U.S. patent application number 15/032852 was filed with the patent office on 2016-09-01 for polarizing plate.
The applicant listed for this patent is SUMITOMO CHEMICAL COMPANY, LIMITED. Invention is credited to Yuuhei INOKUCHI, Kenji MATSUNO.
Application Number | 20160252660 15/032852 |
Document ID | / |
Family ID | 53004041 |
Filed Date | 2016-09-01 |
United States Patent
Application |
20160252660 |
Kind Code |
A1 |
MATSUNO; Kenji ; et
al. |
September 1, 2016 |
POLARIZING PLATE
Abstract
There is provided a polarizing plate, including: a polarizing
layer having a thickness not greater than 20 .mu.m; a first
protective film stacked on one surface of the polarizing layer,
with a first adhesive layer formed from an active energy ray curing
adhesive being interposed; and a second protective film stacked on
the other surface of the polarizing layer, with a second adhesive
layer formed from a water-soluble adhesive being interposed. There
are also provided a polarizing plate with a pressure sensitive
adhesive layer, a substrate having a polarizing plate bonded
thereto, a liquid crystal display device, and an organic
electroluminescence display device, all of which include the
polarizing plate. Preferably, at least one of the first protective
film and the second protective film has a moisture permeability not
higher than 1000 g/m.sup.2/24 hr.
Inventors: |
MATSUNO; Kenji;
(Niihama-shi, Ehime, JP) ; INOKUCHI; Yuuhei;
(Niihama-shi, Ehime, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SUMITOMO CHEMICAL COMPANY, LIMITED |
Tokyo |
|
JP |
|
|
Family ID: |
53004041 |
Appl. No.: |
15/032852 |
Filed: |
October 22, 2014 |
PCT Filed: |
October 22, 2014 |
PCT NO: |
PCT/JP2014/078036 |
371 Date: |
April 28, 2016 |
Current U.S.
Class: |
359/487.02 |
Current CPC
Class: |
B32B 7/12 20130101; B32B
2457/202 20130101; B32B 2307/4026 20130101; G02B 1/14 20150115;
B32B 2457/206 20130101; B32B 27/06 20130101; G02F 1/133528
20130101; G02B 5/3033 20130101; B32B 2307/42 20130101; B32B 27/306
20130101; B32B 2307/412 20130101 |
International
Class: |
G02B 1/14 20060101
G02B001/14; G02F 1/1335 20060101 G02F001/1335; G02B 5/30 20060101
G02B005/30 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 29, 2013 |
JP |
2013-224018 |
Jul 17, 2014 |
JP |
2014-146785 |
Claims
1. A polarizing plate assembly, comprising a polarizing plate and a
transparent pressure sensitive adhesive layer, the polarizing plate
including: a polarizing layer having a thickness not greater than
20 .mu.m; a first protective film stacked on one surface of the
polarizing layer, with a first adhesive layer formed from an active
energy ray curing adhesive interposed therebetween; and a second
protective film stacked on the other surface of the polarizing
layer, with a second adhesive layer formed from a water-soluble
adhesive interposed therebetween, and the transparent pressure
sensitive adhesive layer being located on a side of the polarizing
plate having the first protective film.
2. The polarizing plate assembly according to claim 1, wherein at
least one of the first protective film and the second protective
film has a moisture permeability not higher than 1000 g/m.sup.2/24
hr.
3. The polarizing plate assembly according to claim 1, wherein the
second protective film has a moisture permeability of 10 to 1000
g/m.sup.2/24 hr.
4. The polarizing plate assembly according to claim 1, wherein the
polarizing layer is a stretched polyvinyl alcohol-based resin layer
containing a dichroic colorant.
5. The polarizing plate assembly according to claim 1, wherein the
polarizing layer has a thickness not greater than 10 .mu.m.
6. The polarizing plate assembly according to claim 1, wherein the
polarizing plate has a rectangular shape having a diagonal length
of 3 to 32 cm.
7. The polarizing plate assembly according to claim 1, further
comprising a surface treatment layer stacked on a surface of the
first protective film or the second protective film, the surface
being a surface on an opposite side of the polarizing layer.
8. The polarizing plate assembly according to claim 7, wherein the
surface treatment layer is a hard coat layer, an antireflective
layer or an electroconductive layer.
9. The polarizing plate assembly according to claim 1, wherein the
first protective film or the second protective film has a thickness
not greater than 50 .mu.m.
10. The polarizing plate assembly according to claim 1, wherein a
tensile elastic modulus at 80.degree. C. of the first protective
film or the second protective film is not lower than 1500 MPa.
11. The polarizing plate assembly according to claim 1, wherein:
the polarizing plate assembly is disposed at a viewing side of an
image display element.
12. A substrate having a polarizing plate bonded thereto,
comprising: the polarizing plate assembly as recited in claim 1;
and a substrate, wherein the polarizing plate is bonded to a
surface of the substrate on a side of the polarizing plate having
the first protective film, with the transparent pressure sensitive
adhesive layer being interposed therebetween.
13. A liquid crystal display device, comprising: the polarizing
plate assembly as recited in claim 1; and a liquid crystal cell
including a substrate, wherein the polarizing plate is bonded to a
surface of the substrate on a side of the polarizing plate having
the first protective film, with the transparent pressure sensitive
adhesive layer being interposed therebetween, and a resolution of a
display screen is not lower than 300 dpi.
14. The liquid crystal display device according to claim 13,
wherein the liquid crystal cell is a normally black-type liquid
crystal cell.
15. An organic electroluminescence display device, comprising: the
polarizing plate assembly as recited in claim 1; and an organic
electroluminescence display element including a substrate, wherein
the polarizing plate is bonded to a surface of the substrate on a
side of the polarizing plate having the first protective film, with
the transparent pressure sensitive adhesive layer being interposed
therebetween, and the first protective film has an in-plane phase
retardation value of 100 to 180 nm, and an angle of a slow axis of
the first protective film with respect to an absorption axis of the
polarizing layer is substantially 45.degree. or substantially
135.degree..
Description
TECHNICAL FIELD
[0001] The present invention relates to a polarizing plate having
protective films bonded to opposing surfaces of a polarizing
layer.
BACKGROUND ART
[0002] A polarizing plate has been widely used as a polarization
supply element or a polarization detection element in a display
device such as a liquid crystal display device. Generally, the
polarizing plate has such a configuration that a protective
film/protective films is/are bonded to one surface or both surfaces
of a polarizer by using an adhesive.
[0003] The use of a water-soluble adhesive as the adhesive for
bonding the polarizer and the protective film has been
conventionally known. The use of an active energy ray curing
adhesive has also been conventionally known. For example, Japanese
Patent Laying-Open No. 2012-208250 (PTD 1) discloses a polarizing
plate obtained by bonding a protective film to a polarizer with an
adhesive layer formed of an active energy ray curing adhesive being
interposed, and thereafter, curing the adhesive layer. When the
water-soluble adhesive is used, high moisture permeability is
required in the protective film. On the other hand, when the active
energy ray curing adhesive is used, the moisture permeability of
the protective film is not restricted, and thus, the active energy
ray curing adhesive is advantageous in this respect. In addition,
the active energy ray curing adhesive is also advantageous in that
the adhesive layer does not need to be dried and the drying step
which requires relatively long time can be omitted. Actually, in
Examples of PTD 1, the protective films on opposing surfaces of the
polarizer are both bonded by using the active energy ray curing
adhesive.
CITATION LIST
Patent Document
[0004] PTD 1: Japanese Patent Laying-Open No. 2012-208250
SUMMARY OF INVENTION
Technical Problem
[0005] Currently, a thickness of a polarizer constituting a
polarizing plate is generally approximately 30 .mu.m. However, in
accordance with requests from the market for reducing a thickness
of a polarizing plate, further reduction in thickness of a
polarizer is demanded. However, as a result of study by the
inventors of the present invention, it became clear that a
polarizing plate obtained by reducing a thickness of a polarizer to
approximately 20 .mu.m or smaller, bonding protective films to
opposing surfaces of the polarizer by using an active energy ray
curing adhesive, and curing the adhesive layers may cause a problem
of poor appearance, i.e., occurrence of minor irregularities over
the entire surface of the polarizing plate. This problem was not
caused in the case of using a thick polarizer of approximately 30
.mu.m.
[0006] These minor irregularities can also be visually recognized
when the polarizing plate is bonded to a flat surface such as a
substrate (e.g., a glass substrate constituting a liquid crystal
cell), and thus, these minor irregularities degrade the appearance
of the polarizing plate.
[0007] Thus, an object of the present invention is to provide a
polarizing plate with good appearance in which the occurrence of
the aforementioned minor irregularities is suppressed, the
polarizing plate having protective films stacked on opposing
surfaces of a thin polarizer of not greater than 20 .mu.m in
thickness, with adhesive layers being interposed.
Solution to Problem
[0008] The present invention provides a polarizing plate, a
polarizing plate with a pressure sensitive adhesive layer, a
substrate having a polarizing plate bonded thereto, a liquid
crystal display device, and an organic electroluminescence display
device described below.
[0009] [1] A polarizing plate, including:
[0010] a polarizing layer having a thickness not greater than 20
.mu.m;
[0011] a first protective film stacked on one surface of the
polarizing layer, with a first adhesive layer formed from an active
energy ray curing adhesive being interposed; and
[0012] a second protective film stacked on the other surface of the
polarizing layer, with a second adhesive layer formed from a
water-soluble adhesive being interposed.
[0013] [2] The polarizing plate according to [1], wherein at least
one of the first protective film and the second protective film has
a moisture permeability not higher than 1000 g/m.sup.2/24 hr.
[0014] [3] The polarizing plate according to [1] or [2], wherein
the second protective film has a moisture permeability of 10 to
1000 g/m.sup.2/24 hr.
[0015] [4] The polarizing plate according to any one of [1] to [3],
wherein the polarizing layer is a stretched polyvinyl alcohol-based
resin layer containing a dichroic colorant.
[0016] [5] The polarizing plate according to any one of [1] to [4],
wherein the polarizing layer has a thickness not greater than 10
.mu.m.
[0017] [6] The polarizing plate according to any one of [1] to [5],
wherein the polarizing plate has a rectangular shape having a
diagonal length of 3 to 32 cm.
[0018] [7] The polarizing plate according to any one of [1] to [6],
further including a surface treatment layer stacked on a surface of
the first protective film or the second protective film, the
surface being a surface on an opposite side of the polarizing
layer.
[0019] [8] The polarizing plate according to [7], wherein the
surface treatment layer is a hard coat layer, an antireflective
layer or an electroconductive layer.
[0020] [9] The polarizing plate according to any one of [1] to [8],
wherein the first protective film or the second protective film has
a thickness not greater than 50 .mu.m.
[0021] [10] The polarizing plate according to any one of [1] to
[9], wherein a tensile elastic modulus at 80.degree. C. of the
first protective film or the second protective film is not lower
than 1500 MPa.
[0022] [11] A polarizing plate with a pressure sensitive adhesive
layer, including:
[0023] the polarizing plate as recited in any one of [1] to [10];
and
[0024] a transparent pressure sensitive adhesive layer provided on
the first protective film side of the polarizing plate.
[0025] [12] A substrate having a polarizing plate bonded thereto,
including:
[0026] the polarizing plate as recited in any one of [1] to [10];
and
[0027] a substrate, wherein
[0028] the polarizing plate is bonded to a surface of the substrate
on the first protective film side of the polarizing plate, with a
transparent pressure sensitive adhesive layer being interposed.
[0029] [13] A liquid crystal display device, including:
[0030] the polarizing plate as recited in any one of [1] to [10];
and
[0031] a liquid crystal cell including a substrate, wherein
[0032] the polarizing plate is bonded to a surface of the substrate
on the first protective film side of the polarizing plate, and
[0033] a resolution of a display screen is not lower than 300
dpi.
[0034] [14] The liquid crystal display device according to [13],
wherein the liquid crystal cell is a normally black-type liquid
crystal cell.
[0035] [15] An organic electroluminescence display device,
including:
[0036] the polarizing plate as recited in any one of [1] to [10];
and
[0037] an organic electroluminescence display element including a
substrate, wherein
[0038] the polarizing plate is bonded to a surface of the substrate
on the first protective film side of the polarizing plate, and
[0039] the first protective film has an in-plane phase retardation
value of 100 to 180 nm, and an angle of a slow axis of the first
protective film with respect to an absorption axis of the
polarizing layer is substantially 45.degree. or substantially
135.degree..
Advantageous Effects of Invention
[0040] According to the present invention, there can be provided a
polarizing plate with good appearance in which the occurrence of
the aforementioned minor irregularities is suppressed, the
polarizing plate having protective films stacked on opposing
surfaces of a thin polarizer of not greater than 20 .mu.m in
thickness, with adhesive layers being interposed.
