WO2022209338A1 - 偏光子および偏光子の製造方法 - Google Patents
偏光子および偏光子の製造方法 Download PDFInfo
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- WO2022209338A1 WO2022209338A1 PCT/JP2022/005325 JP2022005325W WO2022209338A1 WO 2022209338 A1 WO2022209338 A1 WO 2022209338A1 JP 2022005325 W JP2022005325 W JP 2022005325W WO 2022209338 A1 WO2022209338 A1 WO 2022209338A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/12—Chemical modification
- C08J7/16—Chemical modification with polymerisable compounds
-
- 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
Definitions
- the present invention relates to a polarizer and a method for manufacturing a polarizer.
- Image display devices represented by liquid crystal display devices and electroluminescence (EL) display devices are rapidly spreading.
- a polarizing plate is typically used for an image display panel mounted in an image display device.
- a polarizing plate with a retardation layer, in which a polarizing plate and a retardation plate are integrated, is widely used (for example, Patent Document 1).
- the polarizer contained in the polarizing plate undergoes decolorization (color loss) when the image display device is used for a long time or placed in a harsh environment (for example, in a high-temperature, high-humidity environment). In some cases, the polarization performance is degraded.
- the present invention has been made to solve the above problems, and its main purpose is to provide a polarizer in which the occurrence of decolorization is suppressed.
- a polarizer contains iodine and is composed of a resin film having a first principal surface and a second principal surface facing each other, and has a chemically modified portion obtained by chemically modifying the resin film on an end surface, and the chemically modified portion is more hydrophobic than other moieties that are not chemically modified.
- the chemical modifier comprises a fluorine-containing group.
- the fluorine containing group comprises a trifluoroacetyl group.
- the chemically modified portion is chemically modified with trifluoroacetic anhydride.
- the end face has a ratio of absorbance at 1787 cm ⁇ 1 to absorbance at 2940 cm ⁇ 1 greater than 0.2 in an FT-IR spectrum measured by ATR.
- the edge including the edge includes fluorine.
- the chemically modified portion is chemically modified with a silylating agent.
- the edge including the edge includes silicon.
- the polarizer has a covering portion covering an end surface of the resin film. According to another embodiment of the present invention, a method for manufacturing the polarizer is provided.
- This manufacturing method includes a resin film containing iodine and having a first main surface and a second main surface facing each other; a first protective material arranged on the first main surface; and a second protective material; and chemically modifying an end surface of the resin film of the laminate.
- a polarizer is provided.
- This polarizing plate has the polarizer and at least one of a protective layer and a retardation layer.
- a method for manufacturing the polarizing plate there is provided.
- This manufacturing method includes a resin film containing iodine and having a first main surface and a second main surface facing each other; a first protective material arranged on the first main surface; and chemically modifying the end face of the resin film of the laminate, wherein the protective material is at least the protective layer or the retardation layer including one.
- a polarizer in which the occurrence of decolorization is suppressed can be obtained by forming a chemically modified portion.
- FIG. 1 is a schematic cross-sectional view of a polarizer according to one embodiment of the invention
- FIG. BRIEF DESCRIPTION OF THE DRAWINGS It is typical sectional drawing which shows a schematic structure of the laminated body used for manufacture of the polarizer in 1st embodiment of this invention.
- FIG. 4 is a schematic cross-sectional view showing a schematic configuration of a laminate used for manufacturing a polarizer in the second embodiment of the invention.
- 2 is an observation photograph showing evaluation results of durability of Example 2-1.
- 2 is an observation photograph showing evaluation results of durability of Example 2-2.
- 4 is an observation photograph showing the durability evaluation results of Comparative Example 2.
- FIG. 1 shows FT-IR spectra corresponding to Examples 1-1, 1-2, 1-3 and Comparative Example 1.
- FIG. FIG. 10 is a cross-sectional SEM observation photograph (magnification: 5 ⁇ ) of the end portion of the retardation layer-attached polarizing plate of Example 2-1.
- refractive index (nx, ny, nz) is the refractive index in the direction in which the in-plane refractive index is maximum (i.e., slow axis direction), and "ny” is the in-plane direction orthogonal to the slow axis (i.e., fast axis direction) and "nz” is the refractive index in the thickness direction.
- In-plane retardation (Re) “Re( ⁇ )” is an in-plane retardation measured at 23° C. with light having a wavelength of ⁇ nm.
- Re(550) is the in-plane retardation measured with light having a wavelength of 550 nm at 23°C.
- Thickness direction retardation (Rth) is the retardation in the thickness direction measured at 23° C. with light having a wavelength of ⁇ nm.
- Rth(550) is the retardation in the thickness direction measured at 23° C. with light having a wavelength of 550 nm.
- FIG. 1 is a schematic cross-sectional view of a polarizer according to one embodiment of the invention. In addition, in FIG. 1, hatching is omitted from the cross section of the polarizer in order to make the drawing easier to see.
- the polarizer 10 is composed of a resin film having a first major surface 10a and a second major surface 10b facing each other.
- An end face 10c of the polarizer 10 has a chemically modified portion in which a resin film is chemically modified.
- the chemically modified portion may be formed on at least a portion of the end surface 10c, and the formation region is not particularly limited, but for example, it is formed over the entire end surface 10c.
- the polarizer is composed of a resin film containing iodine.
- resin film for example, hydrophilic polymer films such as polyvinyl alcohol (PVA) films, partially formalized PVA films, and partially saponified ethylene/vinyl acetate copolymer films are used.
- PVA polyvinyl alcohol
- partially formalized PVA films partially saponified ethylene/vinyl acetate copolymer films are used.
- the thickness of the polarizer 10 is preferably 15 ⁇ m or less, may be 12 ⁇ m or less, may be 10 ⁇ m or less, or may be 8 ⁇ m or less. On the other hand, the thickness of the polarizer is preferably 1 ⁇ m or more.
- the polarizer 10 preferably exhibits absorption dichroism at any wavelength from 380 nm to 780 nm.
- the single transmittance (Ts) of the polarizer 10 is preferably 41.0% or higher, more preferably 42.0% or higher, and even more preferably 42.5% or higher. On the other hand, the single transmittance of the polarizer 10 is, for example, 44.2% or less.
- the degree of polarization (P) of the polarizer 10 is preferably 99.95% or higher, more preferably 99.98% or higher, even more preferably 99.99% or higher. On the other hand, the degree of polarization of the polarizer 10 is, for example, 99.996% or less.
- the single transmittance is typically a Y value measured using an ultraviolet-visible spectrophotometer and subjected to visibility correction.
- the degree of polarization is typically obtained by the following formula based on the parallel transmittance Tp and the orthogonal transmittance Tc measured using an ultraviolet-visible spectrophotometer and subjected to visibility correction.
- Degree of polarization (%) ⁇ (Tp-Tc)/(Tp+Tc) ⁇ 1/2 ⁇ 100
- the chemically modified part is more hydrophobic than other parts that are not chemically modified (for example, the main surface).
- a chemically modified portion By forming such a chemically modified portion, it is possible to obtain a polarizer (polarizing plate) in which moisture is suppressed from entering the polarizer (resin film) and decolorization is suppressed. Decoloration tends to occur at the edges of the polarizing plate, and for example, the display performance may deteriorate at the edges of the image display panel including the polarizing plate.
- the chemically modified portion on the end face, decolorization can be effectively suppressed.
- the other parts include not only the surface of the resin film but also the inside of the resin film.
- the chemically modified portion can be formed by chemically modifying the resin film.
- it can be formed by a modification reaction of the hydroxy groups of the resin film.
- Modification reactions of hydroxy groups in resin films include, for example, methyl ether, substituted methyl ether, substituted ethyl ether, methoxy-substituted benzyl ether, silyl ether, ester (formate, acetyl, benzoyl), micellized ester, sulfonate, and sulfenate.
- modifying groups such as acid esters, sulfinic acid esters, carbonates, carbamates, cyclic acetals, cyclic ketals, cyclic orthoesters, silyl derivative groups, cyclic carbonates, cyclic borate esters and the like can be mentioned.
- the conditions for the modification reaction appropriate conditions can be appropriately adopted depending on the type of modification group and the like.
- the resin film and the chloride of the modifying group to be substituted are brought into contact with each other at 0° C. to 100° C. for 1 minute to 20 hours in the presence of a catalyst, if necessary, for modification reaction.
