.
　以上に説明した本実施形態に係る偏光フィルムＦの製造方法によれば、第１タンク２０内に貯留されている接着剤ａｄが偏光子Ｆ１及び保護フィルムＦ２に塗工されて、第１タンク２０内の接着剤ａｄの貯留量が所定値以下となった場合に、第２タンク３０から第１タンク２０に接着剤ａｄが供給されることになる。第２タンク３０では、接着剤ａｄが密封されて貯留されているため、雰囲気中の水分を吸収し難く、溶媒成分も揮発し難い。また、塗工機６で塗工されなかった接着剤ａｄは、第２タンク３０には戻らず第１タンク２０に戻るため、第２タンク３０内には、第１タンク２０と塗工機６との間の循環使用によって雰囲気中の水分を吸収した接着剤ａｄや、溶媒成分の揮発した接着剤ａｄが混入しない。このため、新品に近い接着剤ａｄが第２タンク３０から第１タンク２０に供給され、この新品に近い接着剤ａｄが第１タンク２０と塗工機６との間で新たに循環することになる。第２タンク３０における接着剤ａｄの貯留量は第１タンク２０よりも大きいため、第２タンク３０内の接着剤が無くなるまで、第２タンク３０内の接着剤ａｄを交換することなく、長期に亘って使用可能である。
　したがい、本実施形態に係る偏光フィルムＦの製造方法によれば、接着剤ａｄのランニングコストを抑制し且つ偏光フィルムＦの製造効率を損なうことなく、偏光フィルムＦにおける偏光子Ｆ１と保護フィルムＦ２との間の良好な接着性を維持することが可能である。 According to the method for producing the polarizing film F according to the present embodiment described above, the adhesive ad stored in the first tank 20 is applied to the polarizer F1 and the protective film F2, and the first tank 20 When the amount of the adhesive ad stored in the film is equal to or less than a predetermined value, the adhesive ad is supplied from the second tank 30 to the first tank 20. In the second tank 30, since the adhesive ad is sealed and stored, it is difficult to absorb the moisture in the atmosphere, and the solvent component is also difficult to volatilize. Further, since the adhesive ad that has not been coated by the coating machine 6 does not return to the second tank 30 but returns to the first tank 20, the first tank 20 and the coating machine 6 are contained in the second tank 30. Adhesive ad that has absorbed moisture in the atmosphere and adhesive ad that has volatilized solvent components will not be mixed in by circulating use with. Therefore, the adhesive ad close to new is supplied from the second tank 30 to the first tank 20, and the adhesive ad close to new is newly circulated between the first tank 20 and the coating machine 6. Become. Since the amount of the adhesive ad stored in the second tank 30 is larger than that in the first tank 20, the adhesive ad in the second tank 30 is not replaced for a long period of time until the adhesive in the second tank 30 is exhausted. It can be used over.
Therefore, according to the method for producing the polarizing film F according to the present embodiment, the polarizer F1 and the protective film F2 in the polarizing film F are combined without suppressing the running cost of the adhesive ad and impairing the manufacturing efficiency of the polarizing film F. It is possible to maintain good adhesion between.
　図３は、図２に示す屈折率計２３で測定した接着剤ａｄの屈折率の変化と、測定した屈折率から演算した接着剤ａｄの水分率の変化との一例を示す図である。なお、図３において、屈折率についての縦軸（図３の左側の縦軸）は、初期の屈折率からの変化量で表している。
　接着剤ａｄの屈折率と水分率とは、屈折率をＸ、水分率をＹとすると、Ｙ＝ａＸ＋ｂ（ａ、ｂは接着剤ａｄに応じて決まる係数）で表される関係があり、この関係式を用いて、測定した屈折率から水分率を演算することが可能である。
　接着剤ａｄの屈折率（図３において実線で示す）及び水分率（図３において破線で示す）は、第１タンク２０と塗工機６との間での接着剤ａｄの循環を開始してから、「連続運転開始時点」（１９時間経過後）までの間は、塗工機６から接着剤ａｄを塗工せずに、第１タンク２０と塗工機６との間で接着剤ａｄを循環させた状態で測定・演算した。また、「連続運転開始時点」経過後は、第１タンク２０と塗工機６との間で接着剤ａｄを循環させながら、塗工機６から接着剤ａｄを塗工した状態で測定・演算した。図３に白抜き矢符で示す時点は、ポンプ４２を駆動して第２タンク３０から第１タンク２０に接着剤ａｄを供給したタイミングを示す。
　図３に示すように、時間の経過と共に、雰囲気中の水分を吸収することで、接着剤ａｄの屈折率は低下（水分率は上昇）しているが、白抜き矢符のタイミングで第２タンク３０から第１タンク２０に新品に近い接着剤ａｄが供給されることで、塗工される接着剤ａｄの屈折率は上昇（水分率は低下）し、良好な接着性の維持が期待できることが分かる。 FIG. 3 is a diagram showing an example of a change in the refractive index of the adhesive ad measured by the refractive index meter 23 shown in FIG. 2 and a change in the water content of the adhesive ad calculated from the measured refractive index. In FIG. 3, the vertical axis of the refractive index (the vertical axis on the left side of FIG. 3) is represented by the amount of change from the initial refractive index.