BRIEF DESCRIPTION OF DRAWINGS
[0041] FIG. 1(a) is a schematic cross-sectional view showing one
example of a layer configuration of a polarizing plate according to
the present invention, and FIG. 1(b) is a schematic cross-sectional
view showing one example of a layer configuration of a polarizing
plate with a pressure sensitive adhesive layer and a substrate
having a polarizing plate bonded thereto according to the present
invention.
[0042] FIG. 2 is a flowchart showing one preferable example of a
method of manufacturing the polarizing plate.
[0043] FIG. 3 is a schematic cross-sectional view showing one
example of a layer configuration of a laminated film obtained in a
resin layer formation step.
[0044] FIG. 4 is a schematic cross-sectional view showing one
example of a layer configuration of a stretched film obtained in a
stretching step.
[0045] FIG. 5 is a schematic cross-sectional view showing one
example of a layer configuration of a polarizing laminated film
obtained in a coloring step.
[0046] FIG. 6 is a schematic cross-sectional view showing one
example of a layer configuration of a bonded film obtained in a
first bonding step.
[0047] FIG. 7 is a schematic cross-sectional view showing one
example of a layer configuration of a polarizing plate with a
protective film on one surface obtained in a separation step.
[0048] FIG. 8 is a schematic view for describing a method of
evaluating an appearance of a surface of the polarizing plate.
[0049] FIG. 9 is a schematic view for describing a method of
measuring a reflection sharpness of the polarizing plate.
[0050] FIG. 10 is a schematic view for describing a method of
measuring a surface shape of the polarizing plate.
[0051] FIG. 11 is a schematic cross-sectional view showing one
example of a liquid crystal display device according to the present
invention.
[0052] FIG. 12 is a schematic cross-sectional view showing one
example of an organic electroluminescence display device according
to the present invention.
DESCRIPTION OF EMBODIMENTS
[0053] A polarizing plate according to the present invention will
hereinafter be described in detail with reference to
embodiments.
[0054] <Polarizing Plate>
[0055] FIG. 1(a) is a schematic cross-sectional view showing one
example of a layer configuration of a polarizing plate according to
the present invention. As shown in FIG. 1(a), a polarizing plate 1
of the present invention has such a configuration that protective
films are stacked on opposing surfaces of a polarizing layer 5 with
adhesive layers being interposed. Specifically, polarizing plate 1
of the present invention includes: thin polarizing layer 5 having a
thickness not greater than 20 .mu.m; a first protective film 10
stacked on one surface of polarizing layer 5, with a first adhesive
layer 15 formed from an active energy ray curing adhesive being
interposed; and a second protective film 20 stacked on the other
surface of polarizing layer 5, with a second adhesive layer 25
formed from a water-soluble adhesive being interposed.
[0056] According to such a configuration, it is possible to
effectively suppress or prevent the poor appearance caused by the
minor irregularities that occur on the surfaces of the protective
films in the polarizing plate obtained by reducing a thickness of
the polarizing layer to 20 .mu.m or smaller, bonding the protective
films to the opposing surfaces of the polarizing layer by using the
active energy ray curing adhesive, and curing the adhesive layers.
In particular, it is possible to more effectively suppress or
prevent the occurrence of the minor irregularities on an outer
surface (surface on the opposite side of polarizing layer 5) of
second protective film 20.
[0057] It is not clear why the minor irregularities on the surfaces
of the protective films can be suppressed or prevented in the
polarizing plate of the present invention although the thickness of
polarizing layer 5 is not greater than 20 .mu.m. However, the
active energy ray curing adhesive shrinks relatively greatly when
hardened, and thus, it is conceivable that by stacking second
protective film 20 using the water-soluble adhesive, the influence
of shrinkage of the active energy ray curing adhesive is mitigated
and the minor irregularities on the surfaces are suppressed.
[0058] FIG. 1(b) is a schematic cross-sectional view showing one
example of a substrate having a polarizing plate bonded thereto,
which has polarizing plate 1 shown in FIG. 1(a) bonded to a
substrate 4. In this example, polarizing plate 1 is provided with a
transparent pressure sensitive adhesive layer 3 on the first
protective film 10 side thereof and forms a polarizing plate with a
pressure sensitive adhesive layer. A glass substrate made of glass
is used as substrate 4. Polarizing plate 1 is bonded to substrate 4
on the first protective film 10 side, with transparent pressure
sensitive adhesive layer 3 being interposed. Substrate 4 may be a
glass substrate made of glass, or a resin substrate made of resin,
and a surface of substrate 4 on the side where substrate 4 and
polarizing plate 1 are bonded is preferably formed of a flat
surface.
[0059] Components constituting polarizing plate 1 will be described
hereinafter.
[0060] (1) Polarizing Layer
[0061] Polarizing layer 5 can be a uniaxially stretched polyvinyl
alcohol-based resin layer having a dichroic colorant adsorbed and
oriented therein. In the present invention, a thickness of
polarizing layer 5 is not greater than 20 .mu.m, preferably not
greater than 15 .mu.m, more preferably not greater than 11 .mu.m,
further preferably not greater than 10 .mu.m, and particularly
preferably not greater than 7 .mu.m. From the perspectives of
easiness to handle as well as easiness to achieve a degree of
polarization of not lower than 95% which is suitable for use in
display device applications and particularly a degree of
polarization of not lower than 99.9% which is suitable for use in
liquid crystal display device applications, the thickness of
polarizing layer 5 is normally not smaller than 2 .mu.m. Since the
thickness of polarizing layer 5 is set to be not greater than 20
.mu.m, a thickness of polarizing plate 1 can be reduced. On the
other hand, according to the present invention, even when such thin
polarizing layer 5 is used, the protective films can be bonded to
the opposing surfaces of polarizing layer 5 without the occurrence
of poor appearance (irregularities on the surface of polarizing
plate 1).
[0062] As a polyvinyl alcohol-based resin forming the polyvinyl
alcohol-based resin layer, a saponified polyvinyl acetate-based
resin can be used. As the polyvinyl acetate-based resin, a
copolymer of vinyl acetate and another monomer copolymerizable
therewith is indicated as an example, in addition to polyvinyl
acetate which is a homopolymer of vinyl acetate. Examples of
another monomer copolymerizable with vinyl acetate include
unsaturated carboxylic acids, olefins, vinyl ethers, unsaturated
sulfonic acids, acrylamides having an ammonium group, and the
like.
[0063] A degree of saponification of the polyvinyl alcohol-based
resin can be within a range of 80.0 to 100.0 mol %, preferably
within a range of 90.0 to 99.5 mol %, and more preferably within a
range of 94.0 to 99.0 mol %. If the degree of saponification is
lower than 80.0 mol %, the water resistance and the moisture and
heat resistance of obtained polarizing plate 1 decrease. When a
polyvinyl alcohol-based resin having a degree of saponification
exceeding 99.5 mol % is used, the coloring speed may decrease and
the productivity may decrease, and in addition, polarizing layer 5
having sufficient polarization characteristics is not obtained in
some cases.
[0064] The degree of saponification refers to a rate in unit ratio
(mol %) at which acetic acid groups (acetoxy groups: --OCOCH.sub.3)
included in the polyvinyl acetate-based resin which is a raw
material of the polyvinyl alcohol-based resin have changed into
hydroxyl groups by a saponification step. The degree of
saponification is defined by the following equation:
degree of saponification (mol %)=100.times.(the number of hydroxyl
groups)/(the number of hydroxyl groups+the number of acetic acid
groups).
[0065] The degree of saponification can be determined in accordance
with JIS K 6726 (1994). Higher degree of saponification indicates
higher rate of the hydroxyl groups, and thus, lower rate of acetic
acid groups that inhibit crystallization.
[0066] The polyvinyl alcohol-based resin may be a modified
polyvinyl alcohol which has been partially modified. Examples of
the modified polyvinyl alcohol include a substance obtained by
modifying the polyvinyl alcohol-based resin with olefin such as
ethylene and propylene; unsaturated carboxylic acid such as acrylic
acid, methacrylic acid and crotonic acid; alkyl ester of
unsaturated carboxylic acid; acrylamide; or the like. A rate of
modification is preferably lower than 30 mol %, and more preferably
lower than 10%. If modification is performed at a rate exceeding 30
mol %, adsorption of the dichroic colorant becomes less likely and
polarizing layer 5 having sufficient polarization characteristics
is not obtained.
[0067] An average degree of polymerization of the polyvinyl
alcohol-based resin is preferably 100 to 10000, more preferably
1500 to 8000, and further preferably 2000 to 5000. The average
degree of polymerization of the polyvinyl alcohol-based resin can
also be determined in accordance with JIS K 6726 (1994). If the
average degree of polymerization is lower than 100, it is difficult
to obtain preferable polarization characteristics. If the average
degree of polymerization exceeds 10000, the solubility in a solvent
becomes worse and formation of the polyvinyl alcohol-based resin
layer becomes difficult.
[0068] Examples of commercially available products of the polyvinyl
alcohol-based resin suitably used in the present invention include:
"PVA124" (a degree of saponification: 98.0 to 99.0 mol %), "PVA117"
(a degree of saponification: 98.0 to 99.0 mol %), "PVA624" (a
degree of saponification: 95.0 to 96.0 mol %), and "PVA617" (a
degree of saponification: 94.5 to 95.5 mol %) manufactured by
Kuraray Co., Ltd.; "AH-26" (a degree of saponification: 97.0 to
98.8 mol %), "AH-22" (a degree of saponification: 97.5 to 98.5 mol
%), "NH-18" (a degree of saponification: 98.0 to 99.0 mol %), and
"N-300" (a degree of saponification: 98.0 to 99.0 mol %)
manufactured by The Nippon Synthetic Chemical Industry Co., Ltd.;
and "JC-33" (a degree of saponification: not lower than 99.0 mol
%), "JM-33" (a degree of saponification: 93.5 to 95.5 mol %),
"JM-26" (a degree of saponification: 95.5 to 97.5 mol %), "JP-45"
(a degree of saponification: 86.5 to 89.5 mol %), "JF-17" (a degree
of saponification: 98.0 to 99.0 mol %), "JF-17L" (a degree of
saponification: 98.0 to 99.0 mol %), and "JF-20" (a degree of
saponification: 98.0 to 99.0 mol %) manufactured by Japan Vam &
Poval Co., Ltd., all of which are trade names.
[0069] The dichroic colorant contained (adsorbed and oriented) in
polarizing layer 5 can be iodine or dichroic organic dye. Specific
examples of the dichroic organic dye include red BR, red LR, red R,
pink LB, rubine BL, Bordeaux GS, sky blue LG, lemon yellow, blue
BR, blue 2R, navy RY, green LG, violet LB, violet B, black H, black
B, black GSP, yellow 3G, yellow R, orange LR, orange 3R, scarlet
GL, scarlet KGL, congo red, brilliant violet BK, supra blue G,
supra blue GL, supra orange GL, direct sky blue, direct fast orange
S, and fast black. Only one type of dichroic colorant may be used
alone, or two or more types of dichroic colorants may be used
together.
[0070] (2) First and Second Protective Films
[0071] Each of first protective film 10 and second protective film
20 can be a transparent resin film composed of a thermoplastic
resin, e.g., a polyolefin-based resin such as a chainlike
polyolefin-based resin (a polypropylene-based resin and the like)
and a cyclic polyolefin-based resin (a norbornene-based resin and
the like); a cellulose ester-based resin such as cellulose
triacetate and cellulose diacetate; a polyester-based resin such as
polyethylene terephthalate, polyethylene naphthalate and
polybutylene terephthalate; a polycarbonate-based resin; a
(meth)acryl-based resin; or a mixture thereof, a copolymer thereof,
or the like. In addition, first protective film 10 and second
protective film 20 may be glass films. Only first protective film
10 may be a glass film and second protective film 20 may be a
transparent resin film. Alternatively, only second protective film
20 may be a glass film and first protective film 10 may be a
transparent resin film. Alternatively, both first protective film
10 and second protective film 20 may be glass films.
[0072] The cyclic polyolefin-based resin is a generic designation
of resins polymerized by using cyclic olefin as a polymerization
unit, and examples of the cyclic polyolefin-based resin include
resins described in Japanese Patent Laying-Open No. 1-240517,
Japanese Patent Laying-Open No. 3-14882, Japanese Patent
Laying-Open No. 3-122137 and the like. Specific examples of the
cyclic polyolefin-based resin include a ring-opening (co)polymer of
cyclic olefin, an addition polymer of cyclic olefin, a copolymer of
cyclic olefin and chainlike olefin such as ethylene and propylene
(representatively a random copolymer), a graft polymer obtained by
modifying the former with unsaturated carboxylic acid or a
derivative thereof, a hydride thereof, and the like. Among these, a
norbornene-based resin using a norbornene-based monomer such as
norbornene or a polycyclic norbornene-based monomer is preferably
used as cyclic olefin.