- the above-mentioned chemical modification part is a modification having groups such as alkyl groups, halogeno groups, halogenated alkyl groups, aryl groups, acyl groups, and silyl groups (groups that improve hydrophobicity) on the hydroxy groups of the resin film. It can be formed by reacting agents. Chemical modification is performed by, for example, alkylation, halogenation, acylation (eg, acetylation, esterification), silylation, etherification, and the like. These may be used alone or in combination of two or more.
- acylating agents used for the above acylation include carboxylic acid anhydrides, carboxylic acid halides, benzoyl halides, esters, amides, and ketene. Specific examples include trifluoroacetic anhydride, acetic anhydride, acetyl chloride, chloroacetic anhydride, chloroacetyl chloride, dichloroacetic anhydride, trichloroacetic anhydride, and benzoyl chloride.
- silylating agent used for the silylation examples include chlorotrimethylsilane, chlorotriethylsilane, chlorotriisopropylsilane, chlorotriphenylsilane, tert-butyldimethylchlorosilane, dichlorodimethylsilane, dichlorodiethylsilane, dichlorodiisopropylsilane, and the like. chlorosilanes of.
- amide-based silylating agents such as N,O-bis(trimethylsilyl)acetamide and N,O-bis(trimethylsilyl)trifluoroacetamide, and amine-based silylating agents such as N-trimethylsilylimidazole are also used. be able to.
- etherification agent used for the etherification examples include benzyl bromide, 4-methoxybenzyl chloride, chloromethyl methyl ether, and trityl chloride.
- the chemical modification portion has a fluorine-containing group.
- Groups containing fluorine include, for example, fluoroalkyl groups having one or more fluoro groups, and fluoroacyl groups (eg, trifluoroacetyl group).
- the chemically modified portion is chemically modified with trifluoroacetic anhydride.
- the end portion 10d including the end face 10c may contain fluorine.
- the width of the end portion containing fluorine (the distance from the end surface of the portion where fluorine is confirmed) may be, for example, 1 ⁇ m or more, 10 ⁇ m or more, or 20 ⁇ m or more.
- the width of the edge containing fluorine is preferably 100 ⁇ m or less, and may be 50 ⁇ m or less.
- the end face having a chemically modified portion preferably has a ratio of absorbance at 1787 cm -1 to absorbance at 2940 cm -1 exceeding 0.2, more preferably 0.25 or more, in an FT-IR spectrum measured by ATR. More preferably, it is 0.3 or more.
- the ratio of absorbance at 1787 cm -1 to absorbance at 2940 cm -1 is less than one, for example.
- the absorption peak near 2940 cm ⁇ 1 is derived from the C—H stretching vibration of the resin film, and the absorption peak near 1787 cm ⁇ 1 is derived from the C ⁇ O stretching vibration of the trifluoroacetyl group.
- the chemically modified portion is chemically modified with a silylating agent.
- end portion 10d including end face 10c, may contain silicon.
- the width of the end portion containing silicon (the distance from the end surface of the portion where silicon is confirmed) may be, for example, 1 ⁇ m or more, 10 ⁇ m or more, or 20 ⁇ m or more.
- the width of the edge containing silicon is preferably 100 ⁇ m or less, and may be 50 ⁇ m or less.
- the polarizer contains iodine and can be obtained by chemically modifying the end faces of a resin film having a first main surface and a second main surface facing each other.
- the end surface of the resin film is chemically modified while the first protective material is arranged on the first main surface of the resin film and the second protective material is arranged on the second main surface of the resin film.
- a laminate having a first protective material, a resin film and a second protective material is prepared, and the end face of the resin film of this laminate is chemically modified.
- the end faces of the resin film can be selectively chemically modified.
- FIG. 2 is a schematic cross-sectional view showing a schematic configuration of a laminate used for manufacturing a polarizer in the first embodiment of the invention.
- a laminate 100 has a first protective material 1, a resin film 10 and a second protective material 2 in this order.
- the resin film 10 has a first main surface 10a and a second main surface 10b facing each other, the first protective material 1 is arranged on the first main surface 10a of the resin film 10, and the second main surface 10b of the resin film 10
- the second protective material 2 is arranged in the .
- the first protective material 1 includes a first protective layer 21 and a surface protective film 60 in this order from the resin film 10 side.
- the second protective material 2 has a second protective layer 22, a retardation layer 30, an adhesive layer 40 and a release film (separator) 50 in this order from the resin film 10 side.
- the surface protective film 60 includes a substrate 61 and an adhesive layer 62 formed on one side of the substrate 61, and is detachably attached to the first protective layer 21.
- the retardation layer 30 has a laminated structure including a first retardation layer 31 and a second retardation layer 32 .
- the release film 50 is detachably attached to the adhesive layer 40 and can protect the adhesive layer 40 . By using the release film 50, roll formation of the laminate 100 becomes possible, for example.
- the retardation layer 30 has a laminated structure including the first retardation layer 31 and the second retardation layer 32. However, unlike the illustrated example, the retardation layer 30 has a laminated structure of three or more layers. It may have a structure or may be a single layer.
- FIG. 3 is a schematic cross-sectional view showing a schematic configuration of a laminate used for manufacturing a polarizer in the second embodiment of the invention.
- the second embodiment differs from the first embodiment in that the second protective material 2 of the laminate 100 does not include the second protective layer 22 and the retardation layer 30 .
- Each member constituting the laminate can be laminated via any appropriate adhesive layer (some of which are not shown).
- the adhesive layer include an adhesive layer and an adhesive layer.
- the protective layers 21 and 22 are typically bonded to the resin film 10 via an adhesive layer.
- the retardation layer 30 may be attached to the second protective layer 22 via an adhesive layer (preferably using an active energy ray-curable adhesive), or an adhesive layer (for example, an acrylic adhesive It may be attached to the second protective layer 22 via an agent).
- an adhesive layer preferably using an active energy ray-curable adhesive
- the retardation layers are attached to each other, for example, via an adhesive layer (preferably using an active energy ray-curable adhesive). be matched.
- the laminate may be elongated or sheet-shaped.
- elongated refers to an elongated shape whose length is sufficiently longer than its width, for example, an elongated shape whose length is 10 times or more, preferably 20 times or more, its width.
- a long laminate can be wound into a roll.
- the resin film included in the laminate can be produced by any suitable method.
- hydrophilic polymer films such as polyvinyl alcohol (PVA) films, partially formalized PVA films, and partially saponified ethylene/vinyl acetate copolymer films are added with iodine, dichroic dyes, and the like. It is produced by a method including dyeing with a dichroic material and stretching. The method may further include an insolubilization treatment, a swelling treatment, a cross-linking treatment, and the like. Since such a manufacturing method is well known and commonly used in the industry, detailed description thereof will be omitted.
- the resin film contained in the laminate is produced using a laminate of a resin substrate and a resin layer (typically, a PVA-based resin layer).
- a PVA-based resin solution is applied to a resin substrate and dried to form a PVA-based resin layer on the resin substrate to obtain a laminate of the resin substrate and the PVA-based resin layer; stretching and dyeing;
- a PVA-based resin layer containing a halide and a PVA-based resin is formed on one side of the resin substrate.
- Stretching typically includes immersing the laminate in an aqueous boric acid solution for stretching.
- stretching may further include stretching the laminate in air at a high temperature (eg, 95° C.
- the laminate is preferably subjected to drying shrinkage treatment in which the laminate is heated while being conveyed in the longitudinal direction to shrink the laminate by 2% or more in the width direction.
- the manufacturing method of the present embodiment includes subjecting the laminate to an in-air auxiliary stretching treatment, a dyeing treatment, an underwater stretching treatment, and a drying shrinkage treatment in this order.
- the resin substrate may be used as a protective material, may be used as it is as a protective layer of the obtained polarizer, or may be peeled off from the laminate of the resin substrate/PVA-based resin layer. Details of the method for producing such a resin film (polarizer) are described in, for example, Japanese Patent Application Laid-Open No. 2012-73580 and Japanese Patent No. 6470455. These publications are incorporated herein by reference in their entireties.
- the protective layer can be formed of any suitable film that can be used as a protective layer for a polarizer.
- the material that is the main component of the film include cellulose-based resins such as triacetyl cellulose (TAC), polyester-based, polyvinyl alcohol-based, polycarbonate-based, polyamide-based, polyimide-based, polyethersulfone-based, and polysulfone-based resins.
- TAC triacetyl cellulose
- polyester-based polyvinyl alcohol-based
- polycarbonate-based polyamide-based
- polyimide-based polyimide-based
- polyethersulfone-based polysulfone-based resins.