The refractive index and the moisture content of the adhesive ad have a relationship expressed by Y = aX + b (a and b are coefficients determined according to the adhesive ad), where X is the refractive index and Y is the moisture content. It is possible to calculate the moisture content from the measured refractive index using the relational expression.
The refractive index of the adhesive ad (shown by the solid line in FIG. 3) and the moisture content (shown by the broken line in FIG. 3) start the circulation of the adhesive ad between the first tank 20 and the coating machine 6. From to "the start of continuous operation" (after 19 hours have passed), the adhesive ad is not applied from the coating machine 6 between the first tank 20 and the coating machine 6. Was measured and calculated in a state of circulation. After the "continuous operation start time" has elapsed, the adhesive ad is circulated between the first tank 20 and the coating machine 6, and the measurement / calculation is performed with the adhesive ad applied from the coating machine 6. did. The time indicated by the white arrow in FIG. 3 indicates the timing at which the pump 42 is driven to supply the adhesive ad from the second tank 30 to the first tank 20.
As shown in FIG. 3, the refractive index of the adhesive ad decreases (the moisture content increases) by absorbing the moisture in the atmosphere with the passage of time, but the second is at the timing of the white arrow. By supplying the adhesive ad that is close to new to the first tank 20 from the tank 30, the refractive index of the adhesive ad to be coated increases (the moisture content decreases), and good adhesiveness can be expected to be maintained. I understand.
　以下、実施例及び比較例を説明し、本発明を更に詳述する。ただし、本発明は、下記実施例に限定されるものではない。 Hereinafter, examples and comparative examples will be described, and the present invention will be described in more detail. However, the present invention is not limited to the following examples.
　［使用材料］
　＜活性エネルギー線硬化型接着剤Ａ＞
　５５重量％の１，９－ノナンジオールジアクリレート、１０重量％のヒドロキシエチルアクリルアミド及び３０重量％のアクリロイルモルフォリン（活性エネルギー線硬化性成分）と、３重量％のＩＲＧＡＣＵＲＥ　９０７及び２重量％のＫＡＹＡＣＵＲＥ　ＤＥＴＸ－Ｓ（重合開始剤）と、を混合し、３時間撹拌することにより、活性エネルギー線硬化型接着剤Ａを得た。
　この活性エネルギー線硬化型接着剤Ａの塗工開始時の２５℃における粘度は、２０ｍＰａ・ｓであった。 [Material used]
<Active energy ray-curable adhesive A>
55% by weight 1,9-nonanediol diacrylate, 10% by weight hydroxyethylacrylamide and 30% by weight acryloylmorpholine (active energy ray-curable component), 3% by weight IRGACURE 907 and 2% by weight KAYACURE DETX-S (polymerization initiator) was mixed and stirred for 3 hours to obtain an active energy ray-curable adhesive A.
The viscosity of this active energy ray-curable adhesive A at 25 ° C. at the start of coating was 20 mPa · s.