[0073] Various products of the cyclic polyolefin-based resin are
commercially available. Examples of commercially available products
of the cyclic polyolefin-based resin include "Topas" (manufactured
by Topas Advanced Polymers GmbH and available from Polyplastics
Co., Ltd.), "ARTON" (manufactured by JSR Corporation), "ZEONOR"
(manufactured by ZEON Corporation), "ZEONEX" (manufactured by ZEON
Corporation), and "APEL" (manufactured by Mitsui Chemicals, Inc.),
all of which are trade names.
[0074] Commercially available products of a cyclic polyolefin-based
resin film such as "Escena" (manufactured by Sekisui Chemical Co.,
Ltd.), "SCA40" (manufactured by Sekisui Chemical Co., Ltd.) and
"ZEONOR film" (manufactured by ZEON Corporation), all of which are
trade names, may also be used as the protective film.
[0075] The cellulose ester-based resin is an ester of cellulose and
fatty acid. Specific examples of the cellulose ester-based resin
include cellulose triacetate, cellulose diacetate, cellulose
tripropionate, and cellulose dipropionate. In addition, a copolymer
thereof, and a substance obtained by modifying some hydroxyl groups
with other type of substituent can also be used. Among these,
cellulose triacetate (triacetylcellulose: TAC) is particularly
preferable. Many cellulose triacetate products are commercially
available, and are advantageous also in terms of availability and
cost. Examples of commercially available products of cellulose
triacetate include "FUJITAC TD80" (manufactured by Fujifilm
Corporation), "FUJITAC TD80UF" (manufactured by Fujifilm
Corporation), "FUJITAC TD80UZ" (manufactured by Fujifilm
Corporation), "FUJITAC TD40UZ" (manufactured by Fujifilm
Corporation), "KC8UX2M" (manufactured by Konica Minolta Optics,
Inc.), and "KC4UY" (manufactured by Konica Minolta Optics, Inc.),
all of which are trade names.
[0076] First protective film 10 or second protective film 20 can
also be a protective film further having an optical function such
as a phase retardation film and a luminance enhancement film. For
example, by stretching (uniaxially stretching, biaxially stretching
or the like) the transparent resin film composed of the
aforementioned material or by forming a liquid crystal layer or the
like on this film, a phase retardation film having an arbitrary
phase retardation value can be obtained. Only first protective film
10 may further have the optical function, or only second protective
film 20 may further have the optical function, or both first
protective film 10 and second protective film 20 may further have
the optical function.
[0077] A surface treatment layer (coating layer) such as a hard
coat layer, an antiglare layer, an antireflective layer, an
antistatic layer, an antifouling layer, and an electroconductive
layer can also be formed on a surface of first protective film 10
or second protective film 20, wherein the surface is a surface on
the opposite side of polarizing layer 5. A method of forming the
surface treatment layer on the surface of the protective film is
not particularly limited, and a known method can be used. This
surface treatment layer may be formed on first protective film 10
and second protective film 20, or may be formed only on first
protective film 10. However, this surface treatment layer is
preferably formed on second protective film 20, and in this case,
the surface of first protective film 10 may be a non-treated
surface that does not have the surface treatment layer.
[0078] In the case where the hard coat layer or the antireflective
layer is provided on the surface, on the opposite side of
polarizing layer 5, of first protective film 10 or second
protective film 20, the poor appearance caused by the minor
irregularities present on the surface of the protective film is
easily noticeable when the polarizing plate is viewed from the hard
coat layer side or the antireflective layer side. Therefore, the
present invention is preferably applied in the above-mentioned
case.
[0079] In addition, in the case where the electroconductive layer
is provided on the surface, on the opposite side of polarizing
layer 5, of first protective film 10 and/or second protective film
20 and a surface of the electroconductive layer is bonded to a
cover glass or a touch panel with an optically transparent resin
layer being interposed, the poor appearance caused by the minor
irregularities present on the surface of the protective film tends
to be easily noticeable when the polarizing plate is viewed from
the cover glass side or the touch panel side, because an optical
reflectivity of many electroconductive layers is relatively high
due to a refractive index thereof. Therefore, the present invention
is particularly preferably applied in the above-mentioned case.
Examples of the electroconductive layer include a layer formed of
ATO (antimony tin oxide), ITO (indium tin oxide) or the like, and
others.
[0080] First protective film 10 and second protective film 20 may
be protective films of the same type, or may be protective films of
different types. Examples of the protective films of different
types include, for example, a combination of protective films
different at least in type of the thermoplastic resin constituting
the protective film, a combination of protective films different at
least in presence or absence of the optical function of the
protective film or type thereof, and a combination of protective
films different at least in presence or absence of the surface
treatment layer formed on the surface or type thereof.
[0081] From the perspective of reducing the thickness of polarizing
plate 1, it is preferable that a thickness of each of first and
second protective films 10 and 20 is small. However, when the
thickness is too small, the strength decreases and the workability
deteriorates. Therefore, the thickness of each of first and second
protective films 10 and 20 is preferably 5 to 90 .mu.m, more
preferably 5 to 60 .mu.m, and further preferably 5 to 50 .mu.m.
[0082] When first protective film 10 or second protective film 20
has a thickness not greater than 50 .mu.m, the minor irregularities
tend to easily occur on the surface thereof. Therefore, the present
invention is preferably applied in the above-mentioned case.
[0083] As described above, polarizing layer 5 used in polarizing
plate 1 of the present invention is thin, and thus, decoloration of
the dichroic colorant tends to easily occur under the
high-temperature and high-humidity environment. Therefore, a lower
moisture permeability is more preferable in first and second
protective films 10 and 20. Specifically, the moisture permeability
of each of first and second protective films 10 and 20 is
preferably not higher than 1000 g/m.sup.2/24 hr, and more
preferably not higher than 150 g/m.sup.2/24 hr.
[0084] On the other hand, the water-soluble adhesive is used to
bond second protective film 20 with second adhesive layer 25
interposed. Therefore, if the moisture permeability of second
protective film 20 is too low, drying of the adhesive layer
requires time, which may lead to low productivity. Thus, from the
perspective of productivity of polarizing plate 1, the moisture
permeability of second protective film 20 is preferably 10 to 1000
g/m.sup.2/24 hr, and more preferably 10 to 150 g/m.sup.2/24 hr.
[0085] A higher tensile elastic modulus is more preferable in first
protective film 10 and/or second protective film 20 used in the
present invention. It is preferable that a tensile elastic modulus
at 80.degree. C. is not lower than 1500 MPa, and preferably not
lower than 2000 MPa, and is normally not higher than 10000 MPa. By
applying the protective film having a high tensile elastic modulus,
the poor appearance can be effectively suppressed or prevented.
[0086] (3) First Adhesive Layer
[0087] The adhesive forming first adhesive layer 15 is an active
energy ray curing adhesive that can be hardened by irradiation with
an active energy ray such as an ultraviolet ray, visible light, an
electron beam, and an X ray, and first adhesive layer 15 is a
hardened product layer of the adhesive. Among these, an active
energy ray curing adhesive including, as a curing component, an
epoxy-based compound hardened by cationic polymerization can be
more preferably used, and an ultraviolet curing adhesive including
the epoxy-based compound as the curing component can be further
preferably used as the adhesive forming first adhesive layer 15.
The epoxy-based compound herein refers to a compound having one or
more epoxy groups, and preferably two or more epoxy groups, on
average in a molecule. Only one type of epoxy-based compound may be
used alone, or two or more types of epoxy-based compounds may be
used together.
[0088] Examples of the epoxy-based compound that can be suitably
used include: a hydrogenated epoxy-based compound (glycidyl ether
of polyol having an alicyclic ring) obtained by reacting
epichlorohydrin with alicyclic polyol obtained by the hydrogenation
reaction of an aromatic ring of aromatic polyol; an aliphatic
epoxy-based compound such as polyglycidyl ether of aliphatic
polyalcohol or alkylene oxide adduct thereof; and an alicyclic
epoxy-based compound which is an epoxy-based compound having, in a
molecule, one or more epoxy groups coupled to an alicyclic
ring.
[0089] The active energy ray curing adhesive can also further
contain a radically polymerizable (meth)acryl-based compound as a
curing component. Examples of the (meth)acryl-based compound can
include a (meth)acryloyloxy group-containing compound such as a
(meth)acrylate monomer having at least one (meth)acryloyloxy group
in a molecule, and a (meth)acrylate oligomer obtained by reacting
two or more types of functional group-containing compounds and
having at least two (meth)acryloyloxy groups in a molecule.
[0090] When the active energy ray curing adhesive includes, as a
curing component, the epoxy-based compound hardened by cationic
polymerization, the active energy ray curing adhesive preferably
contains a photocationic polymerization initiator. Examples of the
photocationic polymerization initiator can include: an aromatic
diazonium salt; an onium salt such as an aromatic iodonium salt and
an aromatic sulfonium salt; an iron-allene complex; and the like.
When the active energy ray curing adhesive contains the radically
polymerizable curing component such as the (meth)acryl-based
compound, the active energy ray curing adhesive preferably contains
a photoradical polymerization initiator. Examples of the
photoradical polymerization initiator can include an
acetophenone-based initiator, a benzophenone-based initiator, a
benzoin ether-based initiator, a thioxanthone-based initiator,
xanthone, fluorenone, camphorquinone, benzaldehyde, anthraquinone
and the like.
[0091] As needed, the active energy ray curing adhesive can contain
an additive such as a cationic polymerization accelerator including
oxetanes and polyols, a photosensitizer, an ion trap agent, an
antioxidant, a chain transfer agent, a tackiness imparting agent, a
thermoplastic resin, a filler, a fluidity controlling agent, a
plasticizer, a defoamant, an antistatic agent, a leveling agent,
and a solvent.
[0092] A thickness of first adhesive layer 15 is, for example,
approximately 0.01 to 10 .mu.m, preferably approximately 0.01 to 5
.mu.m, and more preferably not greater than 2 .mu.m (e.g., not
greater than 1 .mu.m), and preferably not smaller than 0.4 .mu.m.
First adhesive layer 15 having a thickness not smaller than 0.4
.mu.m is advantageous in that first adhesive layer 15 is relatively
easily formed without entry of bubbles. On the other hand, the
minor irregularities become more likely to occur on the surface of
the protective film as the thickness becomes greater. Therefore,
when the thickness of first adhesive layer 15 is not smaller than
0.4 .mu.m, the present invention is particularly preferably
applied.
[0093] In addition, first adhesive layer 15 is formed of the active
energy ray curing adhesive and shrinks when the adhesive is
hardened. Therefore, polarizing plate 1 is likely to have a concave
shape when polarizing plate 1 is placed on a flat surface with
first protective film 10 of polarizing plate 1 facing upward.
Therefore, in order to suppress such curl, the thickness of first
adhesive layer 15 is preferably set to be not greater than 2 .mu.m
(e.g., not greater than 1 .mu.m).
[0094] (4) Second Adhesive Layer
[0095] The water-soluble adhesive forming second adhesive layer 25
is obtained by dissolving an adhesive component in water or by
dispersing an adhesive component in water. The preferably used
water-soluble adhesive is, for example, an adhesive composition
including a polyvinyl alcohol-based resin or a urethane resin as a
main component. A thickness of second adhesive layer 25 formed from
the water-soluble adhesive is normally not greater than 1 .mu.m,
and normally not smaller than 0.01 .mu.m.
[0096] When the polyvinyl alcohol-based resin is used as the main
component of the adhesive, the polyvinyl alcohol-based resin may be
a modified polyvinyl alcohol-based resin such as carboxyl
group-modified polyvinyl alcohol, acetoacetyl group-modified
polyvinyl alcohol, methylol group-modified polyvinyl alcohol, and
amino group-modified polyvinyl alcohol, or may be partially
saponified polyvinyl alcohol or completely saponified polyvinyl
alcohol. The polyvinyl alcohol-based resin may be a polyvinyl
alcohol-based copolymer obtained by saponifying a copolymer of
vinyl acetate and another monomer copolymerizable therewith, or may
be a vinyl alcohol homopolymer obtained by saponifying polyvinyl
acetate which is a homopolymer of vinyl acetate.
[0097] The water-soluble adhesive including the polyvinyl
alcohol-based resin as the adhesive component is normally an
aqueous solution of the polyvinyl alcohol-based resin. A
concentration of the polyvinyl alcohol-based resin in the adhesive
is normally 1 to 10 parts by weight, and preferably 1 to 5 parts by
weight, with respect to 100 parts by weight of water.