- polystyrene cycloolefin such as polynorbornene, polyolefin, (meth)acrylic, and acetate.
- the polarizing plate (polarizing plate with retardation layer) obtained from the laminate is typically arranged on the viewing side of the image display device, and the first protective layer 21 is arranged on the viewing side. Therefore, the first protective layer 21 may be subjected to surface treatment such as hard coat (HC) treatment, anti-reflection treatment, anti-sticking treatment, anti-glare treatment, etc., if necessary.
- surface treatment such as hard coat (HC) treatment, anti-reflection treatment, anti-sticking treatment, anti-glare treatment, etc.
- the thickness of the protective layer is preferably 5 ⁇ m to 80 ⁇ m, more preferably 10 ⁇ m to 40 ⁇ m, still more preferably 15 ⁇ m to 35 ⁇ m.
- the thickness of the 1st protective layer 21 is thickness including the thickness of a surface treatment layer.
- the second protective layer 22 arranged between the resin film 10 and the retardation layer 30 is preferably optically isotropic in one embodiment.
- optically isotropic means that the in-plane retardation Re (550) is 0 nm to 10 nm and the thickness direction retardation Rth (550) is ⁇ 10 nm to +10 nm.
- the thickness of the second protective layer 22 placed between the resin film 10 and the retardation layer 30 is preferably 5 ⁇ m to 80 ⁇ m, more preferably 10 ⁇ m to 40 ⁇ m, and even more preferably 10 ⁇ m to 30 ⁇ m.
- the thickness of the retardation layer is preferably 10 ⁇ m or less, more preferably 8 ⁇ m or less, and even more preferably 6 ⁇ m or less, although it depends on its configuration (whether it is a single layer or has a laminated structure). is. On the other hand, the thickness of the retardation layer is, for example, 1 ⁇ m or more.
- the "thickness of the retardation layer” means the total thickness of each retardation layer. Specifically, the "thickness of the retardation layer" does not include the thickness of the adhesive layer.
- an alignment fixed layer (liquid crystal alignment fixed layer) of a liquid crystal compound is preferably used.
- a liquid crystal compound for example, the difference between nx and ny in the resulting retardation layer can be significantly increased compared to a non-liquid crystal material. thickness can be significantly reduced. Therefore, it is possible to realize a remarkable thinning of the polarizing plate with the retardation layer.
- the term "fixed alignment layer” refers to a layer in which a liquid crystal compound is aligned in a predetermined direction and the alignment state is fixed.
- the "alignment fixed layer” is a concept including an alignment cured layer obtained by curing a liquid crystal monomer as described later.
- rod-shaped liquid crystal compounds are typically aligned in the slow axis direction of the retardation layer (homogeneous alignment).
- the liquid crystal alignment fixed layer is formed by subjecting the surface of a predetermined base material to an alignment treatment, coating the surface with a coating liquid containing a liquid crystal compound, and orienting the liquid crystal compound in a direction corresponding to the alignment treatment. It can be formed by fixing the orientation state. Any appropriate orientation treatment can be adopted as the orientation treatment. Specific examples include mechanical orientation treatment, physical orientation treatment, and chemical orientation treatment. Specific examples of mechanical orientation treatment include rubbing treatment and stretching treatment. Specific examples of physical orientation treatment include magnetic orientation treatment and electric field orientation treatment. Specific examples of chemical alignment treatment include oblique vapor deposition and photo-alignment treatment. Arbitrary appropriate conditions can be adopted as the processing conditions for various alignment treatments depending on the purpose.
- the alignment of the liquid crystal compound is performed by processing at a temperature that exhibits a liquid crystal phase depending on the type of liquid crystal compound. By performing such a temperature treatment, the liquid crystal compound assumes a liquid crystal state, and the liquid crystal compound is aligned in accordance with the orientation treatment direction of the surface of the base material.
- the alignment state is fixed by cooling the liquid crystal compound aligned as described above.
- the orientation state is fixed by subjecting the liquid crystal compound oriented as described above to a polymerization treatment or a crosslinking treatment.
- liquid crystal compound and details of the method for forming the alignment fixed layer are described in JP-A-2006-163343. The description of the publication is incorporated herein by reference.
- the retardation layer may be a single layer or may have a laminated structure of two or more layers.
- the retardation layer can function as a ⁇ /4 plate.
- Re(550) of the retardation layer is preferably 100 nm to 180 nm, more preferably 110 nm to 170 nm, still more preferably 110 nm to 160 nm.
- the thickness of the retardation layer can be adjusted so as to obtain the desired in-plane retardation of the ⁇ /4 plate.
- the retardation layer is the liquid crystal alignment fixing layer described above, its thickness is, for example, 1.0 ⁇ m to 2.5 ⁇ m.
- the angle formed by the slow axis of the retardation layer and the absorption axis of the polarizer is preferably 40 ° to 50 °, more preferably 42 ° to 48 °, still more preferably 44 ° to 46°.
- the retardation layer preferably exhibits reverse dispersion wavelength characteristics in which the retardation value increases according to the wavelength of the measurement light.
- the retardation layer can function as a ⁇ /2 plate.
- Re(550) of the retardation layer is preferably 200 nm to 300 nm, more preferably 230 nm to 290 nm, still more preferably 230 nm to 280 nm.
- the thickness of the retardation layer can be adjusted so as to obtain the desired in-plane retardation of the ⁇ /2 plate.
- the retardation layer is the liquid crystal alignment fixed layer described above, its thickness is, for example, 2.0 ⁇ m to 4.0 ⁇ m.
- the angle formed by the slow axis of the retardation layer and the absorption axis of the polarizer is preferably 10 ° to 20 °, more preferably 12 ° to 18 °, still more preferably 12 ° to 16°.
- the retardation layer 30 includes a first retardation layer (H layer) 31 and a second retardation layer in order from the resin film 10 side. It has a two-layer laminated structure in which a layer (Q layer) 32 is arranged.
- the H layer can typically function as a ⁇ /2 plate and the Q layer can typically function as a ⁇ /4 plate.
- Re(550) of the H layer is preferably 200 nm to 300 nm, more preferably 220 nm to 290 nm, still more preferably 230 nm to 280 nm;
- Re(550) of the Q layer is preferably It is 100 nm to 180 nm, more preferably 110 nm to 170 nm, even more preferably 110 nm to 150 nm.
- the thickness of the H layer can be adjusted to obtain the desired in-plane retardation of the ⁇ /2 plate.
- the H layer is the liquid crystal alignment fixing layer described above, its thickness is, for example, 2.0 ⁇ m to 4.0 ⁇ m.
- the thickness of the Q layer can be adjusted to obtain the desired in-plane retardation of the ⁇ /4 plate.
- the Q layer is the liquid crystal alignment fixing layer described above, its thickness is, for example, 1.0 ⁇ m to 2.5 ⁇ m.
- the angle between the slow axis of the H layer and the absorption axis of the polarizer is preferably 10° to 20°, more preferably 12° to 18°, still more preferably 12°. ⁇ 16°; the angle formed by the slow axis of the Q layer and the absorption axis of the polarizer is preferably 70° to 80°, more preferably 72° to 78°, still more preferably 72° ⁇ 76°.
- each layer (for example, the H layer and the Q layer) may exhibit an inverse dispersion wavelength characteristic in which the retardation value increases according to the wavelength of the measurement light, and the retardation value varies according to the wavelength of the measurement light.
- a small positive wavelength dispersion characteristic may be exhibited, or a flat wavelength dispersion characteristic in which the retardation value hardly changes even with the wavelength of the measurement light may be exhibited.
- the Nz coefficient of the retardation layer is preferably 0.9 to 1.5, more preferably 0.9 to 1.3.
- the retardation layer is preferably a liquid crystal alignment fixed layer.
- the liquid crystal compound include a liquid crystal compound having a nematic liquid crystal phase (nematic liquid crystal).
- a liquid crystal compound for example, a liquid crystal polymer or a liquid crystal monomer can be used. Either lyotropic or thermotropic mechanism may be used to develop the liquid crystallinity of the liquid crystal compound.
- the liquid crystal polymer and liquid crystal monomer may be used alone or in combination.
- the liquid crystal monomer is preferably a polymerizable monomer and a crosslinkable monomer.
- the alignment state of the liquid crystal monomer can be fixed by polymerizing or cross-linking (that is, curing) the liquid crystal monomer. After aligning the liquid crystal monomers, for example, the alignment state can be fixed by polymerizing or cross-linking the liquid crystal monomers.