　＜活性エネルギー線硬化型接着剤Ｂ＞
　５２重量％の１，９－ノナンジオールジアクリレート、１０重量％のヒドロキシエチルアクリルアミド及び３０重量％のアクリロイルモルフォリン、３重量部の３－アクリルアミドフェニルボロン酸（活性エネルギー線硬化性成分）と、３重量％のＩＲＧＡＣＵＲＥ　９０７及び２重量％のＫＡＹＡＣＵＲＥ　ＤＥＴＸ－Ｓ（重合開始剤）と、を混合し、３時間撹拌することにより、活性エネルギー線硬化型接着剤Ｂを得た。
　この活性エネルギー線硬化型接着剤Ｂの塗工開始時の２５℃における粘度は、２２ｍＰａ・ｓであった。 <Active energy ray-curable adhesive B>
52% by weight 1,9-nonanediol diacrylate, 10% by weight hydroxyethylacrylamide and 30% by weight acryloylmorpholine, 3 parts by weight 3-acrylamide phenylboronic acid (active energy ray-curable component), 3 IRGACURE 907 by weight% and KAYACURE DETX-S (polymerization initiator) by weight 2% by weight were mixed and stirred for 3 hours to obtain an active energy ray-curable adhesive B.
The viscosity of this active energy ray-curable adhesive B at 25 ° C. at the start of coating was 22 mPa · s.
　＜活性エネルギー線硬化型接着剤Ｃ＞
　５３重量％の１，９－ノナンジオールジアクリレート、１０重量％のヒドロキシエチルアクリルアミド及び３０重量％のアクリロイルモルフォリン、１重量部の３－アクリルアミドフェニルボロン酸（活性エネルギー線硬化性成分）、１重量部のオルガチックスＴＡ－３０：テトラオクチルチタネートと、３重量％のＩＲＧＡＣＵＲＥ　９０７及び２重量％のＫＡＹＡＣＵＲＥ　ＤＥＴＸ－Ｓ（重合開始剤）と、を混合し、３時間撹拌することにより、活性エネルギー線硬化型接着剤Ｃを得た。
　この活性エネルギー線硬化型接着剤Ｃの塗工開始時の２５℃における粘度は、２０ｍＰａ・ｓであった。 <Active energy ray-curable adhesive C>
53% by weight 1,9-nonanediol diacrylate, 10% by weight hydroxyethylacrylamide and 30% by weight acryloylmorpholin, 1 part by weight 3-acrylamide phenylboronic acid (active energy ray-curable component), 1 part by weight Part of Organtic TA-30: Tetraoctyl titanate, 3% by weight IRGACURE 907 and 2% by weight KAYACURE DETX-S (polymerization initiator) are mixed and stirred for 3 hours to cure active energy rays. Mold adhesive C was obtained.
The viscosity of this active energy ray-curable adhesive C at 25 ° C. at the start of coating was 20 mPa · s.
　＜活性エネルギー線硬化型接着剤Ｄ＞
　６２重量％のグリセリントリアクリレート、１０重量％の４－ヒドロキシブチルアクリレート、２０重量％の３－エチル－３－｛［（３－エチルオキセタン－３－イル）メトキシ］メチル｝オキセタン、３重量％のＩＲＧＡＣＵＲＥ　９０７及び２重量％のＫＡＹＡＣＵＲＥ　ＤＥＴＸ－Ｓ（重合開始剤）、３重量％のＣＰＩ－１００Ｐ（光酸発生剤）を混合し、３時間撹拌することにより、活性エネルギー線硬化型接着剤Ｄを得た。
　この活性エネルギー線硬化型接着剤Ｄの塗工開始時の２５℃における粘度は、３５ｍＰａ・ｓであった。
　なお、活性エネルギー線硬化型接着剤Ａ～Ｄの塗工開始時の２５℃における粘度は、Ｅ型粘度計を用いて測定した。 <Active energy ray-curable adhesive D>
62% by weight glycerin triacrylate, 10% by weight 4-hydroxybutyl acrylate, 20% by weight 3-ethyl-3-{[(3-ethyloxetane-3-yl) methoxy] methyl} oxetane, 3% by weight IRGACURE 907 and 2% by weight KAYACURE DETX-S (polymerization initiator) and 3% by weight CPI-100P (photoacid generator) are mixed and stirred for 3 hours to obtain an active energy ray-curable adhesive D. Obtained.
The viscosity of this active energy ray-curable adhesive D at 25 ° C. at the start of coating was 35 mPa · s.
The viscosity of the active energy ray-curable adhesives A to D at 25 ° C. at the start of coating was measured using an E-type viscometer.