[0098] In order to enhance adhesion, a cross-linker or a curing
component such as polyaldehyde, a melamine-based compound, a
zirconia compound, a zinc compound, glyoxal, and a water-soluble
epoxy resin is preferably added to the adhesive formed of the
aqueous solution of the polyvinyl alcohol-based resin. As the
water-soluble epoxy resin, a polyamide polyamine epoxy resin
obtained by reacting epichlorohydrin with polyamideamine obtained
by reaction of polyalkylene polyamine such as diethylene triamine
and triethylenetetramine with dicarboxylic acid such as adipic acid
can, for example, be suitably used. Examples of commercially
available products of the polyamide polyamine epoxy resin include
"Sumirez Resin 650" (manufactured by Taoka Chemical Company, Ltd.),
"Sumirez Resin 675" (manufactured by Taoka Chemical Company, Ltd.),
"WS-525" (manufactured by Japan PMC Corporation) and the like. An
amount of addition of these curing component or cross-linker (when
both the curing component and the cross-linker are added, a total
amount thereof) is normally 1 to 100 parts by weight, and
preferably 1 to 50 parts by weight, with respect to 100 parts by
weight of the polyvinyl alcohol-based resin. If the aforementioned
amount of addition of the curing component or cross-linker is
smaller than 1 part by weight with respect to 100 parts by weight
of the polyvinyl alcohol-based resin, the effect of enhancing
adhesion tends to become small. If the aforementioned amount of
addition of the curing component or cross-linker exceeds 100 parts
by weight with respect to 100 parts by weight of the polyvinyl
alcohol-based resin, the adhesive layer tends to become
brittle.
[0099] When the urethane resin is used as the main component of the
adhesive, examples of the appropriate adhesive composition can
include a mixture of a polyester-based ionomer-type urethane resin
and a compound having a glycidyloxy group. The polyester-based
ionomer-type urethane resin refers to a urethane resin having a
polyester main chain, into which a small amount of an ionic
component (hydrophilic component) is introduced. This ionomer-type
urethane resin is suitable as the water-soluble adhesive because
the ionomer-type urethane resin is directly emulsified in water and
becomes emulsion without using an emulsifier.
[0100] <Method of Manufacturing Polarizing Plate>
[0101] Polarizing plate 1 of the present invention shown in FIG.
1(a) can be manufactured by, for example, the following
methods:
[0102] [a] a method of fabricating, as a single-layer film, a
polyvinyl alcohol-based resin film (hereinafter also referred to as
"polarizing film") having polarization characteristics as
polarizing layer 5 from a polyvinyl alcohol-based resin film, and
bonding first and second protective films 10 and 20 to this
polarizing film; and
[0103] [b] a method of applying a coating liquid containing a
polyvinyl alcohol-based resin to at least one surface of a
substrate film to form a polyvinyl alcohol-based resin layer, and
thereafter, providing prescribed treatment for the obtained
laminated film to obtain polarizing layer 5 from the polyvinyl
alcohol-based resin layer, and bonding one of first and second
protective films 10 and 20 to the obtained polarizing laminated
film, and thereafter, separating the substrate film, and then,
bonding the other protective film.
[0104] [Manufacturing Method [a]]
[0105] The polarizing film as polarizing layer 5 used in the
manufacturing method [a] can be fabricated by using, as a starting
material, the polyvinyl alcohol-based resin film made by forming a
film of the aforementioned polyvinyl alcohol-based resin. A method
of forming a film of the polyvinyl alcohol-based resin is not
particularly limited, and a known method such as a melt extrusion
method and a solvent casting method can be used. A thickness of the
polyvinyl alcohol-based resin film is, for example, approximately
10 to 150 .mu.m.
[0106] The polarizing film can be manufactured through a step of
uniaxially stretching the polyvinyl alcohol-based resin film, a
step of coloring the polyvinyl alcohol-based resin film with a
dichroic colorant to adsorb the dichroic colorant, a step of
treating the polyvinyl alcohol-based resin film having the dichroic
colorant adsorbed therein with a boric acid aqueous solution, and a
step of washing the polyvinyl alcohol-based resin film with water
after treatment with the boric acid aqueous solution.
[0107] Uniaxial stretching of the polyvinyl alcohol-based resin
film can be performed before, simultaneously with or after coloring
with the dichroic colorant. When uniaxial stretching is performed
after coloring, this uniaxial stretching may be performed before or
during boric acid treatment. Alternatively, uniaxial stretching may
be performed at a plurality of these stages.
[0108] In uniaxial stretching, the polyvinyl alcohol-based resin
film may be uniaxially stretched between rolls having different
circumferential speeds, or may be uniaxially stretched by using a
heat roll. In addition, uniaxial stretching may be dry stretching
in which stretching is performed in the atmosphere, or may be wet
stretching in which a solvent is used and stretching is performed
with the polyvinyl alcohol-based resin film being swollen with the
solvent. A stretching magnification is normally approximately 3 to
17, and preferably not lower than 4, and preferably not higher than
8.
[0109] As a method of coloring the polyvinyl alcohol-based resin
film with the dichroic colorant, a method of immersing the
polyvinyl alcohol-based resin film in an aqueous solution (coloring
solution) containing the dichroic colorant can, for example, be
used. The polyvinyl alcohol-based resin film is preferably
subjected to treatment of immersion in water (swelling treatment)
before coloring treatment.
[0110] When iodine is used as the dichroic colorant, a method of
immersing the polyvinyl alcohol-based resin film in an aqueous
solution containing iodine and potassium iodide and coloring the
polyvinyl alcohol-based resin film is normally used. An amount of
iodine contained in this coloring aqueous solution is normally
approximately 0.01 to 1 parts by weight with respect to 100 parts
by weight of water. In addition, an amount of contained potassium
iodide is normally approximately 0.5 to 20 parts by weight with
respect to 100 parts by weight of water. A temperature of the
coloring aqueous solution is normally approximately 20 to
40.degree. C. In addition, a time period of immersion in the
coloring aqueous solution (coloring time period) is normally
approximately 20 to 1800 seconds.
[0111] On the other hand, when the dichroic organic dye is used as
the dichroic colorant, a method of immersing the polyvinyl
alcohol-based resin film in a coloring aqueous solution including a
water-soluble dichroic organic dye and coloring the polyvinyl
alcohol-based resin film is normally used. An amount of the
dichroic organic dye contained in the coloring aqueous solution is
normally approximately 1.times.10.sup.-4 to 10 parts by weight, and
preferably approximately 1.times.10.sup.-3 to 1 parts by weight,
with respect to 100 parts by weight of water. This coloring aqueous
solution may contain an inorganic salt of sodium sulfate and the
like as a coloring aid. A temperature of the coloring aqueous
solution is normally approximately 20 to 80.degree. C.
[0112] In addition, a time period of immersion in the coloring
aqueous solution (coloring time period) is normally approximately
10 to 1800 seconds.
[0113] The boric acid treatment after coloring with the dichroic
colorant can be performed by immersing the colored polyvinyl
alcohol-based resin film in a boric acid-containing aqueous
solution.
[0114] An amount of boric acid in the boric acid-containing aqueous
solution is normally approximately 2 to 15 parts by weight, and
preferably 5 to 12 parts by weight, with respect to 100 parts by
weight of water. When iodine is used as the dichroic colorant, this
boric acid-containing aqueous solution preferably contains
potassium iodide. An amount of potassium iodide in the boric
acid-containing aqueous solution is normally approximately 0.1 to
15 parts by weight, and preferably approximately 5 to 12 parts by
weight, with respect to 100 parts by weight of water. A time period
of immersion in the boric acid-containing aqueous solution is
normally approximately 60 to 1200 seconds, preferably approximately
150 to 600 seconds, and more preferably approximately 200 to 400
seconds. A temperature of the boric acid-containing aqueous
solution is normally not lower than 50.degree. C., preferably 50 to
85.degree. C., and more preferably 60 to 80.degree. C.
[0115] The polyvinyl alcohol-based resin film subjected to boric
acid treatment is normally subjected to water washing treatment.
The water washing treatment can be performed, for example, by
immersing the polyvinyl alcohol-based resin film subjected to boric
acid treatment in water. A temperature of water in the water
washing treatment is normally approximately 5 to 40.degree. C. In
addition, a time period of immersion is normally approximately 1 to
120 seconds.
[0116] After water washing, the drying treatment is performed and
the polarizing film serving as polarizing layer 5 is obtained. The
drying treatment can be performed by using a hot-air dryer or a
far-infrared heater. A temperature of the drying treatment is
normally approximately 30 to 100.degree. C., and preferably 50 to
80.degree. C. A time period of the drying treatment is normally
approximately 60 to 600 seconds, and preferably 120 to 600
seconds.
[0117] By the drying treatment, a water content rate of the
polarizing film is reduced to a practical level. This water content
rate is normally 5 to 20 weight %, and preferably 8 to 15 weight %.
If the water content rate is lower than 5 weight %, the flexibility
of the polarizing film is lost and the polarizing film may be
damaged or fractured after drying. If the water content rate
exceeds 20 weight %, the thermal stability of the polarizing film
may deteriorate.
[0118] First protective film 10 is bonded to one surface of the
aforementioned polarizing film (polarizing layer 5) by using the
active energy ray curing adhesive, and second protective film 20 is
bonded to the other surface by using the water-soluble adhesive,
and thereafter, the adhesive layer formed of the active energy ray
curing adhesive is hardened by irradiating the obtained film stack
with an active energy ray. Polarizing plate 1 can thus be
obtained.
[0119] Examples of a method of bonding first and second protective
films 10 and 20 to the polarizing film (polarizing layer 5) by
using the active energy ray curing adhesive and the water-soluble
adhesive can include a method of applying an adhesive to one or
both bonding surfaces of two films to be bonded, and lying one film
over the other with the adhesive layer being interposed. A casting
method, a Meyer bar coating method, a gravure coating method, a
comma coater method, a doctor blade method, a die coating method, a
dip coating method, a spraying method or the like can, for example,
be used to apply the adhesive. The casting method refers to a
method of flowing down an adhesive over a surface of a film to be
bonded and spreading the adhesive over the same while the film is
moved substantially in a vertical direction, substantially in a
horizontal direction, or in a diagonal direction between them. The
film stack formed by lying one film over the other with the
adhesive layer being interposed is normally passed between nip
rolls (bonding rolls) or the like and pressed from above and
below.
[0120] When the protective film is bonded to the polarizing film,
the bonding surface of the protective film or the polarizing film
can be subjected to easy adhesion treatment such as plasma
treatment, corona treatment, ultraviolet irradiation treatment,
flame treatment, and saponification treatment, in order to enhance
adhesion. Among these, plasma treatment, corona treatment or
saponification treatment is preferable. For example, when the
protective film is composed of the cyclic polyolefin-based resin,
the bonding surface of the protective film is normally subjected to
plasma treatment or corona treatment. When the protective film is
composed of the cellulose ester-based resin, the bonding surface of
the protective film is normally subjected to saponification
treatment. Examples of the saponification treatment include a
method of immersion in an alkaline aqueous solution such as sodium
hydroxide or potassium hydroxide.
[0121] After the aforementioned film bonding is performed, a drying
step of drying the film stack in order to remove water included in
the adhesive layer formed of the water-soluble adhesive is
preferably performed. The drying can be performed, for example, by
introducing the film stack into a drying furnace. A drying
temperature (temperature in the drying furnace) is preferably 30 to
90.degree. C. If the drying temperature is lower than 30.degree.
C., the protective film tends to be easily separated from the
polarizing film. If the drying temperature exceeds 90.degree. C.,
the polarization characteristics of the polarizing film may
deteriorate by heat. A time period of drying can be approximately
10 to 1000 seconds, and from the perspective of productivity, the
time period of drying is preferably 60 to 750 seconds, and more
preferably 150 to 600 seconds.
[0122] After the drying step, an aging step of aging the film stack
for approximately 12 to 600 hours at a room temperature or a
temperature slightly higher than the room temperature, e.g., at a
temperature of approximately 20 to 45.degree. C., may be provided.
An aging temperature is generally set to be lower than the drying
temperature.
[0123] In addition, after the aforementioned film bonding is
performed, a curing step of curing the adhesive layer formed of the
active energy ray curing adhesive is performed. This curing of the
adhesive layer can be performed by irradiating the film stack with
an active energy ray. The active energy ray is normally provided
from the first protective film 10 side. The active energy ray is
preferably an ultraviolet ray.
[0124] Although a light source of the active energy ray is not
particularly limited, an active energy ray having a light emission
distribution in a region of wavelengths not longer than 400 nm is
preferable. Specifically, a low-pressure mercury lamp, a
medium-pressure mercury lamp, a high-pressure mercury lamp, a
super-high-pressure mercury lamp, a chemical lamp, a black light
lamp, a microwave excited mercury lamp, a metal halide lamp or the
like is preferably used.