- a polymer is formed by polymerization and a three-dimensional network structure is formed by cross-linking, but these are non-liquid crystalline. Therefore, the formed retardation layer does not undergo a transition to a liquid crystal phase, a glass phase, or a crystal phase due to a change in temperature, which is peculiar to liquid crystalline compounds. As a result, the retardation layer becomes a highly stable retardation layer that is not affected by temperature changes.
- the temperature range in which the liquid crystal monomer exhibits liquid crystallinity differs depending on the type. Specifically, the temperature range is preferably 40°C to 120°C, more preferably 50°C to 100°C, and most preferably 60°C to 90°C.
- liquid crystal monomer Any appropriate liquid crystal monomer can be adopted as the liquid crystal monomer.
- polymerizable mesogenic compounds described in JP-T-2002-533742 WO00/37585
- EP358208 US5211877
- EP66137 US4388453
- WO93/22397 EP0261712, DE19504224, DE4408171, and GB2280445
- Specific examples of such polymerizable mesogenic compounds include LC242 (trade name) available from BASF, E7 (trade name) available from Merck, and LC-Sillicon-CC3767 (trade name) available from Wacker-Chem.
- a nematic liquid crystal monomer is preferable as the liquid crystal monomer.
- the retardation layer 30 includes a first retardation layer 31 that can function as a ⁇ /4 plate and a second retardation layer 32 (so-called It has a laminated structure with a positive C plate).
- the details of the ⁇ /4 plate are as described above.
- the angle between the slow axis of the first retardation layer and the absorption axis of the polarizer is preferably 40° to 50°, more preferably 42° to 48°, still more preferably is 44° to 46°.
- the first retardation layer preferably exhibits reverse dispersion wavelength characteristics in which the retardation value increases according to the wavelength of the measurement light.
- the thickness direction retardation Rth (550) of the positive C plate is preferably ⁇ 50 nm to ⁇ 300 nm, more preferably ⁇ 70 nm to ⁇ 250 nm, still more preferably ⁇ 90 nm to ⁇ 200 nm, and particularly preferably is -100 nm to -180 nm.
- the in-plane retardation Re(550) of the positive C plate is, for example, less than 10 nm.
- a liquid crystal material (liquid crystal compound) capable of homeotropic alignment may be a liquid crystal monomer or a liquid crystal polymer.
- Specific examples of the liquid crystal compound and the method for forming the retardation layer include the liquid crystal compound and the method for forming the retardation layer described in [0020] to [0028] of JP-A-2002-333642.
- the thickness of the second retardation layer is preferably 0.5 ⁇ m to 5 ⁇ m.
- the substrate of the surface protection film can be made of any appropriate material.
- forming materials include polyester-based polymers such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and polybutylene terephthalate (PBT); cellulose-based polymers such as diacetyl cellulose and triacetyl cellulose; polycarbonate-based polymers; (meth)acrylic polymers such as methyl methacrylate; cycloolefin polymers such as polynorbornene; These may be used alone or in combination of two or more.
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- PBT polybutylene terephthalate
- cellulose-based polymers such as diacetyl cellulose and triacetyl cellulose
- polycarbonate-based polymers such as polycarbonate-based polymers
- (meth)acrylic polymers such as methyl methacrylate
- cycloolefin polymers such as polynor
- the thickness of the substrate of the surface protective film is, for example, 10 ⁇ m or more and 100 ⁇ m or less, preferably 15 ⁇ m or more and 90 ⁇ m or less, and more preferably 25 ⁇ m or more and 80 ⁇ m or less.
- any appropriate configuration can be adopted as the pressure-sensitive adhesive layer of the surface protection film.
- Specific examples include acrylic adhesives, rubber adhesives, silicone adhesives, polyester adhesives, urethane adhesives, epoxy adhesives, and polyether adhesives.
- an adhesive having desired properties according to the purpose. can be prepared.
- the base resin of the adhesive may be used alone or in combination of two or more.
- the base resin is preferably an acrylic resin (specifically, the pressure-sensitive adhesive layer is preferably composed of an acrylic pressure-sensitive adhesive).
- the thickness of the adhesive layer is, for example, 5 ⁇ m to 15 ⁇ m.
- the storage modulus of the pressure-sensitive adhesive layer at 25° C. is, for example, 1.0 ⁇ 10 5 Pa to 1.0 ⁇ 10 7 Pa.
- the thickness of the surface protective film is, for example, 30 ⁇ m or more and 100 ⁇ m or less.
- the thickness of the adhesive layer 40 is preferably 10 ⁇ m to 20 ⁇ m.
- the details of the adhesive constituting the adhesive layer 40 are the same as those of the adhesive layer included in the surface protection film.
- the release film may be composed of any suitable plastic film.
- plastic films include polyethylene terephthalate (PET) films, polyethylene films, and polypropylene films.
- PET polyethylene terephthalate
- a release film can function as a separator.
- a plastic film whose surface is coated with a release agent is preferably used as the release film.
- release agents include silicone-based release agents, fluorine-based release agents, and long-chain alkyl acrylate-based release agents.
- the thickness of the release film is preferably 20 ⁇ m to 80 ⁇ m, more preferably 35 ⁇ m to 55 ⁇ m.
- the laminate according to the embodiment of the present invention can be obtained by placing the first protective material on the first main surface of the resin film and placing the second protective material on the second main surface of the resin film. can. Specifically, it can be obtained by laminating each layer constituting the first protective material and the second protective material on a resin film. Lamination of each layer is performed, for example, while conveying these by rolls (so-called roll-to-roll).
- Lamination of the retardation layer is typically carried out by transferring the liquid crystal alignment solidified layer formed on the substrate.
- the respective retardation layers may be sequentially laminated (transferred) to the resin film, and the laminate of the retardation layers is laminated (transferred) to the resin film.
- You may Transfer is performed using, for example, an active energy ray-curable adhesive.
- the thickness of the active energy ray-curable adhesive after curing is preferably 0.4 ⁇ m or more, more preferably 0.4 ⁇ m to 3.0 ⁇ m, and still more preferably 0.6 ⁇ m to 1.5 ⁇ m.
- the chemical modification can be carried out by any appropriate method depending on, for example, the properties of the modifying agent used.
- it can be carried out by a gas phase reaction.
- it can be carried out by placing the laminate in an atmosphere containing a vaporized modifier.
- the reaction time is, for example, 30 seconds to 60 minutes.
- it can be carried out by a liquid phase reaction.
- the laminate (for example, the end surface of the laminate) may be coated with a reaction liquid containing a modifying agent, or the laminate may be immersed in a reaction liquid containing a modifying agent.
- the immersion time is, for example, 10 seconds to 5 minutes.
- the end portion of the layer (second protective layer) 22 arranged adjacent to is deformed by chemical modification (for example, by dissolving in a modifying agent) to cover the end face 10c of the resin film 10 .
- the components contained in the layer 21 and the components contained in the layer 22 can be transformed by the modifying agent (for example, dissolved in the modifying agent).
- the layers 21 and 22 preferably contain resins such as cellulose-based resins such as TAC, polycarbonate-based resins, (meth)acrylic-based resins, and polyester-based resins.
- resins such as cellulose-based resins such as TAC, polycarbonate-based resins, (meth)acrylic-based resins, and polyester-based resins.
- the material forming the layer 21 and the material forming the layer 22 may be the same or different, but the layers 21 and 22 preferably contain common components. In this specification, "adjacent" also includes the case of adjoining via an adhesive layer.
- Polarizing plate (polarizing plate with retardation layer)
- a polarizing plate (polarizing plate with a retardation layer) obtained by chemically modifying the laminate is typically used in an image display panel. Practically, the obtained polarizing plate (retardation layer-attached polarizing plate) can be attached to the image display panel main body by the adhesive layer 40 .
- the release film 50 can function as a separator that is temporarily attached until the obtained polarizing plate (polarizing plate with retardation layer) is used.
- the resin film protective material can be used as it is as a product, but it is not limited to such a form.
- a laminate is separately prepared using an appropriate protective material and chemically modified, and then the protective material is removed from the laminate to obtain a polarizer.
- At least the protective layer or the retardation layer is A polarizing plate may be obtained by laminating one.
- thickness is the value measured by the following measuring method.
- parts and “%” in Examples and Comparative Examples are by weight.