　＜偏光子Ｘ＞
　図１に示す繰出ローラ１、処理槽２及びオーブン３を備える既存の偏光子製造装置を用い、平均重合度２４００、ケン化度９９．９モル％の厚み４５μｍのポリビニルアルコールフィルムを、３０℃の温水中に６０秒間浸漬し膨潤させた。次いで、ヨウ素／ヨウ化カリウム（重量比＝０．５／８）の濃度０．３％の水溶液に浸漬し、３．５倍まで延伸させながらフィルムを染色した。その後、６５℃のホウ酸エステル水溶液中で、トータルの延伸倍率が６倍となるように延伸を行った。延伸後に、４０℃のオーブンにて３分間乾燥させ、長尺帯状のポリビニルアルコール系偏光子（厚み１８μｍ）Ｘを得た。
　なお、偏光子Ｘに易接着処理を施す場合には、特許文献３の表３に記載の実施例１６の易接着組成物を用いた。 <Polarizer X>
Using an existing polarizing element manufacturing apparatus equipped with a feeding roller 1, a processing tank 2 and an oven 3 shown in FIG. 1, a polyvinyl alcohol film having an average degree of polymerization of 2400 and a saponification degree of 99.9 mol% and a thickness of 45 μm was formed at 30 ° C. It was immersed in warm water for 60 seconds to swell. Then, the film was dyed by immersing it in an aqueous solution having a concentration of iodine / potassium iodide (weight ratio = 0.5 / 8) at a concentration of 0.3% and stretching it up to 3.5 times. Then, stretching was carried out in a boric acid ester aqueous solution at 65 ° C. so that the total stretching ratio was 6 times. After stretching, it was dried in an oven at 40 ° C. for 3 minutes to obtain a long strip-shaped polyvinyl alcohol-based polarizer (thickness 18 μm) X.
When the polarizer X was subjected to the easy-adhesion treatment, the easy-adhesion composition of Example 16 described in Table 3 of Patent Document 3 was used.
　＜保護フィルムＹ、Ｚ＞
　偏光子Ｘの一方の片面に貼り合わせる保護フィルムＹとして、厚み５２μｍの環状ポリオレフィンフィルム（日本ゼオン（株）製）を用い、偏光子Ｘとの貼り合わせ面にコロナ処理等のドライ処理を施した。
　偏光子Ｘの他方の片面に貼り合わせる保護フィルムＺとして、厚み６０μｍのトリアセチルセルロースフィルム（富士フイルム（株）製）を用いた。 <Protective film Y, Z>
A cyclic polyolefin film (manufactured by Nippon Zeon Corporation) having a thickness of 52 μm was used as the protective film Y to be bonded to one side of the polarizing element X, and the surface to be bonded to the polarizer X was subjected to a dry treatment such as corona treatment. ..
A triacetyl cellulose film (manufactured by FUJIFILM Corporation) having a thickness of 60 μm was used as the protective film Z to be attached to the other side of the polarizer X.
　［実施例１］
　偏光子Ｘと保護フィルムＹ、Ｚとを活性エネルギー線硬化型接着剤Ａを用いて貼り合わせ、接着剤Ａを硬化させることで偏光フィルムを作製した。偏光子Ｘには易接着処理を施さなかった。そして、初期の接着剤Ａ（図３の「連続運転開始時点」相当の接着剤）を用いて作製した偏光フィルムに対して９０度剥離試験を行い、偏光子Ｘと保護フィルムＹとの間の剥離力、及び、偏光子Ｘと保護フィルムＺとの間の剥離力を測定した。また、３２時間連続運転後の接着剤Ａを用いて作製した偏光フィルムに対して９０度剥離試験を行い、偏光子Ｘと保護フィルムＹとの間の剥離力、及び、偏光子Ｘと保護フィルムＺとの間の剥離力を測定した。 [Example 1]
A polarizing film X was bonded to the protective films Y and Z using an active energy ray-curable adhesive A, and the adhesive A was cured to prepare a polarizing film. The polarizer X was not subjected to an easy adhesion treatment. Then, a 90-degree peeling test was performed on a polarizing film produced using the initial adhesive A (adhesive corresponding to the "starting point of continuous operation" in FIG. 3), and a 90-degree peel test was performed between the polarizing element X and the protective film Y. The peeling force and the peeling force between the polarizer X and the protective film Z were measured. Further, a 90-degree peeling test was performed on the polarizing film prepared using the adhesive A after continuous operation for 32 hours, and the peeling force between the polarizing element X and the protective film Y and the peeling force between the polarizing element X and the protective film were performed. The peeling force with Z was measured.