[0125] Intensity of irradiation of the adhesive layer formed of the
active energy ray curing adhesive with the active energy ray is
determined as appropriate depending on a composition of the
adhesive. However, the irradiation intensity is preferably set such
that irradiation intensity in a wavelength region effective for
activation of a polymerization initiator is 0.1 to 6000
mW/cm.sup.2. If the irradiation intensity is not lower than 0.1
mW/cm.sup.2, the reaction time period is not excessively long. If
the irradiation intensity is not higher than 6000 mW/cm.sup.2,
yellowing of the adhesive layer or deterioration of the polarizing
film due to heat radiated from the light source and heat generation
during curing of the adhesive is less likely.
[0126] A time period of irradiation with the active energy ray is
also determined as appropriate depending on a composition of the
adhesive. However, the time period of irradiation is preferably set
such that a multiplied quantity of light represented as a product
of the irradiation intensity and the irradiation time period above
is 10 to 10000 mJ/cm.sup.2. If the multiplied quantity of light is
not smaller than 10 mJ/cm.sup.2, active species derived from a
polymerization initiator can be generated in a sufficient amount
and the curing reaction can more reliably proceed. If the
multiplied quantity of light is not larger than 10000 mJ/cm.sup.2,
the irradiation time period is not excessively long and good
productivity can be maintained.
[0127] Irradiation with the active energy ray is preferably
performed under such a condition that various functions of the
polarizing plate do not decrease, such as a degree of polarization,
transmissivity and a hue of the polarizing film, as well as
transparency of the protective film.
[0128] When first protective film 10 and second protective film 20
are stacked on the polarizing film, one of the protective films may
be stacked on the polarizing film and thereafter the other
protective film may be stacked, or both of the protective films may
be stacked on the polarizing film substantially simultaneously.
Desirably, however, second protective film 20 is stacked by using
the water-soluble adhesive, and thereafter, first protective film
10 is stacked by using the active energy ray curing adhesive. By
first stacking second protective film 20 and forming the film stack
thicker than the polarizing film alone, the aforementioned
distortion occurring on the polarizing film or the protective film
when bonding first protective film 10 and curing the active energy
ray curing adhesive can be suppressed more effectively. As a
result, the minor irregularities occurring on the surface of the
polarizing plate can be suppressed more effectively.
[0129] The order of bonding of first and second protective films 10
and 20, the aforementioned drying step, and the aforementioned
curing step may take various embodiments. Examples of the
embodiments include:
[0130] 1) an embodiment of simultaneously bonding first and second
protective films 10 and 20, and thereafter, performing the drying
step and the curing step in this order;
[0131] 2) an embodiment of simultaneously bonding first and second
protective films 10 and 20, and thereafter, performing the curing
step and the drying step in this order;
[0132] 3) an embodiment of performing bonding of second protective
film 20, the drying step, bonding of first protective film 10, and
the curing step in this order;
[0133] 4) an embodiment of performing bonding of second protective
film 20, bonding of first protective film 10, the drying step, and
the curing step in this order;
[0134] 5) an embodiment of performing bonding of second protective
film 20, bonding of first protective film 10, the curing step, and
the drying step in this order;
[0135] 6) an embodiment of performing bonding of first protective
film 10, the curing step, bonding of second protective film 20, and
the drying step in this order;
[0136] 7) an embodiment of performing bonding of first protective
film 10, bonding of second protective film 20, the drying step, and
the curing step in this order; and
[0137] 8) an embodiment of performing bonding of first protective
film 10, bonding of second protective film 20, the curing step, and
the drying step in this order.
[0138] When bonding of first and second protective films 10 and 20
is performed sequentially, the embodiment of 3), 4) or 5) is
preferable for the aforementioned reason.
[0139] The heat shrinkage force of polarizing layer 5 in polarizing
plate 1 thus obtained can be measured as follows. Specifically,
first protective film 10 and second protective film 20 are
dissolved and only polarizing layer 5 is taken out, and then, with
a direction of an absorption axis thereof (a direction of
stretching) being a longer side, a film of 2 mm in width and 8 mm
in length is cut out to obtain a sample for measurement, and the
shrinkage force in a direction of the length of 8 mm generated when
this sample is heated at 80.degree. C. for 240 minutes with the
dimension of this sample being kept constant is defined as the heat
shrinkage force. A value of the heat shrinkage force is, for
example, 0.5 N to 3.0 N, and preferably 1.0 N to 2.0 N.
[0140] [Manufacturing Method [b]]
[0141] FIG. 2 is a flowchart showing a preferred embodiment of a
method of manufacturing a polarizing plate in accordance with the
manufacturing method [b]. The manufacturing method shown in FIG. 2
includes the following steps in the listed order:
[0142] (1) a resin layer formation step S10 of applying a coating
liquid containing a polyvinyl alcohol-based resin to at least one
surface of a substrate film, and thereafter, drying the coated
layer to form a polyvinyl alcohol-based resin layer and obtain a
laminated film;
[0143] (2) a stretching step S20 of stretching the laminated film
to obtain a stretched film;
[0144] (3) a coloring step S30 of coloring the polyvinyl
alcohol-based resin layer of the stretched film with a dichroic
colorant to form a polarizing layer and obtain a polarizing
laminated film;
[0145] (4) a first bonding step S40 of bonding one of first and
second protective films onto the polarizing layer of the polarizing
laminated film to obtain a bonded film;
[0146] (5) a separation step S50 of separating and removing the
substrate film from the bonded film to obtain a polarizing plate
with the protective film on one surface; and
[0147] (6) a second bonding step S60 of bonding the other
protective film to a polarizing layer surface of the polarizing
plate with the protective film on one surface.
[0148] The steps will be described hereinafter with reference to
FIGS. 3 to 7.
[0149] (1) Resin Layer Formation Step S10
[0150] Referring to FIG. 3, this step is a step of forming a
polyvinyl alcohol-based resin layer 6 on at least one surface of a
substrate film 30 to obtain a laminated film 100. This polyvinyl
alcohol-based resin layer 6 is a layer that will become polarizing
layer 5 through stretching step S20 and coloring step S30.
Polyvinyl alcohol-based resin layer 6 can be formed by applying a
coating liquid containing a polyvinyl alcohol-based resin to one
surface or both surfaces of substrate film 30 and drying the coated
layer. The aforementioned method of forming the polyvinyl
alcohol-based resin layer by coating is advantageous in that thin
polarizing layer 5 is easily obtained.
[0151] (Substrate Film)
[0152] Substrate film 30 can be composed of a thermoplastic resin,
and particularly, is preferably composed of a thermoplastic resin
excellent in transparency, mechanical strength, thermal stability,
ductility and the like. Specific examples of such a thermoplastic
resin include: for example, a polyolefin-based resin such as an
acyclic polyolefin-based resin and a cyclic polyolefin-based resin
(a norbornene-based resin and the like); a polyester-based resin; a
(meth)acryl-based resin; a cellulose ester-based resin such as
cellulose triacetate and cellulose diacetate; a polycarbonate-based
resin; a polyvinyl alcohol-based resin; a polyvinyl acetate-based
resin; a polyarylate-based resin; a polystyrene-based resin; a
polyether sulfone-based resin; a polysulfone-based resin; a
polyamide-based resin; a polyimide-based resin; and a mixture
thereof and a copolymer thereof
[0153] Substrate film 30 may have a single layer structure
including one resin layer composed of one type or two or more types
of thermoplastic resins, or may have a multilayer structure formed
by stacking a plurality of resin layers composed of one type or two
or more types of thermoplastic resins.
[0154] Examples of the acyclic polyolefin-based resin can include a
homopolymer of an acyclic olefin such as a polyethylene resin and a
polypropylene resin, and a copolymer formed of two or more types of
olefins. Substrate film 30 composed of the acyclic polyolefin-based
resin is preferable in that substrate film 30 is easily stretched
at a high ratio in a stable manner. Particularly, substrate film 30
is more preferably composed of a polypropylene-based resin (a
polypropylene resin which is a homopolymer of propylene, and a
copolymer mainly composed of propylene) or a polyethylene-based
resin (a polyethylene resin which is a homopolymer of ethylene, and
a copolymer mainly composed of ethylene).
[0155] The copolymer mainly composed of propylene, which is one of
the examples suitably used as the thermoplastic resin constituting
substrate film 30, is a copolymer of propylene and another monomer
copolymerizable therewith.
[0156] Examples of another monomer copolymerizable with propylene
can include ethylene and .alpha.-olefin. As .alpha.-olefin,
.alpha.-olefin having a carbon number not smaller than 4 is
preferably used and .alpha.-olefin having a carbon number of 4 to
10 is more preferably used. Specific examples of .alpha.-olefin
having a carbon number of 4 to 10 include: for example, linear
monoolefins such as 1-butene, 1-pentene, 1-hexene, 1-heptene,
1-octene, and 1-decene; branched monoolefins such as
3-methyl-1-butene, 3-methyl-1-pentene and 4-methyl-1-pentene; and
vinylcyclohexane. The copolymer of propylene and another monomer
copolymerizable therewith may be a random copolymer or a block
copolymer.
[0157] An amount of aforementioned another monomer contained in the
copolymer is, for example, 0.1 to 20 weight %, and preferably 0.5
to 10 weight %. The amount of another monomer contained in the
copolymer can be determined by performing infrared (IR) spectrum
measurement in accordance with the method described on page 616 of
"Handbook of Polymer Analysis" (1995, published by Kinokuniya
Company Ltd.).
[0158] Among the above, as the polypropylene-based resin, a
homopolymer of propylene, a propylene-ethylene random copolymer, a
propylene-1-butene random copolymer, or a
propylene-ethylene-1-butene random copolymer is preferably
used.
[0159] Stereoregularity of the polypropylene-based resin is
preferably substantially isotactic or syndiotactic. Substrate film
30 composed of the polypropylene-based resin having substantially
isotactic or syndiotactic stereoregularity is relatively good in
its handleability and excellent in mechanical strength in a
high-temperature environment.
[0160] The polyester-based resin is a resin having ester linkage,
and is generally composed of a polycondensation product of
polyvalent carboxylic acid or a derivative thereof and polyalcohol.
Divalent dicarboxylic acid or a derivative thereof can be used as
polyvalent carboxylic acid or a derivative thereof, and examples
thereof include terephthalic acid, isophthalic acid, dimethyl
terephthalate, dimethyl naphthalene dicarboxylate and the like.
Divalent diol can be used as the polyalcohol, and examples thereof
include ethylene glycol, propanediol, butanediol, neopentylglycol,
cyclohexanedimethanol and the like.
[0161] Representative examples of the polyester-based resin include
polyethylene terephthalate which is a polycondensation product of
terephthalic acid and ethylene glycol. Although polyethylene
terephthalate is a crystalline resin, polyethylene terephthalate
before crystallization treatment is more easily subjected to
treatment such as stretching. If necessary, the crystallization
treatment can be performed by heat treatment or the like during or
after stretching. In addition, copolymerized polyester having
crystallinity lowered by copolymerization of a main chain of
polyethylene terephthalate further with other types of monomers (or
made amorphous) is also suitably used. Examples of such a resin
include, for example, a resin copolymerized with
cyclohexanedimethanol or isophthalic acid, and the like. These
resins are also excellent in ductility, and thus, these resins can
be suitably used.
[0162] Specific examples of the polyester-based resin other than
polyethylene terephthalate and a copolymer thereof include, for
example, polybutylene terephthalate, polyethylene naphthalate,
polybutylene naphthalate, polytrimethylene terephthalate,
polytrimethylene naphthalate, polycyclohexane
dimethylterephthalate, polycyclohexane dimethylnaphthalate, and a
mixture thereof, a copolymer thereof and the like.
[0163] The (meth)acryl-based resin is a resin including, as a main
constituent monomer, a compound having a (meth)acryloyl group.
Specific examples of the (meth)acryl-based resin include: for
example, poly (meth)acrylic acid ester such as
polymethylmethacrylate; a methyl methacrylate-(meth)acrylic acid
copolymer; a methyl methacrylate-(meth)acrylic acid ester
copolymer; a methyl methacrylate-acrylic acid ester-(meth)acrylic
acid copolymer; a methyl (meth)acrylate-styrene copolymer (such as
an MS resin); and a copolymer of methyl methacrylate and a compound
having an alicyclic hydrocarbon group (e.g., a methyl
methacrylate-cyclohexyl methacrylate copolymer, a methyl
methacrylate-norbornyl (meth)acrylate copolymer and the like). A
polymer mainly composed of poly (meth)acrylic acid C.sub.1-6 alkyl
ester such as poly methyl (meth)acrylate is preferably used, and a
methyl methacrylate-based resin mainly composed of methyl
methacrylate (50 to 100 weight %, and preferably 70 to 100 weight
%) is more preferably used.
[0164] The polycarbonate-based resin is an engineering plastic
composed of a polymer resulting from bonding of monomer units with
a carbonate group being interposed, and is a resin having high
shock resistance, heat resistance, flame resistance, and
transparency. The polycarbonate-based resin constituting substrate
film 30 may be a resin referred to as modified polycarbonate, as
obtained by modifying a polymer main chain in order to lower a
modulus of photoelasticity, copolymerized polycarbonate of which
wavelength dependence has been improved, or the like.