- ⁇ Thickness> The thickness of 10 ⁇ m or less was measured using a scanning electron microscope (manufactured by JEOL Ltd., product name “JSM-7100F”). A thickness exceeding 10 ⁇ m was measured using a digital micrometer (manufactured by Anritsu Co., Ltd., product name “KC-351C”).
- Example 1-1 (Production of resin film)
- a thermoplastic resin substrate a long amorphous isophthalic copolymerized polyethylene terephthalate film (thickness: 100 ⁇ m) having a Tg of about 75° C. was used, and one side of this resin substrate was subjected to corona treatment.
- Polyvinyl alcohol degree of polymerization: 4,200, degree of saponification: 99.2 mol%) and acetoacetyl-modified PVA (manufactured by Nippon Synthetic Chemical Industry Co., Ltd., trade name "GOSEFIMER”) were mixed at a ratio of 9:1, and 100 parts by weight of PVA-based resin.
- aqueous PVA solution (coating solution).
- the above PVA aqueous solution was applied to the corona-treated surface of the resin base material and dried at 60° C. to form a PVA-based resin layer having a thickness of 13 ⁇ m, thereby producing a laminate.
- the resulting laminate was uniaxially stretched 2.4 times in the machine direction (longitudinal direction) in an oven at 130° C. (in-air auxiliary stretching treatment).
- the laminate was immersed in an insolubilizing bath (an aqueous boric acid solution obtained by mixing 4 parts by weight of boric acid with 100 parts by weight of water) at a liquid temperature of 40° C.
- the finally obtained polarizer is added to a dyeing bath (iodine aqueous solution obtained by blending iodine and potassium iodide at a weight ratio of 1:7 with respect to 100 parts by weight of water) at a liquid temperature of 30 ° C. It was immersed for 60 seconds while adjusting the concentration so that the single transmittance (Ts) was a desired value (dyeing treatment). Next, it was immersed for 30 seconds in a cross-linking bath at a liquid temperature of 40°C (an aqueous solution of boric acid obtained by blending 3 parts by weight of potassium iodide and 5 parts by weight of boric acid with respect to 100 parts by weight of water).
- crosslinking treatment After that, while immersing the laminate in an aqueous solution of boric acid (boric acid concentration: 4% by weight, potassium iodide concentration: 5% by weight) at a liquid temperature of 70° C., the laminate was moved vertically (longitudinally) between rolls with different peripheral speeds. Uniaxial stretching was performed so that the stretching ratio was 5.5 times (underwater stretching treatment). After that, the laminate was immersed in a washing bath (aqueous solution obtained by blending 4 parts by weight of potassium iodide with 100 parts by weight of water) at a liquid temperature of 20° C. (washing treatment).
- a washing bath aqueous solution obtained by blending 4 parts by weight of potassium iodide with 100 parts by weight of water
- HC-TAC film (thickness: 32 ⁇ m) was attached as a first protective layer to the resin film side of the laminate via an ultraviolet curable adhesive.
- the HC-TAC film is a film in which a hard coat (HC) layer (7 ⁇ m in thickness) is formed on a TAC film (25 ⁇ m in thickness), and the TAC film is attached to the resin film side.
- a surface protective film (thickness: 48 ⁇ m) was attached to the HC-TAC film.
- the surface protective film is a PET film (thickness: 38 ⁇ m) with an adhesive layer (thickness: 10 ⁇ m) formed thereon.
- a first protective member was formed on one side of the resin film.
- the resin base material was peeled off from the laminate, a pressure-sensitive adhesive layer with a thickness of 15 ⁇ m was formed on the other side of the resin film, and a separator (PET film, thickness of 38 ⁇ m) was attached. Thus, a second protective material was formed on the other side of the resin film, and a laminate A was obtained.
- the obtained long laminate was cut along the longitudinal direction and the width direction to prepare 10 sheet laminates of 30 mm ⁇ 30 mm.
- the longitudinal direction corresponds to the absorption axis direction of the polarizer.
- PS polystyrene
- Example 1-2 In the chemical modification, a polarizer (polarizing plate) was obtained in the same manner as in Example 1-1, except that the standing time was set to 10 minutes.
- Example 1-3 In chemical modification, a polarizer (polarizing plate) was obtained in the same manner as in Example 1-1, except that the laminate assembly was treated according to the following procedure.
- Example 1-5 A polarizer (polarizing plate) was obtained in the same manner as in Example 1-4 except that the immersion time was changed to 2 minutes for the chemical modification.
- Example 2-1 A polarizer (polarizing plate with a retardation layer) was obtained in the same manner as in Example 1-3, except that the laminate was produced by the following procedure.
- a long roll of polyvinyl alcohol (PVA) film with a thickness of 30 ⁇ m (manufactured by Kuraray, product name “PE3000”) is uniaxially stretched 5.9 times in the longitudinal direction by a roll stretching machine while being swollen at the same time. , dyeing, cross-linking, and washing in this order, and finally dried, to prepare a resin film having a thickness of 12 ⁇ m.
- the swelling treatment the film was stretched 2.2 times while being treated with pure water at 20°C.
- the dyeing treatment is performed in an aqueous solution at 30° C.
- the cross-linking treatment employed two-step cross-linking treatment, and the first-step cross-linking treatment was performed by stretching the film 1.2 times while treating it in an aqueous solution of boric acid and potassium iodide at 40°C.
- the boric acid content of the aqueous solution for the first-stage cross-linking treatment was 5.0% by weight, and the potassium iodide content was 3.0% by weight.
- the film was stretched 1.6 times while being treated in an aqueous solution of boric acid and potassium iodide at 65°C.
- the boric acid content of the aqueous solution for the second-stage cross-linking treatment was 4.3% by weight, and the potassium iodide content was 5.0% by weight.
- the washing treatment was carried out with an aqueous potassium iodide solution at 20°C.
- the potassium iodide content of the aqueous solution for the cleaning treatment was 2.6% by weight.
- a drying treatment was performed at 70° C. for 5 minutes to obtain a resin film.
- Polymerizable liquid crystal exhibiting a nematic liquid crystal phase (manufactured by BASF: trade name “Paliocolor LC242”, represented by the following formula) 10 g, and a photopolymerization initiator for the polymerizable liquid crystal compound (manufactured by BASF: trade name “Irgacure 907 ”) was dissolved in 40 g of toluene to prepare a liquid crystal composition (coating liquid).
- the surface of a polyethylene terephthalate (PET) film was rubbed with a rubbing cloth and subjected to orientation treatment.
- the direction of the orientation treatment was set at 15° to the direction of the absorption axis of the resin film (polarizer) when viewed from the viewing side when laminated on the resin film (polarizer).
- the above liquid crystal coating solution was applied to the alignment-treated surface using a bar coater, and dried by heating at 90° C. for 2 minutes to align the liquid crystal compound.
- the liquid crystal layer thus formed is irradiated with light of 1 mJ/cm 2 using a metal halide lamp to cure the liquid crystal layer, thereby forming a liquid crystal alignment fixed layer A (H layer) on the PET film.
- a liquid crystal alignment fixed layer B (Q layer) was formed on the PET film.
- HC-TAC film (thickness: 32 ⁇ m) was attached as a first protective layer to one side of the resin film via a PVA-based adhesive.
- the HC-TAC film is a film in which a hard coat (HC) layer (7 ⁇ m in thickness) is formed on a TAC film (25 ⁇ m in thickness), and the TAC film is attached to the resin film side.
- a surface protective film (thickness: 48 ⁇ m) was attached to the HC-TAC film.
- the surface protective film is a PET film (thickness: 38 ⁇ m) with an adhesive layer (thickness: 10 ⁇ m) formed thereon.
- a first protective member was formed on one side of the resin film.
- a TAC film (thickness: 25 ⁇ m) with Re (550) of 0 nm was attached as a second protective layer via a PVA-based adhesive.
- the obtained liquid crystal alignment fixed layer A (H layer) and liquid crystal alignment fixed layer B (Q layer) were transferred in this order to the TAC film.
- the angle between the absorption axis of the resin film (polarizer) and the slow axis of the oriented fixed layer A is 15°
- the angle between the absorption axis of the resin film (polarizer) and the slow axis of the oriented fixed layer B is 15°.
- the transfer (bonding) was performed at an angle of 75°.
- Example 2-2 A polarizer (polarizing plate with a retardation layer) was obtained in the same manner as in Example 2-1, except that dichlorodimethylsilane was used instead of trifluoroacetic anhydride in the chemical modification.