　［実施例２］
　活性エネルギー線硬化型接着剤Ｂを用いたこと以外は、実施例１と同様にして、偏光フィルムを作製し、剥離力を測定した。 [Example 2]
A polarizing film was prepared and the peeling force was measured in the same manner as in Example 1 except that the active energy ray-curable adhesive B was used.
　［実施例３］
　活性エネルギー線硬化型接着剤Ｃを用いたこと以外は、実施例１と同様にして、偏光フィルムを作製し、剥離力を測定した。 [Example 3]
A polarizing film was prepared and the peeling force was measured in the same manner as in Example 1 except that the active energy ray-curable adhesive C was used.
　［実施例４］
　活性エネルギー線硬化型接着剤Ｄを用い、偏光子Ｘに易接着処理を施したこと以外は、実施例１と同様にして、偏光フィルムを作製し、剥離力を測定した。 [Example 4]
A polarizing film was prepared and the peeling force was measured in the same manner as in Example 1 except that the polarizer X was subjected to an easy-adhesion treatment using the active energy ray-curable adhesive D.
　［比較例１］
　第２タンク３０を密封せずに接着剤を貯留し、塗工機６で塗工されなかった接着剤を第１タンク２０ではなく第２タンク３０に戻した（すなわち、第２タンク３０、第１タンク２０及び塗工機６の間で接着剤を循環使用した）こと以外は、実施例１と同様にして、偏光フィルムを作製し、剥離力を測定した。 [Comparative Example 1]
The adhesive was stored without sealing the second tank 30, and the adhesive that was not applied by the coating machine 6 was returned to the second tank 30 instead of the first tank 20 (that is, the second tank 30, the second tank 30). A polarizing film was prepared and the peeling force was measured in the same manner as in Example 1 except that the adhesive was circulated between the tank 20 and the coating machine 6).
　［比較例２］
　第２タンク３０を密封せずに接着剤を貯留し、塗工機６で塗工されなかった接着剤を第１タンク２０ではなく第２タンク３０に戻した（すなわち、第２タンク３０、第１タンク２０及び塗工機６の間で接着剤を循環使用した）こと以外は、実施例２と同様にして、偏光フィルムを作製し、剥離力を測定した。 [Comparative Example 2]
The adhesive was stored without sealing the second tank 30, and the adhesive that was not applied by the coating machine 6 was returned to the second tank 30 instead of the first tank 20 (that is, the second tank 30, the second tank 30). A polarizing film was prepared and the peeling force was measured in the same manner as in Example 2 except that the adhesive was circulated between the tank 20 and the coating machine 6).
　［比較例３］
　第２タンク３０を密封せずに接着剤を貯留し、塗工機６で塗工されなかった接着剤を第１タンク２０ではなく第２タンク３０に戻した（すなわち、第２タンク３０、第１タンク２０及び塗工機６の間で接着剤を循環使用した）こと以外は、実施例３と同様にして、偏光フィルムを作製し、剥離力を測定した。 [Comparative Example 3]
The adhesive was stored without sealing the second tank 30, and the adhesive that was not applied by the coating machine 6 was returned to the second tank 30 instead of the first tank 20 (that is, the second tank 30, the second tank 30). A polarizing film was prepared and the peeling force was measured in the same manner as in Example 3 except that the adhesive was circulated between the tank 20 and the coating machine 6).
　［比較例４］
　第２タンク３０を密封せずに接着剤を貯留し、塗工機６で塗工されなかった接着剤を第１タンク２０ではなく第２タンク３０に戻した（すなわち、第２タンク３０、第１タンク２０及び塗工機６の間で接着剤を循環使用した）こと以外は、実施例４と同様にして、偏光フィルムを作製し、剥離力を測定した。 [Comparative Example 4]
The adhesive was stored without sealing the second tank 30, and the adhesive that was not applied by the coating machine 6 was returned to the second tank 30 instead of the first tank 20 (that is, the second tank 30, the second tank 30). A polarizing film was prepared and the peeling force was measured in the same manner as in Example 4 except that the adhesive was circulated between the tank 20 and the coating machine 6).