[0165] Various products of the polycarbonate-based resin are
commercially available. Examples of commercially available products
of the polycarbonate-based resin include "Panlite" (manufactured by
TEIJIN Chemicals Ltd.), "Iupilon" (manufactured by Mitsubishi
Engineering-Plastics Corporation), "SD Polyca" (manufactured by
Sumitomo Dow Limited), "CALIBRE" (manufactured by The Dow Chemical
Company) and the like, all of which are trade names.
[0166] Among the above, the polypropylene-based resin is preferably
used from the perspectives of ductility, heat resistance and the
like.
[0167] As to the cyclic polyolefin-based resin and the cellulose
ester-based resin that can be used for substrate film 30, the
description about the protective films is cited. In addition, the
acyclic polyolefin-based resin, the polyester-based resin, the
(meth)acryl-based resin, and the polycarbonate-based resin
described above in connection with substrate film 30 can also be
used as a constituent material for the protective films.
[0168] Any appropriate additive may be added to substrate film 30,
in addition to the aforementioned thermoplastic resin. Examples of
such an additive include a UV absorber, an antioxidant, a
lubricant, a plasticizer, a release agent, an anti-coloring agent,
a flame retardant, a nucleating agent, an antistatic agent, a
pigment, a coloring agent and the like. An amount of the
thermoplastic resin contained in substrate film 30 is preferably 50
to 100 weight %, more preferably 50 to 99 weight %, further
preferably 60 to 98 weight %, and particularly preferably 70 to 97
weight %. If the amount of the thermoplastic resin contained in
substrate film 30 is lower than 50 weight %, high transparency or
the like originally possessed by the thermoplastic resin may not be
sufficiently exhibited.
[0169] A thickness of substrate film 30 can be determined as
appropriate. Generally, however, from the perspectives of strength
and workability such as handleability, the thickness of substrate
film 30 is preferably 1 to 500 more preferably 1 to 300 further
preferably 5 to 200 and most preferably 5 to 150
[0170] A tensile elastic modulus of substrate film 30 at 80.degree.
C. is preferably 100 MPa to 1500 MPa, more preferably 140 MPa to
1000 MPa, and further preferably 150 MPa to 500 MPa. If the tensile
elastic modulus is too low, the hardness of substrate film 30 is
insufficient during stretching and a defect such as a wrinkle is
likely to occur. If the tensile elastic modulus is too high, the
workability in stretching becomes worse.
[0171] The tensile elastic modulus can be determined by cutting out
substrate film 30 into a test piece of a prescribed size and
performing a tensile test. In order to determine the tensile
elastic modulus at 80.degree. C., a tensile testing machine
including a thermostatic bath is used.
[0172] (Coating Liquid Containing Polyvinyl Alcohol-Based
Resin)
[0173] The coating liquid is preferably a polyvinyl alcohol-based
resin solution obtained by dissolving a powder of a polyvinyl
alcohol-based resin in a good solvent (e.g., water).
[0174] The coating liquid may contain an additive such as a
plasticizer and a surfactant, as needed. As the plasticizer, polyol
or a condensation product thereof can be used, and glycerin,
diglycerin, triglycerin, ethylene glycol, propylene glycol,
polyethylene glycol and the like are, for example, exemplified. A
blending amount of the additive is suitably not larger than 20
weight % of the polyvinyl alcohol-based resin.
[0175] (Application of Coating Liquid and Drying of Coated
Layer)
[0176] A method of applying the aforementioned coating liquid to
substrate film 30 can be selected as appropriate from methods
including: a wire bar coating method; a roll coating method such as
reverse coating and gravure coating; a die coating method; a comma
coating method; a lip coating method; a spin coating method; a
screen coating method; a fountain coating method; a dipping method;
a spraying method and the like.
[0177] When the coating liquid is applied to opposing surfaces of
substrate film 30, the coating liquid can be applied to one surface
and then to the other surface in turn by using the aforementioned
method, or the coating liquid can be simultaneously applied to the
opposing surfaces of substrate film 30 by using the dipping method,
the spray coating method or any other special device.
[0178] A temperature and a time period of drying the coated layer
(polyvinyl alcohol-based resin layer before drying) are set
depending on the type of the solvent included in the coating
liquid. The drying temperature is, for example, 50 to 200.degree.
C., and preferably 60 to 150.degree. C. When the solvent includes
water, the drying temperature is preferably not lower than
80.degree. C. The drying time period is, for example, 2 to 20
minutes.
[0179] Polyvinyl alcohol-based resin layer 6 may be formed only on
one surface of substrate film 30, or may be formed on both surfaces
of substrate film 30. When polyvinyl alcohol-based resin layer 6 is
formed on both surfaces, curl of the film that may occur during
manufacturing of the polarizing laminated film can be suppressed,
and in addition, two polarizing plates can be obtained from one
polarizing laminated film, and thus, this is advantageous also in
terms of production efficiency of the polarizing plate.
[0180] A thickness of polyvinyl alcohol-based resin layer 6 in
laminated film 100 is preferably 3 to 60 .mu.m, more preferably 3
to 30 .mu.m, and further preferably 5 to 20 .mu.m. Polyvinyl
alcohol-based resin layer 6 having a thickness falling within this
range can provide, through stretching step S20 and coloring step
S30 described below, polarizing layer 5 which is good in coloring
affinity of the dichroic colorant, excellent in polarization
characteristics, and sufficiently small in thickness. If the
thickness of polyvinyl alcohol-based resin layer 6 exceeds 60
.mu.m, a thickness of polarizing layer 5 may exceed 20 .mu.m. If
the thickness of polyvinyl alcohol-based resin layer 6 is smaller
than 3 .mu.m, polarizing layer 5 tends to become too thin after
stretching and the coloring affinity tends to become worse.
[0181] Prior to the application of the coating liquid, at least the
surface of substrate film 30 on the side where polyvinyl
alcohol-based resin layer 6 is formed may be subjected to corona
treatment, plasma treatment, flame treatment or the like, in order
to enhance adhesion between substrate film 30 and polyvinyl
alcohol-based resin layer 6.
[0182] Prior to the application of the coating liquid, polyvinyl
alcohol-based resin layer 6 may also be formed on substrate film 30
with a primer layer or an adhesive layer being interposed, in order
to enhance adhesion between substrate film 30 and polyvinyl
alcohol-based resin layer 6.
[0183] (Primer Layer)
[0184] The primer layer can be formed by applying a coating liquid
for formation of the primer layer to the surface of substrate film
30, and thereafter, drying the coated surface. The coating liquid
for formation of the primer layer includes a component that
produces strong adhesion of a certain degree with both substrate
film 30 and polyvinyl alcohol-based resin layer 6. Normally, the
coating liquid for formation of the primer layer contains a solvent
and a resin component that provides such adhesion. A thermoplastic
resin excellent in transparency, thermal stability and ductility is
preferably used as the resin component, and examples of the resin
component include a (meth)acryl-based resin, a polyvinyl
alcohol-based resin and the like. Among these, the polyvinyl
alcohol-based resin that provides good adhesion is preferably
used.
[0185] Examples of the polyvinyl alcohol-based resin include a
polyvinyl alcohol resin and a derivative thereof. Examples of the
derivative of the polyvinyl alcohol resin include: a substance
obtained by modifying a polyvinyl alcohol resin with olefins such
as ethylene and propylene; a substance obtained by modifying a
polyvinyl alcohol resin with unsaturated carboxylic acids such as
acrylic acid, methacrylic acid and crotonic acid; a substance
obtained by modifying a polyvinyl alcohol resin with alkyl ester of
unsaturated carboxylic acid; a substance obtained by modifying a
polyvinyl alcohol resin with acrylamide, and the like, in addition
to polyvinyl formal, polyvinyl acetal and the like. Among the
aforementioned polyvinyl alcohol-based resins, the polyvinyl
alcohol resin is preferably used.
[0186] A general organic solvent or water-soluble solvent that can
dissolve the aforementioned resin component is normally used as the
solvent. Examples of the solvent include: for example, aromatic
hydrocarbons such as benzene, toluene and xylene; ketones such as
acetone, methyl ethyl ketone and methyl isobutyl ketone; esters
such as ethyl acetate and isobutyl acetate; chlorinated
hydrocarbons such as methylene chloride, trichloroethylene and
chloroform; and alcohols such as ethanol, 1-propanol, 2-propanol,
and 1-butanol. When the primer layer is formed by using the coating
liquid for formation of the primer layer including the organic
solvent, substrate film 30 is dissolved in some cases, and thus,
the solvent is preferably selected in consideration of the
solubility of substrate film 30 as well. In consideration of the
influence on the environment as well, the primer layer is
preferably formed by using a coating liquid including water as a
solvent.
[0187] In order to increase the strength of the primer layer, a
cross-linker may be added to the coating liquid for formation of
the primer layer. As the cross-linker, any appropriate cross-linker
is selected as appropriate from known cross-linkers such as an
organic cross-linker and an inorganic cross-linker, depending on
the type of the used thermoplastic resin. Examples of the
cross-linker include, for example, an epoxy-based cross-linker, an
isocyanate-based cross-linker, a dialdehyde-based cross-linker, and
a metallic cross-linker.
[0188] A one-component curing-type cross-linker and a two-component
curing-type cross-linker can be both used as the epoxy-based
cross-linker, and examples of the epoxy-based cross-linker include
ethylene glycol diglycidylether, polyethylene glycol
diglycidylether, glycerin di- or tri-glycidylether, 1,6-hexanediol
diglycidylether, trimethylolpropane triglycidylether,
diglycidylaniline, diglycidylamine and the like.
[0189] Examples of the isocyanate-based cross-linker include
tolylene diisocyanate, hydrogenated tolylene diisocyanate,
trimethylolpropane-tolylene diisocyanate adduct, triphenylmethane
triisocyanate, methylenebis (4-phenylmethane) triisocyanate,
isophorone diisocyanate, and a ketoxime block or a phenol block
thereof, and the like.
[0190] Examples of the dialdehyde-based cross-linker include
glyoxal, malondialdehyde, succindialdehyde, glutardialdehyde,
maleic dialdehyde, phthaldialdehyde and the like.
[0191] Examples of the metallic cross-linker include a metal salt,
a metal oxide, a metal hydroxide, and an organic metal compound.
Examples of the metal salt, the metal oxide and the metal hydroxide
include a salt, an oxide and a hydroxide of a metal having a
valence of 2 or greater, such as magnesium, calcium, aluminum,
iron, nickel, zirconium, titanium, silicon, boron, zinc, copper,
vanadium, chromium, and tin.
[0192] The organic metal compound refers to a compound having, in a
molecule, at least one structure in which an organic group is
directly coupled to a metal atom or an organic group is coupled
with an oxygen atom, a nitrogen atom or the like being interposed.
The organic group refers to a monovalent or multivalent group
including at least a carbon element, and can be, for example, an
alkyl group, an alkoxy group, an acyl group or the like. In
addition, coupling does not refer to only covalent coupling, and
may be coordination coupling by coordination such as a chelate-like
compound.
[0193] Suitable examples of the organic metal compound include an
organic titanium compound, an organic zirconium compound, an
organic aluminum compound, and an organic silicon compound. Only
one type of organic metal compound may be used alone, or two or
more types of organic metal compounds may be used together.
[0194] Examples of the organic titanium compound include: titanium
orthoesters such as tetra-n-butyl titanate, tetraisopropyl
titanate, butyl titanate dimer, tetra(2-ethylhexyl)titanate, and
tetramethyl titanate; titanium chelates such as titanium
acetylacetonato, titanium tetraacetylacetonato, polytitanium
acetylacetonato, titanium octylene glycolate, titanium lactate,
titanium triethanolaminato, and titanium ethylacetoacetate; and
titanium acylates such as polyhydroxy titanium stearate, and the
like.
[0195] Examples of the organic zirconium compound include
zirconium-n-propionate, zirconium-n-butyrate, zirconium
tetraacetylacetonato, zirconium monoacetylacetonato, zirconium
bisacetylacetonato, zirconium acetylacetonato-bis-ethylacetoacetate
and the like.
[0196] Examples of the organic aluminum compound include aluminum
acetylacetonato, aluminum organic acid chelate and the like.
Examples of the organic silicon compound include a compound in
which a ligand previously exemplified in the organic titanium
compound and the organic zirconium compound is coupled to
silicon.
[0197] In addition to the low molecule-based cross-linker described
above, a polymer-based cross-linker such as a methylolated melamine
resin and a polyamide epoxy resin can also be used. Examples of
commercially available products of the polyamide epoxy resin
include "Sumirez Resin 650 (30)" and "Sumirez Resin 675" (all of
which are trade names) sold by Taoka Chemical Company, Ltd., and
the like.