- Example 3 A polarizer (polarizing plate with a retardation layer) was obtained in the same manner as in Example 1-3, except that the laminate was produced by the following procedure.
- Example 2-1 A laminate C was obtained in the same manner as in Example 2-1, except that the resin film with a thickness of 5 ⁇ m used in Example 1-1 was used instead of the resin film with a thickness of 12 ⁇ m.
- Example 1 A polarizer (polarizing plate) was obtained in the same manner as in Example 1-1, except that the resulting laminate was not chemically modified.
- Example 2 A polarizer (polarizing plate with a retardation layer) was obtained in the same manner as in Example 2-1, except that the obtained laminate was not chemically modified.
- Example 3 A polarizer (a polarizing plate with a retardation layer) was obtained in the same manner as in Example 3, except that the obtained laminate was not chemically modified.
- a Fourier transform infrared spectrometer manufactured by PerkinElmer, trade name “Frontier” connected to an accessory (Universal ATR Sampling Accessor manufactured by PerkinElmer) that enables measurement by the ATR method (total reflection absorption method) ) was used to measure absorbance.
- the measurement conditions are as follows.
- Table 1 and FIGS. 4A-4C show the durability evaluation results (edge decolorization width). Also, the results of FT-IR measurement are shown in Table 1 and FIG. 5 (Examples 1-1, 1-2, 1-3 and Comparative Example 1).
- Example 1-1 Elemental analysis of the edges of the polarizing plates (samples) obtained in Examples 1-1 and 1-5 was performed using a scanning electron microscope (manufactured by Hitachi High-Technologies Corporation, product name "S-4800") and an energy dispersive type An X-ray analyzer (manufactured by HORIBA, product name "EMAX ENERGY”) was used.
- S-4800 scanning electron microscope
- EMAX ENERGY energy dispersive type An X-ray analyzer
- fluorine was detected near the end face of the sample, but was not detected at a position 30 ⁇ m in the in-plane direction from the end face of the sample.
- Example 1-5 silicon was detected near the end face of the sample, but was not detected at a position 20 ⁇ m in-plane from the end face of the sample.
- Example 2-1 As shown in the cross-sectional SEM observation photograph of FIG. It was confirmed that Fluorine is detected in the deformed portion (coated portion), and the end portion of the protective layer (TAC film) is deformed by chemical modification (specifically, dissolved in a modifier and solidified) to cover the end surface of the polarizer. Conceivable. As shown in FIG. 6, the deformed portion surrounded by the dashed line is continuously formed in the first protective layer TAC and the second protective layer TAC. A similar situation was confirmed in Example 3 as well. On the other hand, in Example 1-3, formation of such a deformed portion (coated portion) was not confirmed.
- a polarizer according to an embodiment of the present invention is used, for example, in image display devices such as liquid crystal display devices, organic EL display devices, and inorganic EL display devices.
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Abstract
Description
1つの実施形態においては、上記化学修飾部はフッ素を含む基を含む。
1つの実施形態においては、上記フッ素を含む基はトリフルオロアセチル基を含む。
1つの実施形態においては、上記化学修飾部は無水トリフルオロ酢酸により化学修飾されている。
1つの実施形態においては、上記端面は、ATR測定によるFT-IRスペクトルにおいて、2940cm-1における吸光度に対する1787cm-1における吸光度の比が0.2を超える。
1つの実施形態においては、上記端面を含む端部はフッ素を含む。
1つの実施形態においては、上記化学修飾部はシリル化剤により化学修飾されている。
1つの実施形態においては、上記端面を含む端部はケイ素を含む。
1つの実施形態においては、上記偏光子は、上記樹脂フィルムの端面を被覆する被覆部を有する。
本発明の別の実施形態によれば、上記偏光子の製造方法が提供される。この製造方法は、ヨウ素を含み、互いに対向する第一主面および第二主面を有する樹脂フィルムと、前記第一主面に配置された第一保護材と、前記第二主面に配置された第二保護材とを有する積層物を準備すること、および、前記積層物の前記樹脂フィルムの端面を化学修飾すること、を含む。
本発明のさらに別の実施形態によれば、偏光板が提供される。この偏光板は、上記偏光子と、保護層または位相差層の少なくとも一つと、を有する。
本発明のさらに別の実施形態によれば、上記偏光板の製造方法が提供される。この製造方法は、ヨウ素を含み、互いに対向する第一主面および第二主面を有する樹脂フィルムと、前記第一主面に配置された第一保護材と、前記第二主面に配置された第二保護材とを有する積層物を準備すること、および、前記積層物の前記樹脂フィルムの端面を化学修飾すること、を含み、前記保護材は、前記保護層または前記位相差層の少なくとも一つを含む。
本明細書における用語および記号の定義は下記の通りである。
(1)屈折率(nx、ny、nz)
「nx」は面内の屈折率が最大になる方向(すなわち、遅相軸方向)の屈折率であり、「ny」は面内で遅相軸と直交する方向(すなわち、進相軸方向)の屈折率であり、「nz」は厚み方向の屈折率である。
(2)面内位相差(Re)
「Re(λ)」は、23℃における波長λnmの光で測定した面内位相差である。例えば、「Re(550)」は、23℃における波長550nmの光で測定した面内位相差である。Re(λ)は、層(フィルム)の厚みをd(nm)としたとき、式:Re(λ)=(nx-ny)×dによって求められる。