　［測定結果の評価］
　図４は、実施例１～４及び比較例１～４で得られた剥離力の測定結果を示す。
　なお、剥離力の測定（９０度剥離試験）は、長尺帯状の偏光フィルムの先端部（初期に製造される部分）と後端部（約３２時間の稼働後に製造される部分）とを切断して、それぞれ試験片を作製し、各試験片について行った。図４に示す「初期Ｘ－Ｙ間９０度剥離試験」及び「初期Ｘ－Ｚ間９０度剥離試験」の欄に示す剥離力は、偏光フィルムの先端部を切断して得られた試験片について測定した剥離力を意味する。図４に示す「３２時間連続運転後Ｘ－Ｙ間９０度剥離試験」及び「３２時間連続運転後Ｘ－Ｚ間９０度剥離試験」の欄に示す剥離力は、偏光フィルムの後端部を切断して得られた試験片について測定した剥離力を意味する。 [Evaluation of measurement results]
FIG. 4 shows the measurement results of the peeling force obtained in Examples 1 to 4 and Comparative Examples 1 to 4.
In the measurement of peeling force (90-degree peeling test), the front end (the part manufactured at the beginning) and the rear end (the part manufactured after about 32 hours of operation) of the long strip-shaped polarizing film are cut. Then, each test piece was prepared, and each test piece was subjected to the process. The peeling force shown in the columns of "Initial XY 90 degree peeling test" and "Initial XY 90 degree peeling test" shown in FIG. 4 is obtained with respect to the test piece obtained by cutting the tip of the polarizing film. It means the measured peeling force. The peeling force shown in the columns of "90 degree peeling test between XY after continuous operation for 32 hours" and "90 degree peeling test between XY after continuous operation for 32 hours" shown in FIG. 4 is applied to the rear end portion of the polarizing film. It means the peeling force measured for the test piece obtained by cutting.
　具体的には、上記の試験片を、偏光子の延伸方向と平行な方向に２００ｍｍ、直交する方向に１５ｍｍの大きさに切り出したものとし、この試験片をガラス板に貼り合わせた。偏光子Ｘと保護フィルムＹとの間の剥離力を測定する場合には、試験片の偏光子Ｘと保護フィルムＹとの間にカッターナイフで切り込みを入れ、テンシロンを用いて、９０°方向に偏光子Ｘと保護フィルムＹとを剥離速度５００ｍｍ／分で剥離し、その剥離力を測定した。偏光子Ｘと保護フィルムＺとの間の剥離力を測定する場合には、試験片の偏光子Ｘと保護フィルムＺとの間にカッターナイフで切り込みを入れ、テンシロンを用いて、９０°方向に偏光子Ｘと保護フィルムＺとを剥離速度５００ｍｍ／分で剥離し、その剥離力を測定した。 Specifically, the above test piece was cut out to a size of 200 mm in the direction parallel to the stretching direction of the polarizer and 15 mm in the direction orthogonal to the stretching direction, and this test piece was attached to a glass plate. When measuring the peeling force between the polarizing element X and the protective film Y, make a notch between the polarizing element X and the protective film Y of the test piece with a cutter knife, and use Tencilon in the 90 ° direction. The polarizer X and the protective film Y were peeled off at a peeling speed of 500 mm / min, and the peeling force was measured. When measuring the peeling force between the polarizing element X and the protective film Z, make a notch between the polarizing element X and the protective film Z of the test piece with a cutter knife, and use Tencilon in the 90 ° direction. The polarizer X and the protective film Z were peeled off at a peeling speed of 500 mm / min, and the peeling force was measured.
　図４に示すように、実施例１～４によれば、初期の接着剤を用いて作製した偏光フィルムだけでなく、３２時間連続運転後の接着剤を用いて作製した偏光フィルムについても十分に大きな剥離力が得られており、偏光子と保護フィルムとの間の良好な接着性を維持できている。
　これに対し、比較例１～４によれば、初期の接着剤を用いて作製した偏光フィルムでは偏光子と保護フィルムとの間の良好な接着性が得られているが、３２時間連続運転後の接着剤を用いて作製した偏光フィルムについては剥離力が小さくなり、偏光子と保護フィルムとの間の接着性が低下している。 As shown in FIG. 4, according to Examples 1 to 4, not only the polarizing film produced by using the initial adhesive but also the polarizing film produced by using the adhesive after continuous operation for 32 hours is sufficiently used. A large peeling force is obtained, and good adhesion between the polarizer and the protective film can be maintained.