[0198] When the polyvinyl alcohol-based resin is used as the resin
component forming the primer layer, a polyamide epoxy resin, a
methylolated melamine resin, a dialdehyde-based cross-linker, a
metal chelate compound-based cross-linker or the like is suitably
used as the cross-linker.
[0199] A ratio between the resin component and the cross-linker in
the coating liquid for formation of the primer layer may be
determined as appropriate from the range of approximately 0.1 to
100 parts by weight of the cross-linker, depending on the type of
the resin component, the type of the cross-linker and the like, and
is particularly preferably selected from the range of approximately
0.1 to 50 parts by weight. In addition, a solid content of the
coating liquid for formation of the primer layer is preferably set
to be approximately 1 to 25 weight %.
[0200] A thickness of the primer layer is preferably approximately
0.05 to 1 .mu.m, and more preferably 0.1 to 0.4 .mu.m. If the
thickness of the primer layer is smaller than 0.05 .mu.m, the
effect of enhancing adhesion between substrate film 30 and
polyvinyl alcohol-based resin layer 6 is small. If the thickness of
the primer layer is greater than 1 .mu.m, this is disadvantageous
for reducing the thickness of the polarizing plate.
[0201] A method of applying the coating liquid for formation of the
primer layer to substrate film 30 can be similar to that of the
coating liquid for formation of the polyvinyl alcohol-based resin
layer. The primer layer is applied to the surface (one surface or
both surfaces of substrate film 30) to which the coating liquid for
formation of the polyvinyl alcohol-based resin layer is applied. A
drying temperature and a drying time period for the coated layer
formed of the coating liquid for formation of the primer layer are
set depending on the type of the solvent included in the coating
liquid. The drying temperature is, for example, 50 to 200.degree.
C., and preferably 60 to 150.degree. C. When the solvent includes
water, the drying temperature is preferably not lower than
80.degree. C. The drying time period is, for example, 30 seconds to
20 minutes.
[0202] When the primer layer is provided, the order of application
to substrate film 30 is not particularly limited. For example, when
polyvinyl alcohol-based resin layer 6 is formed on opposing
surfaces of substrate film 30, the primer layer may be formed on
the opposing surfaces of substrate film 30, and thereafter,
polyvinyl alcohol-based resin layer 6 may be formed on the opposing
surfaces. Alternatively, the primer layer and polyvinyl
alcohol-based resin layer 6 may be formed on one surface of
substrate film 30 in this order, and thereafter, the primer layer
and polyvinyl alcohol-based resin layer 6 may be formed on the
other surface of substrate film 30 in this order.
[0203] (2) Stretching Step S20
[0204] Referring to FIG. 4, this step is a step of stretching
laminated film 100 composed of substrate film 30 and polyvinyl
alcohol-based resin layer 6, to obtain a stretched film 200
composed of stretched substrate film 30' and polyvinyl
alcohol-based resin layer 6'.
[0205] A stretching magnification of laminated film 100 can be
selected as appropriate depending on desired polarization
characteristics. However, the stretching magnification of laminated
film 100 is preferably higher than 5 and not higher than 17, and
more preferably higher than 5 and not higher than 8, with respect
to the original length of laminated film 100. If the stretching
magnification is not higher than 5, polyvinyl alcohol-based resin
layer 6 is not sufficiently oriented, and thus, a degree of
polarization of polarizing layer 5 does not become sufficiently
high in some cases. On the other hand, if the stretching
magnification exceeds 17, a fracture of the film is more likely to
occur during stretching, and in addition, a thickness of stretched
film 200 becomes smaller than necessary, which may lead to lowering
in workability and handleability in a subsequent step. The
stretching treatment is normally uniaxial stretching.
[0206] The stretching treatment is not limited to stretching in a
single step and can also be performed in multiple steps. In this
case, the stretching treatment in all of the multiple steps may be
performed successively before coloring step S30, or the stretching
treatment in a second step or later may be performed simultaneously
with coloring treatment and/or cross-linking treatment in coloring
step S30. When the stretching treatment is performed in multiple
steps as described above, the stretching treatment is preferably
performed such that the stretching magnification is higher than 5
as the total of ratios in all steps in the stretching
treatment.
[0207] The stretching treatment can be vertical stretching
performed in a longitudinal direction of the film (transportation
direction of the film), or may be lateral stretching performed in a
width direction of the film, diagonal stretching or the like.
Examples of the vertical stretching scheme include roll stretching
performed by using rolls, compression stretching, stretching using
chucks (clips), and the like. Examples of the lateral stretching
scheme include a tenter method and the like. Although either a wet
stretching method or a dry stretching method can be used as the
stretching treatment, use of the dry stretching method is more
preferable because a stretching temperature can be selected from a
wider range.
[0208] The stretching temperature is set to be not lower than a
temperature at which polyvinyl alcohol-based resin layer 6 and
substrate film 30 as a whole exhibit a fluidity of such a degree
that polyvinyl alcohol-based resin layer 6 and substrate film 30
can be stretched, and is preferably within a range of -30.degree.
C. to +30.degree. C., and more preferably within a range of
-30.degree. C. to +5.degree. C., and further preferably within a
range of -25.degree. C. to +0.degree. C., of a phase transition
temperature (melting point or glass transition temperature) of
substrate film 30. When substrate film 30 is composed of a
plurality of resin layers, the aforementioned phase transition
temperature refers to the highest phase transition temperature, of
the phase transition temperatures exhibited by the plurality of
resin layers.
[0209] If the stretching temperature is lower than -30.degree. C.
of the phase transition temperature, a high stretching
magnification of higher than 5 tends to be not easily achieved or
the stretching treatment tends to become difficult because the
fluidity of substrate film 30 is too low. If the stretching
temperature exceeds +30.degree. C. of the phase transition
temperature, stretching tends to become difficult because the
fluidity of substrate film 30 is too high. Since a high stretching
magnification of higher than 5 is achieved more easily, the
stretching temperature is within the aforementioned range, and
further preferably not lower than 120.degree. C. This is because,
if the stretching temperature is not lower than 120.degree. C., the
stretching treatment is performed without difficulty even at a high
stretching magnification of higher than 5.
[0210] Examples of a method of heating laminated film 100 in the
stretching treatment include a zone heating method (e.g., a method
of heating laminated film 100 in a stretching zone such as a
heating furnace whose temperature is adjusted to a prescribed
temperature by blowing the hot air), a method of heating rolls
themselves in the case of stretching laminated film 100 by using
the rolls, a heater heating method (a method of placing an infrared
heater, a halogen heater, a panel heater or the like above and
below laminated film 100, and heating laminated film 100 with
radiation heat), and the like. In the roll stretching scheme, the
zone heating method is preferable from the perspective of
uniformity of the stretching temperature. In this case, a pair of
two nip rolls may be placed inside the stretching zone having the
adjusted temperature, or may be placed outside the stretching zone.
However, in order to prevent adherence between laminated film 100
and the nip rolls, the pair of two nip rolls are preferably placed
outside the stretching zone.
[0211] The stretching temperature refers to an atmospheric
temperature in the zone (e.g., in the heating furnace) in the case
of the zone heating method, and refers to an atmospheric
temperature in a furnace in the case of performing heating in the
furnace in the heater heating method as well. In addition, the
stretching temperature refers to a surface temperature of the rolls
in the case of the method of heating the rolls themselves.
[0212] Prior to stretching step S20, a preheating treatment step of
preheating laminated film 100 may be provided. A method similar to
the heating method in the stretching treatment can be used as a
preheating method. When the stretching treatment scheme is roll
stretching, preheating may be performed at any timing of before,
during and after passage through the nip roll on the upstream side.
When the stretching treatment scheme is heat roll stretching,
preheating is preferably performed before passage through the heat
roll. When the stretching treatment scheme is stretching using the
chucks, preheating is preferably performed before widening a
distance between the chucks. A preheating temperature is preferably
within a range of -50.degree. C. to .+-.0.degree. of the stretching
temperature, and more preferably within a range of -40.degree. C.
to -10.degree. C. of the stretching temperature.
[0213] A heat fixation treatment step may also be provided after
the stretching treatment in stretching step S20. The heat fixation
treatment is treatment of performing heat treatment at a
temperature not lower than a crystallization temperature while
maintaining an end of stretched film 200 in a tension state with
the end grasped by a clip. By this heat fixation treatment,
crystallization of polyvinyl alcohol-based resin layer 6' is
promoted. A temperature of the heat fixation treatment is
preferably within a range of -0.degree. C. to -80.degree. C. of the
stretching temperature, and more preferably within a range of
-0.degree. C. to -50.degree. C. of the stretching temperature.
[0214] (3) Coloring Step S30
[0215] Referring to FIG. 5, this step is a step of coloring
polyvinyl alcohol-based resin layer 6' of stretched film 200 with a
dichroic colorant and adsorbing and orienting the dichroic colorant
to obtain polarizing layer 5. Through this step, a polarizing
laminated film 300 having polarizing layer 5 stacked on one surface
or both surfaces of substrate film 30' is obtained.
[0216] The coloring step can be performed by immersing stretched
film 200 as a whole in a solution (coloring solution) containing
the dichroic colorant. A solution having the aforementioned
dichroic colorant in a solvent can be used as the coloring
solution. Water is generally used as the solvent of the coloring
solution. However, an organic solvent compatible with water may be
further added. A concentration of the dichroic colorant in the
coloring solution is preferably 0.01 to 10 weight %, more
preferably 0.02 to 7 weight %, and further preferably 0.025 to 5
weight %.
[0217] When iodine is used as the dichroic colorant, an iodide is
preferably further added to the coloring solution containing iodine
because the efficiency in coloring can be further enhanced.
Examples of the iodide include potassium iodide, lithium iodide,
sodium iodide, zinc iodide, aluminum iodide, lead iodide, copper
iodide, barium iodide, calcium iodide, tin iodide, titanium iodide
and the like. A concentration of the iodide in the coloring
solution is preferably 0.01 to 20 weight %. Among the iodides,
potassium iodide is preferably added. When potassium iodide is
added, a ratio in weight ratio between iodine and potassium iodide
is preferably within a range of 1:5 to 1:100, more preferably
within a range of 1:6 to 1:80, and further preferably within a
range of 1:7 to 1:70.
[0218] A time period of immersion of stretched film 200 in the
coloring solution is normally within a range of 15 seconds to 15
minutes, and preferably within a range of 30 seconds to 3 minutes.
In addition, a temperature of the coloring solution is preferably
within a range of 10 to 60.degree. C., and more preferably within a
range of 20 to 40.degree. C.
[0219] Stretched film 200 may be further subjected to additional
stretching treatment during coloring step S30. Examples of an
embodiment in this case can include: 1) an embodiment of performing
stretching treatment at a magnification lower than a target
magnification in aforementioned stretching step S20, and
thereafter, performing stretching treatment during coloring
treatment in coloring step S30 such that a total stretching
magnification becomes the target magnification; and as described
below, in the case of performing cross-linking treatment after
coloring treatment, 2) an embodiment of performing stretching
treatment at a magnification lower than a target magnification in
aforementioned stretching step S20, and thereafter, performing
stretching treatment during coloring treatment in coloring step S30
to such an extent that a total stretching magnification does not
reach the target magnification, and then, performing stretching
treatment during cross-linking treatment such that a final total
stretching magnification becomes the target magnification, and
other embodiments.
[0220] Coloring step S30 can include a cross-linking treatment step
performed following the coloring treatment. The cross-linking
treatment can be performed by immersing the colored film in a
solution (cross-linking solution) including a cross-linker. A
conventionally known substance can be used as the cross-linker, and
examples of the cross-linker include a boron compound such as boric
acid and borax, glyoxal, glutaraldehyde and the like. Only one type
of cross-linker may be used alone, or two or more types of
cross-linkers may be used together.
[0221] The cross-linking solution can specifically be a solution
having the cross-linker dissolved in a solvent. Although water can,
for example, be used as the solvent, the solvent may further
include an organic solvent compatible with water. A concentration
of the cross-linker in the cross-linking solution is preferably
within a range of 1 to 20 weight %, and more preferably within a
range of 6 to 15 weight %.
[0222] The cross-linking solution can include an iodide. By adding
the iodide, polarization characteristics in a plane of polarizing
layer 5 can be made more uniform. Examples of the iodide include
potassium iodide, lithium iodide, sodium iodide, zinc iodide,
aluminum iodide, lead iodide, copper iodide, barium iodide, calcium
iodide, tin iodide, titanium iodide and the like. A concentration
of the iodide in the cross-linking solution is preferably 0.05 to
15 weight %, and more preferably 0.5 to 8 weight %.
[0223] A time period of immersion of the colored film in the
cross-linking solution is normally 15 seconds to 20 minutes, and
preferably 30 seconds to 15 minutes. In addition, a temperature of
the cross-linking solution is preferably within a range of 10 to
90.degree. C.