(3)厚み方向の位相差(Rth)
「Rth(λ)」は、23℃における波長λnmの光で測定した厚み方向の位相差である。例えば、「Rth(550)」は、23℃における波長550nmの光で測定した厚み方向の位相差である。Rth(λ)は、層(フィルム)の厚みをd(nm)としたとき、式:Rth(λ)=(nx-nz)×dによって求められる。
(4)Nz係数
Nz係数は、Nz=Rth/Reによって求められる。
(5)角度
本明細書において角度に言及するときは、当該角度は基準方向に対して時計回りおよび反時計回りの両方を包含する。したがって、例えば「45°」は±45°を意味する。
図1は、本発明の1つの実施形態による偏光子の模式的な断面図である。なお、図1では、図を見やすくするために偏光子の断面は、ハッチングを省略している。偏光子10は、互いに対向する第一主面10aおよび第二主面10bを有する樹脂フィルムから構成される。偏光子10の端面10cは、樹脂フィルムが化学修飾された化学修飾部を有する。化学修飾部は、端面10cの少なくとも一部に形成されていればよく、形成領域は特に限定されないが、例えば、端面10cの全体に亘って形成される。
偏光度(%)={(Tp-Tc)/(Tp+Tc)}1/2×100
上記偏光子は、ヨウ素を含み、互いに対向する第一主面および第二主面を有する樹脂フィルムの端面を化学修飾することにより得ることができる。1つの実施形態においては、樹脂フィルムの第一主面に第一保護材が配置され、樹脂フィルムの第二主面に第二保護材が配置された状態で、樹脂フィルムの端面を化学修飾する。具体的には、第一保護材、樹脂フィルムおよび第二保護材を有する積層物を準備し、この積層物の樹脂フィルムの端面を化学修飾する。このような積層物を用いることにより、例えば、樹脂フィルムの端面に対して選択的に化学修飾を行い得る。
上記積層物に含まれる樹脂フィルムは、任意の適切な方法で作製され得る。1つの実施形態においては、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、エチレン・酢酸ビニル共重合体系部分ケン化フィルム等の親水性高分子フィルムに、ヨウ素や二色性染料等の二色性物質による染色処理と延伸処理とを施すことを含む方法により作製される。当該方法は、不溶化処理、膨潤処理、架橋処理等をさらに含んでいてもよい。このような作製方法は、当業界で周知慣用であるので、詳細な説明は省略する。
上記保護層は、偏光子の保護層として使用できる任意の適切なフィルムで形成され得る。当該フィルムの主成分となる材料の具体例としては、トリアセチルセルロース(TAC)等のセルロース系樹脂や、ポリエステル系、ポリビニルアルコール系、ポリカーボネート系、ポリアミド系、ポリイミド系、ポリエーテルスルホン系、ポリスルホン系、ポリスチレン系、ポリノルボルネン等のシクロオレフィン系、ポリオレフィン系、(メタ)アクリル系、アセテート系等の透明樹脂が挙げられる。
上記位相差層の厚みは、その構成(単一層であるか積層構造を有するか)にもよるが、好ましくは10μm以下であり、より好ましくは8μm以下であり、さらに好ましくは6μm以下である。一方、位相差層の厚みは、例えば1μm以上である。なお、位相差層が積層構造である場合、「位相差層の厚み」は、各位相差層の厚みの合計を意味する。具体的には、「位相差層の厚み」には接着層の厚みは含まれない。
上記表面保護フィルムの基材は、任意の適切な材料で形成され得る。形成材料の具体例としては、ポリエチレンテレフタレート(PET)、ポリエチレンナフタレート(PEN)、ポリブチレンテレフタレート(PBT)等のポリエステル系ポリマー;ジアセチルセルロース、トリアセチルセルロース等のセルロース系ポリマー;ポリカーボネート系ポリマー;ポリメチルメタクリレート等の(メタ)アクリル系ポリマー;ポリノルボルネン等のシクロオレフィン系ポリマー;が挙げられる。これらは、単独で用いてもよく二種以上を組み合わせて用いてもよい。
粘着剤層40の厚みは、好ましくは10μm~20μmである。粘着剤層40を構成する粘着剤の詳細については、上記表面保護フィルムに含まれる粘着剤層と同様である。
上記剥離フィルムは、任意の適切なプラスチックフィルムで構成され得る。プラスチックフィルムの具体例としては、ポリエチレンテレフタレート(PET)フィルム、ポリエチレンフィルム、ポリプロピレンフィルムが挙げられる。剥離フィルムは、セパレーターとして機能し得る。具体的には、剥離フィルムとして、表面が剥離剤でコートされたプラスチックフィルムが好ましく用いられる。剥離剤の具体例としては、シリコーン系剥離剤、フッ素系剥離剤、長鎖アルキルアクリレート系剥離剤が挙げられる。
本発明の実施形態による積層物は、樹脂フィルムの第一主面に第一保護材を配置し、樹脂フィルムの第二主面に第二保護材を配置することにより得ることができる。具体的には、樹脂フィルムに、第一保護材および第二保護材を構成する各層を積層することにより得ることができる。各層の積層は、例えば、これらをロール搬送しながら(いわゆるロールトゥロールにより)行われる。
上記化学修飾は、例えば、用いる修飾化剤の性質に応じて、任意の適切な方法により行うことができる。例えば、気相反応により行うことができる。具体的には、気化した修飾化剤を含む雰囲気下に上記積層物を置くことにより行うことができる。気相反応を採用する場合、反応時間は、例えば、30秒~60分である。別の例としては、液相反応により行うことができる。具体的には、上記積層物(例えば、積層物の端面)に修飾化剤を含む反応液を塗工してもよいし、修飾化剤を含む反応液に上記積層物を浸漬してもよい。浸漬による液相反応を採用する場合、浸漬時間は、例えば、10秒~5分である。
上記積層物に対して化学修飾を行って得られた偏光板(位相差層付偏光板)は、代表的には、画像表示パネルに用いられる。実用的には、得られた偏光板(位相差層付偏光板)は、粘着剤層40により、画像表示パネル本体に貼り付け可能とされる。剥離フィルム50は、得られた偏光板(位相差層付偏光板)が使用に供されるまで仮着されるセパレーターとして機能し得る。
<厚み>
10μm以下の厚みは、走査型電子顕微鏡(日本電子社製、製品名「JSM-7100F」)を用いて測定した。10μmを超える厚みは、デジタルマイクロメーター(アンリツ社製、製品名「KC-351C」)を用いて測定した。
(樹脂フィルムの作製)
熱可塑性樹脂基材として、長尺状で、Tg約75℃である、非晶質のイソフタル共重合ポリエチレンテレフタレートフィルム(厚み:100μm)を用い、この樹脂基材の片面に、コロナ処理を施した。
ポリビニルアルコール(重合度4200、ケン化度99.2モル%)およびアセトアセチル変性PVA(日本合成化学工業社製、商品名「ゴーセファイマー」)を9:1で混合したPVA系樹脂100重量部に、ヨウ化カリウム13重量部を添加したものを水に溶かし、PVA水溶液(塗布液)を調製した。
樹脂基材のコロナ処理面に、上記PVA水溶液を塗布して60℃で乾燥することにより、厚み13μmのPVA系樹脂層を形成し、積層体を作製した。
得られた積層体を、130℃のオーブン内で縦方向(長手方向)に2.4倍に一軸延伸した(空中補助延伸処理)。
次いで、積層体を、液温40℃の不溶化浴(水100重量部に対して、ホウ酸を4重量部配合して得られたホウ酸水溶液)に30秒間浸漬させた(不溶化処理)。
次いで、液温30℃の染色浴(水100重量部に対して、ヨウ素とヨウ化カリウムを1:7の重量比で配合して得られたヨウ素水溶液)に、最終的に得られる偏光子の単体透過率(Ts)が所望の値となるように濃度を調整しながら60秒間浸漬させた(染色処理)。
次いで、液温40℃の架橋浴(水100重量部に対して、ヨウ化カリウムを3重量部配合し、ホウ酸を5重量部配合して得られたホウ酸水溶液)に30秒間浸漬させた(架橋処理)。
その後、積層体を、液温70℃のホウ酸水溶液(ホウ酸濃度4重量%、ヨウ化カリウム濃度5重量%)に浸漬させながら、周速の異なるロール間で縦方向(長手方向)に総延伸倍率が5.5倍となるように一軸延伸を行った(水中延伸処理)。
その後、積層体を液温20℃の洗浄浴(水100重量部に対して、ヨウ化カリウムを4重量部配合して得られた水溶液)に浸漬させた(洗浄処理)。
その後、約90℃に保たれたオーブン中で乾燥しながら、表面温度が約75℃に保たれたSUS製の加熱ロールに接触させた(乾燥収縮処理)。
このようにして、樹脂基材上に厚み約5μmの樹脂フィルムを形成し、樹脂基材/樹脂フィルムの構成を有する積層体を得た。
上記積層体の樹脂フィルム側に、紫外線硬化型接着剤を介して、HC-TACフィルム(厚み32μm)を第一保護層として貼り合わせた。HC-TACフィルムは、TACフィルム(厚み25μm)にハードコート(HC)層(厚み7μm)が形成されたフィルムであり、TACフィルムが樹脂フィルム側となるようにして貼り合わせた。次いで、HC-TACフィルムに、表面保護フィルム(厚み48μm)を貼り合わせた。表面保護フィルムは、PET系フィルム(厚み38μm)に粘着剤層(厚み10μm)が形成されたフィルムである。こうして、樹脂フィルムの片側に第一保護材を形成した。
得られた長尺状の積層物を長手方向および幅方向に沿って切断し、30mm×30mmの枚葉状の積層物を10枚作製した。なお、長手方向は、偏光子の吸収軸方向に相当する。
得られた枚葉状の積層物10枚を重ね合わせ、その最上面と最下面に未発泡のポリスチレン(PS)シートを配置し、積層物集合体を得た。
得られた積層物集合体および4mlの無水トリフルオロ酢酸(富士フイルム和光純薬株式会社製、純度98.0%以上)を入れた容器(カップ)を、内部を窒素で満たしたポリエチレン製の袋(旭化成ホームプロダクツ株式会社製、ジップロック(登録商標)フリーザーバッグ、268mm×273mm)に入れて密封し、室温下に30分間静置した。