On the other hand, according to Comparative Examples 1 to 4, the polarizing film produced by using the initial adhesive obtained good adhesion between the polarizer and the protective film, but after 32 hours of continuous operation. The peeling force of the polarizing film produced by using the adhesive of No. 1 is reduced, and the adhesiveness between the polarizing element and the protective film is lowered.
　ａｄ・・・活性エネルギー線硬化型接着剤
　Ｆ１・・・偏光子（第１光学フィルム）
　Ｆ２・・・保護フィルム（第２光学フィルム）
　Ｆ・・・偏光フィルム（光学積層体）
　６・・・塗工機
　２０・・・第１タンク
　２２、４２・・・ポンプ
　３０・・・第２タンク
　４０・・・制御装置
　４３・・・レベル計
　１００・・・接着剤塗工装置 ad ・ ・ ・ Active energy ray-curable adhesive F1 ・ ・ ・ Polarizer (1st optical film)
F2: Protective film (second optical film)
F ... Polarizing film (optical laminate)
6 ... Coating machine 20 ... 1st tank 22, 42 ... Pump 30 ... 2nd tank 40 ... Control device 43 ... Level meter 100 ... Adhesive coating device

Claims (11)

  1. 　第１光学フィルム及び第２光学フィルムのうち少なくとも一方に、接着剤塗工装置によって活性エネルギー線硬化型接着剤を塗工する接着剤塗工工程と、
    　前記第１光学フィルムと前記第２光学フィルムとを前記接着剤を介して貼り合わせ、前記接着剤に活性エネルギー線を照射して前記接着剤を硬化させることで、光学積層体を作製する光学積層体作製工程と、を含み、
    　前記接着剤塗工装置は、
    　前記接着剤を塗工する塗工機と、
    　前記接着剤を貯留し、前記塗工機に前記接着剤を供給する第１タンクと、
    　前記接着剤を密封して貯留し、前記第１タンクに前記接着剤を供給する、前記第１タンクよりも前記接着剤の貯留量が大きな第２タンクとを、備え、
    　前記接着剤塗工工程において、前記第１タンクと前記塗工機との間で前記接着剤を循環させると共に、前記第１タンク内の前記接着剤の貯留量が所定値以下となった場合に、前記第２タンクから前記第１タンクに前記接着剤を供給する、
    光学積層体の製造方法。     An adhesive coating step of applying an active energy ray-curable adhesive to at least one of the first optical film and the second optical film by an adhesive coating device.
    The first optical film and the second optical film are bonded to each other via the adhesive, and the adhesive is irradiated with active energy rays to cure the adhesive to produce an optical laminate. Including the body preparation process
    The adhesive coating device is
    A coating machine that applies the adhesive and
    A first tank that stores the adhesive and supplies the adhesive to the coating machine,
    A second tank, which seals and stores the adhesive and supplies the adhesive to the first tank, has a larger storage amount of the adhesive than the first tank.
    In the adhesive coating step, when the adhesive is circulated between the first tank and the coating machine and the amount of the adhesive stored in the first tank becomes a predetermined value or less. , Supply the adhesive from the second tank to the first tank.
    A method for manufacturing an optical laminate.
  2. 　前記接着剤塗工工程において、前記接着剤の塗工開始時の２５℃での粘度が１ｍＰａ・ｓ～１００ｍＰａ・ｓである、
    請求項１に記載の光学積層体の製造方法。     In the adhesive coating step, the viscosity of the adhesive at 25 ° C. at the start of coating is 1 mPa · s to 100 mPa · s.
    The method for producing an optical laminate according to claim 1.
  3. 　前記接着剤塗工工程において、前記接着剤の塗工厚みが０．１μｍ～５μｍである、
    請求項１又は２に記載の光学積層体の製造方法。     In the adhesive coating step, the coating thickness of the adhesive is 0.1 μm to 5 μm.
    The method for producing an optical laminate according to claim 1 or 2.
  4. 　前記接着剤は、水酸基を含有する、
    請求項１から３の何れか一項に記載の光学積層体の製造方法。     The adhesive contains a hydroxyl group,
    The method for producing an optical laminate according to any one of claims 1 to 3.
  5. 　前記接着剤は、ＳＰ値が２９．０（ＭＪ／ｍ３）１／２以上３２．０（ＭＪ／ｍ３）１／２以下であるラジカル重合性化合物、又は、２１．０（ＭＪ／ｍ３）１／２以上２３．０（ＭＪ／ｍ３）１／２以下であるラジカル重合性化合物を含有する、
    請求項１から４の何れか一項に記載の光学積層体の製造方法。     The adhesive is a radically polymerizable compound having an SP value of 29.0 (MJ / m 3 ) 1/2 or more and 32.0 (MJ / m 3 ) 1/2 or less, or 21.0 (MJ / m). 3 ) Contains a radically polymerizable compound that is 1/2 or more and 23.0 (MJ / m 3 ) 1/2 or less.
    The method for producing an optical laminate according to any one of claims 1 to 4.
  6. 　前記接着剤は、水を含有する、
    請求項１から５の何れか一項に記載の光学積層体の製造方法。     The adhesive contains water,
    The method for producing an optical laminate according to any one of claims 1 to 5.
  7. 　前記接着剤は、金属アルコキシド及び金属キレートからなる群より選択される少なくとも１種の有機金属化合物を含有する、
    請求項１から６の何れか一項に記載の光学積層体の製造方法。     The adhesive contains at least one organometallic compound selected from the group consisting of metal alkoxides and metal chelates.
    The method for producing an optical laminate according to any one of claims 1 to 6.
  8. 　前記接着剤は、カチオン重合性官能基を含有する、
    請求項１から７の何れか一項に記載の光学積層体の製造方法。     The adhesive contains a cationically polymerizable functional group.
    The method for producing an optical laminate according to any one of claims 1 to 7.
  9. 　前記第１光学フィルムが偏光子であり、
    　前記第２光学フィルムが保護フィルムであり、
    　前記光学積層体が偏光フィルムである、
    請求項１から８の何れか一項に記載の光学積層体の製造方法。     The first optical film is a polarizer,
    The second optical film is a protective film.
    The optical laminate is a polarizing film.
    The method for producing an optical laminate according to any one of claims 1 to 8.
  10. 　第１光学フィルム及び第２光学フィルムのうち少なくとも一方に、活性エネルギー線硬化型接着剤を塗工する接着剤塗工装置であって、
    　前記接着剤を塗工する塗工機と、
    　前記接着剤を貯留し、前記塗工機との間で前記接着剤を循環させながら前記塗工機に前記接着剤を供給する第１タンクと、
    　前記接着剤を密封して貯留し、前記第１タンクに前記接着剤を供給する、前記第１タンクよりも前記接着剤の貯留量が大きな第２タンクと、
    　前記第１タンク内の前記接着剤の貯留量が所定値以下となった場合に、前記第２タンクから前記第１タンクに前記接着剤を供給させる制御装置と、
    を備える接着剤塗工装置。     An adhesive coating device for applying an active energy ray-curable adhesive to at least one of a first optical film and a second optical film.
    A coating machine that applies the adhesive and
    A first tank that stores the adhesive and supplies the adhesive to the coating machine while circulating the adhesive between the coating machine and the coating machine.
    A second tank in which the adhesive is sealed and stored, and the adhesive is supplied to the first tank, and the amount of the adhesive stored is larger than that of the first tank.
    A control device for supplying the adhesive from the second tank to the first tank when the amount of the adhesive stored in the first tank becomes a predetermined value or less.
    Adhesive coating device equipped with.
  11. 　請求項１０に記載の接着剤塗工装置と、
    　前記接着剤を介して貼り合わされた前記第１光学フィルム及び前記第２光学フィルム間の前記接着剤に活性エネルギー線を照射して硬化させる活性エネルギー線照射装置と、
    を備える光学積層体の製造装置。     The adhesive coating device according to claim 10,
    An active energy ray irradiating device that irradiates and cures the adhesive between the first optical film and the second optical film bonded via the adhesive.
    An apparatus for manufacturing an optical laminate.
PCT/JP2020/040368 2019-11-19 2020-10-28 Production method for optical layered product, adhesive application device, and production device for optical layered product WO2021100423A1 (en)

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