こうして、偏光子(偏光板)を得た。
化学修飾に際し、上記静置時間を10分としたこと以外は実施例1-1と同様にして、偏光子(偏光板)を得た。
化学修飾に際し、上記積層物集合体に対する処理を下記の手順で行ったこと以外は実施例1-1と同様にして、偏光子(偏光板)を得た。
得られた積層物集合体を、室温下で、無水トリフルオロ酢酸を入れた容器(カップ)に1分間浸漬した。
化学修飾に際し、無水トリフルオロ酢酸のかわりにジクロロジメチルシラン(東京化成工業株式会社製、純度98.0%以上)を用いたこと以外は実施例1-3と同様にして、偏光子(偏光板)を得た。
化学修飾に際し、上記浸漬時間を2分としたこと以外は実施例1-4と同様にして、偏光子(偏光板)を得た。
積層物を下記の手順で作製したこと以外は実施例1-3と同様にして、偏光子(位相差層付偏光板)を得た。
厚み30μmのポリビニルアルコール(PVA)系フィルム(クラレ製、製品名「PE3000」)の長尺ロールを、ロール延伸機により長手方向に5.9倍になるように長手方向に一軸延伸しながら同時に膨潤、染色、架橋、洗浄処理をこの順で施した後、最後に乾燥処理を施すことにより、厚み12μmの樹脂フィルムを作製した。
上記膨潤処理は20℃の純水で処理しながら2.2倍に延伸した。次いで、染色処理は得られる偏光子の単体透過率が45.0%になるようにヨウ素濃度が調整されたヨウ素とヨウ化カリウムの重量比が1:7である30℃の水溶液中において処理しながら1.4倍に延伸した。次いで、架橋処理は、2段階の架橋処理を採用し、1段階目の架橋処理は40℃のホウ酸とヨウ化カリウムを溶解した水溶液において処理しながら1.2倍に延伸した。1段階目の架橋処理の水溶液のホウ酸含有量は5.0重量%で、ヨウ化カリウム含有量は3.0重量%とした。2段階目の架橋処理は65℃のホウ酸とヨウ化カリウムを溶解した水溶液において処理しながら1.6倍に延伸した。2段階目の架橋処理の水溶液のホウ酸含有量は4.3重量%で、ヨウ化カリウム含有量は5.0重量%とした。次いで、洗浄処理は、20℃のヨウ化カリウム水溶液で処理した。洗浄処理の水溶液のヨウ化カリウム含有量は2.6重量%とした。最後に、70℃で5分間乾燥処理して樹脂フィルムを得た。
ネマチック液晶相を示す重合性液晶(BASF社製:商品名「Paliocolor LC242」、下記式で表される)10gと、当該重合性液晶化合物に対する光重合開始剤(BASF社製:商品名「イルガキュア907」)3gとを、トルエン40gに溶解して、液晶組成物(塗工液)を調製した。
上記樹脂フィルムの片側に、PVA系接着剤を介して、HC-TACフィルム(厚み32μm)を第一保護層として貼り合わせた。HC-TACフィルムは、TACフィルム(厚み25μm)にハードコート(HC)層(厚み7μm)が形成されたフィルムであり、TACフィルムが樹脂フィルム側となるようにして貼り合わせた。次いで、HC-TACフィルムに、表面保護フィルム(厚み48μm)を貼り合わせた。表面保護フィルムは、PET系フィルム(厚み38μm)に粘着剤層(厚み10μm)が形成されたフィルムである。こうして、樹脂フィルムの片側に第一保護材を形成した。
化学修飾に際し、無水トリフルオロ酢酸のかわりにジクロロジメチルシランを用いたこと以外は実施例2-1と同様にして、偏光子(位相差層付偏光板)を得た。
積層物を下記の手順で作製したこと以外は実施例1-3と同様にして、偏光子(位相差層付偏光板)を得た。
厚み12μmの樹脂フィルムのかわりに、実施例1-1で用いた厚み5μmの樹脂フィルムを用いたこと以外は実施例2-1と同様にして、積層物Cを得た。
得られた積層物に対し化学修飾を行わなかったこと以外は実施例1-1と同様にして、偏光子(偏光板)を得た。
得られた積層物に対し化学修飾を行わなかったこと以外は実施例2-1と同様にして、偏光子(位相差層付偏光板)を得た。
得られた積層物に対し化学修飾を行わなかったこと以外は実施例3と同様にして、偏光子(位相差層付偏光板)を得た。
各実施例および比較例について、耐久性(端部の脱色具合)を評価した。また、FT-IR測定も行った。
1.耐久性(端部脱色)
実施例および比較例で得られた偏光板(位相差層付偏光板)から表面保護フィルムおよびセパレーターを剥がし、これをガラス板に貼り合わせた。この状態で65℃、90%RHのオーブン内に240時間静置した後、偏光子の端部から脱色が生じているか否かを確認した。確認は、クロス透過(偏光子の吸収軸方向に偏光した入射光を透過させる条件)にて、偏光子の吸収軸方向の端辺を顕微鏡観察することにより行った。具体的には、偏光板の端部から偏光板中央部と同じ色味になる位置を目視で判断し、顕微鏡の測長プログラムを利用して偏光板の端部から偏光板中央部と同じ色味になる位置までの距離(端部脱色幅)を測長した。
2.FT-IR測定
各実施例および比較例で用いた樹脂フィルム(偏光子)を別途用意し、これに対し、各実施例および比較例と同条件で化学修飾したものを、FT-IR測定に供した。具体的には、ATR法(全反射吸収法)による測定を可能とするアクセサリ(PerkinElmer社製、Universal ATR Sampling Accessor)に接続したフーリエ変換赤外分光分析装置(PerkinElmer社製、商品名「Frontier」)を用いて吸光度測定を行った。
なお、測定条件は以下のとおりである。
・赤外光の入射角:45°
・分解能:4cm-1
・ATR結晶:GeのATR結晶(屈折率=4.0)
・測定範囲:600cm-1~4000cm-1(GeのATR結晶)
・積算回数:8回
得られたスペクトルから、2940cm-1における吸光度(A2940)に対する1787cm-1における吸光度(A1787)の比(A1787/A2940)を算出した。
実施例3においても、同様の状態が確認された。一方、実施例1-3においては、このような変形部(被覆部)の形成は確認されなかった。
2 第二保護材
10 偏光子(樹脂フィルム)
21 第一保護層
22 第二保護層
30 位相差層
31 第一位相差層
32 第二位相差層
40 粘着剤層
50 剥離フィルム
60 表面保護フィルム
100 積層物
Claims (12)
- ヨウ素を含み、互いに対向する第一主面および第二主面を有する樹脂フィルムから構成され、
端面に前記樹脂フィルムが化学修飾された化学修飾部を有し、
前記化学修飾部は、化学修飾されていない他の部位よりも疎水性が高い、
偏光子。 - 前記化学修飾部はフッ素を含む基を含む、請求項1に記載の偏光子。
- 前記フッ素を含む基はトリフルオロアセチル基を含む、請求項2に記載の偏光子。
- 前記化学修飾部は無水トリフルオロ酢酸により化学修飾されている、請求項1から3のいずれかに記載の偏光子。
- 前記端面は、ATR測定によるFT-IRスペクトルにおいて、2940cm-1における吸光度に対する1787cm-1における吸光度の比が0.2を超える、請求項1から4のいずれかに記載の偏光子。
- 前記端面を含む端部はフッ素を含む、請求項1から5のいずれかに記載の偏光子。
- 前記化学修飾部はシリル化剤により化学修飾されている、請求項1から6のいずれかに記載の偏光子。
- 前記端面を含む端部はケイ素を含む、請求項1から7のいずれかに記載の偏光子。
- 前記樹脂フィルムの端面を被覆する被覆部を有する、請求項1から8のいずれかに記載の偏光子。
- ヨウ素を含み、互いに対向する第一主面および第二主面を有する樹脂フィルムと、前記第一主面に配置された第一保護材と、前記第二主面に配置された第二保護材とを有する積層物を準備すること、および、
前記積層物の前記樹脂フィルムの端面を化学修飾すること、
を含む、請求項1から9のいずれかに記載の偏光子の製造方法。 - 請求項1から9のいずれかに記載の偏光子と、
保護層または位相差層の少なくとも一つと、
を有する、偏光板。 - ヨウ素を含み、互いに対向する第一主面および第二主面を有する樹脂フィルムと、前記第一主面に配置された第一保護材と、前記第二主面に配置された第二保護材とを有する積層物を準備すること、および、
前記積層物の前記樹脂フィルムの端面を化学修飾すること、を含み、
前記保護材は、前記保護層または前記位相差層の少なくとも一つを含む、
請求項11に記載の偏光板の製造方法。
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JP2006293188A (ja) * | 2005-04-14 | 2006-10-26 | Nippon Kayaku Co Ltd | 偏光素膜、偏光板、及びその製造法 |
WO2015056801A1 (ja) * | 2013-10-17 | 2015-04-23 | ホヤ レンズ タイランド リミテッド | 偏光レンズ、アイウエア、および偏光レンズの製造方法 |
CN109181186A (zh) * | 2018-11-12 | 2019-01-11 | 洪春 | 一种可生物降解疏水性pva树脂复合材料 |
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JP2006293188A (ja) * | 2005-04-14 | 2006-10-26 | Nippon Kayaku Co Ltd | 偏光素膜、偏光板、及びその製造法 |
WO2015056801A1 (ja) * | 2013-10-17 | 2015-04-23 | ホヤ レンズ タイランド リミテッド | 偏光レンズ、アイウエア、および偏光レンズの製造方法 |
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