[0224] The cross-linking treatment can also be performed
simultaneously with the coloring treatment, by blending the
cross-linker in the coloring solution. In addition, the stretching
treatment may be performed during the cross-linking treatment. A
specific embodiment of performing the stretching treatment during
the cross-linking treatment is as described above.
[0225] A cleaning step and a drying step are preferably performed
after coloring step S30 and before first bonding step S40 described
below. The cleaning step normally includes a water cleaning step.
The water cleaning treatment can be performed by immersing the film
subjected to coloring treatment or cross-linking treatment in
purified water such as ion exchange water and distilled water. A
water cleaning temperature is normally within a range of 3 to
50.degree. C., and preferably within a range of 4 to 20.degree. C.
A time period of immersion in water is normally 2 to 300 seconds,
and preferably 3 to 240 seconds.
[0226] The cleaning step may be a combination of the water cleaning
step and a cleaning step with an iodide solution. In addition to
water, liquid alcohol such as methanol, ethanol, isopropyl alcohol,
butanol, and propanol can be contained as appropriate in a cleaning
liquid used in the water cleaning step and a cleaning liquid used
in the cleaning treatment with the iodide solution.
[0227] Any appropriate method such as natural drying, air-blown
drying and heated drying can be used as the drying step performed
after the cleaning step. For example, in the case of heated drying,
a drying temperature is normally 20 to 95.degree. C., and a drying
time period is normally approximately 1 to 15 minutes.
[0228] (4) First Bonding Step S40
[0229] Referring to FIG. 6, this step is a step of bonding one of
first and second protective films 10 and 20 onto polarizing layer 5
of polarizing laminated film 300, i.e., a surface of polarizing
layer 5 opposite to the substrate film 30' side, to obtain a bonded
film 400. When polarizing laminated film 300 has polarizing layers
5 on the opposing surfaces of substrate film 30', the protective
films are normally bonded to polarizing layers 5 on the opposing
surfaces. In this case, these protective films may be protective
films of the same type, or may be protective films of different
types.
[0230] Although the protective film bonded in this step may be any
one of first protective film 10 and second protective film 20,
second protective film 20 is desirably bonded by using the
water-soluble adhesive as in the example shown in FIG. 6. This is
because, in the manufacturing method [b], substrate film 30' is
included in polarizing laminated film 300, and substrate film 30'
has a small tensile elastic modulus to obtain workability in
stretching, and thus, when first protective film 10 is bonded in
first bonding step S40, the effect of suppressing distortion
occurring on polarizing layer 5 and the protective film, and
therefore, the minor irregularities occurring on the surface of
polarizing plate 1, when the active energy ray curing adhesive is
hardened is weakened. By bonding second protective film 20 using
the water-soluble adhesive, distortion occurring on polarizing
layer 5 and the protective film, and therefore, the minor
irregularities occurring on the surface of the polarizing plate,
when first protective film 10 is bonded and the active energy ray
curing adhesive is hardened in second bonding step S60 described
below can be suppressed more effectively, for the reason similar to
the above.
[0231] As to a method of bonding second protective film 20 by using
the water-soluble adhesive and a method of bonding first protective
film 10 by using the active energy ray curing adhesive, the
description about the aforementioned manufacturing method [a] is
cited.
[0232] (5) Separation Step S50
[0233] Referring to FIG. 7, this step is a step of separating and
removing substrate film 30' from bonded film 400 obtained by
bonding one of first and second protective films 10 and 20. Through
this step, a polarizing plate 500 with the protective film on one
surface, which has the protective film stacked on one surface of
polarizing layer 5, is obtained. When polarizing laminated film 300
has polarizing layers 5 on the opposing surfaces of substrate film
30' and the protective films are bonded to both of these polarizing
layers 5, two polarizing plates 500, each of which has the
protective film on one surface, are obtained from one polarizing
laminated film 300 through this separation step S50.
[0234] A method of separating and removing substrate film 30' is
not particularly limited, and separation can be achieved by a
method similar to a step of separating a separator (separation
film), which is normally performed in a polarizing plate with a
pressure sensitive adhesive. Substrate film 30' may be separated
immediately after first bonding step S40, or may be wound up once
into a roll after first bonding step S40 and then wound off and
separated in a subsequent step.
[0235] (6) Second Bonding Step S60
[0236] This step is a step of bonding the other protective film
onto polarizing layer 5 of the polarizing plate with the protective
film on one surface, i.e., a surface on the opposite side of the
protective film bonded in first bonding step S40, by using the
adhesive, to obtain polarizing plate 1 shown in FIG. 1(a). When
second protective film 20 is bonded in first bonding step S40,
first protective film 10 is bonded by using the active energy ray
curing adhesive in this step. When first protective film 10 is
bonded in first bonding step S40, second protective film 20 is
bonded by using the water-soluble adhesive in this step.
[0237] As to a method of bonding first protective film 10 by using
the active energy ray curing adhesive and a method of bonding
second protective film 20 by using the water-soluble adhesive, the
description about the aforementioned manufacturing method [a] is
cited.
[0238] <Polarizing Plate with Pressure Sensitive Adhesive
Layer>
[0239] Polarizing plate 1 of the present invention can become a
polarizing plate with a pressure sensitive adhesive layer, by
providing transparent pressure sensitive adhesive layer 3 on an
outer surface (surface on the opposite side of polarizing layer 5)
of first protective film 10 or second protective film 20 of
polarizing plate 1. This transparent pressure sensitive adhesive
layer 3 can be used to bond polarizing plate 1 to substrate 4 such
as a glass substrate. A stack having polarizing plate 1 bonded to
substrate 4 with transparent pressure sensitive adhesive layer 3
being interposed is herein also referred to as "substrate having
the polarizing plate bonded thereto". In the polarizing plate with
the pressure sensitive adhesive layer, transparent pressure
sensitive adhesive layer 3 may be provided on either the first
protective film 10 side or the second protective film 20 side. As
described above, however, according to the present invention,
particularly because the occurrence of the minor irregularities on
the outer surface (surface on the opposite side of polarizing layer
5) of second protective film 20 can be suppressed or prevented more
effectively, transparent pressure sensitive adhesive layer 3 is
preferably provided on the outer surface of first protective film
10 and the outer surface of second protective film 20, where the
occurrence of the minor irregularities is suppressed or prevented
more effectively, faces outward in the polarizing plate with the
pressure sensitive adhesive layer.
[0240] A so-called separation film for protecting transparent
pressure sensitive adhesive layer 3 from foreign substances such as
dust is normally bonded to an outer surface of transparent pressure
sensitive adhesive layer 3 in the polarizing plate with the
pressure sensitive adhesive layer. The separation film is separated
before polarizing plate 1 is bonded to substrate 4 such as a glass
substrate with transparent pressure sensitive adhesive layer 3
being interposed.
[0241] The glass substrate to which the polarizing plate with the
pressure sensitive adhesive layer is bonded is normally a substrate
made of inorganic glass or organic glass and having a surface
formed of a flat surface. A substrate other than the glass
substrate is normally a substrate having a surface formed of a flat
surface. The polarizing plate with the pressure sensitive adhesive
layer can be stacked on this flat surface. In the case where the
polarizing plate with the pressure sensitive adhesive layer is
stacked on the flat surface of the substrate, the poor appearance
caused by the minor irregularities present on the surface of the
protective film is easily noticeable when the substrate having the
polarizing plate bonded thereto is viewed from the polarizing plate
side, and thus, the present invention is preferably applied in such
a case. The flat surface refers to a surface having an arithmetic
average roughness Ra of not greater than 200 nm, preferably not
greater than 10 nm, and ideally 0 mm, which is defined in
accordance with JIS B 0601-2001. Arithmetic average roughness Ra
can be measured by using a confocal microscope. The glass substrate
to which the polarizing plate with the pressure sensitive adhesive
layer is bonded may be a substrate constituting an image display
element such as, for example, a liquid crystal cell and an organic
electroluminescence (EL) display element.
[0242] <Image Display Device>
[0243] An image display device according to the present invention
includes polarizing plate 1 of the present invention described
above and an image display element. As described above, polarizing
plate 1 is bonded to one surface or both surfaces of the image
display element with transparent pressure sensitive adhesive layer
3 being interposed, and is preferably bonded to a surface of the
image display element on the first protective film 10 side. FIGS.
11 and 12 show an example of the image display device according to
the present invention. FIG. 11 is a schematic cross-sectional view
showing one example of a liquid crystal display device, and FIG. 12
is a schematic cross-sectional view showing one example of an
organic EL display device.
[0244] The liquid crystal display device shown in FIG. 11 includes:
a liquid crystal cell 8; polarizing plate 1 according to the
present invention stacked on a front surface (viewing side) of
liquid crystal cell 8 with transparent pressure sensitive adhesive
layer 3 being interposed; a back-side polarizing plate 40 stacked
on a back surface (backlight side) of liquid crystal cell 8 with
transparent pressure sensitive adhesive layer 3 being interposed;
and a backlight 50 arranged on the back surface side of back-side
polarizing plate 40. Liquid crystal cell 8 can have such a
conventionally known configuration that a liquid crystal layer is
interposed between two glass substrates. Polarizing plate 1 and
back-side polarizing plate 40 can be bonded to surfaces of these
glass substrates with transparent pressure sensitive adhesive layer
3 being interposed. Although back-side polarizing plate 40 and
backlight 50 may also have a conventionally known configuration,
polarizing plate 1 according to the present invention may be used
not only for the front-side polarizing plate but also for back-side
polarizing plate 40.
[0245] According to the present invention, particularly because the
occurrence of the minor irregularities on the outer surface
(surface on the opposite side of polarizing layer 5) of second
protective film 20 can be suppressed or prevented more effectively,
the liquid crystal display device is preferably configured such
that polarizing plate 1 is bonded to the viewing side of liquid
crystal cell 8 on the first protective film 10 side and the outer
surface of second protective film 20 faces the side opposite to
liquid crystal cell 8 (i.e., the viewing side).
[0246] In the case where the glass substrate surface of liquid
crystal cell 8 on which polarizing plate 1 is stacked with
transparent pressure sensitive adhesive layer 3 being interposed is
flat, the poor appearance caused by the minor irregularities
present on the surface of the protective film is easily noticeable
when the liquid crystal display device is viewed from the
polarizing plate 1 side. However, according to the present
invention, the liquid crystal display device with good appearance
can be provided even when the glass substrate surface is flat.
[0247] In the case where a surface treatment layer, particularly a
hard coat layer, an antireflective layer, an electroconductive
layer or the like, is formed on the surface of second protective
film 20 constituting polarizing plate 1, the minor irregularities
are further easily noticeable when the minor irregularities are
present on the surface of second protective film 20. Therefore, the
configuration of the present invention is preferably applied in
such a case.
[0248] The organic EL display device shown in FIG. 12 includes: an
organic EL display element 9; and polarizing plate 1 according to
the present invention stacked on a front surface (viewing side) of
organic EL display element 9 with transparent pressure sensitive
adhesive layer 3 being interposed. Organic EL display element 9 can
have such a conventionally known configuration that a light
emitting layer composed of an organic light emitting material or
another organic layer provided as needed is sandwiched between a
pair of electrodes. A substrate such as a glass substrate is
normally stacked on at least one electrode. Polarizing plate 1 can
be bonded to a surface of this glass substrate with transparent
pressure sensitive adhesive layer 3 being interposed.
[0249] In the organic EL display device, the protective film on the
organic EL display element 9 side, of the protective films
possessed by polarizing plate 1, is a protective film (phase
retardation film) having an in-plane phase retardation. An in-plane
phase retardation value R.sub.0 of this protective film is normally
within a range of 100 to 180 nm. In addition, the protective film
(phase retardation film) on the organic EL display element 9 side
is stacked on polarizing layer 5 such that an angle of a slow axis
of this protective film with respect to an absorption axis of
polarizing layer 5 is substantially 45.degree. or substantially
135.degree.. Substantially 45.degree. or substantially 135.degree.
refers to 45.degree..+-.10.degree. or 135.degree..+-.10.degree.
(preferably 45.degree..+-.5.degree. or 135.degree..+-.5.degree.).
Namely, polarizing plate 1 in this case is an oval (circular)
polarizing plate. By stacking such polarizing plate 1 on the
viewing side of organic EL display element 9, the antireflective
function can be provided to the organic EL display device. In-plane
phase retardation value R.sub.0 can be defined in accordance with
the following equation:
R.sub.0=(n.sub.x-n.sub.y).times.d.
[0250] In the aforementioned equation, n.sub.x represents a
refractive index in a direction of an in-plane slow axis, n.sub.y
represents a refractive index in a direction of an in-plane fast
axis (direction perpendicular to the direction of the in-plane slow
axis), and d represents a thickness of the protective film.
[0251] According to the present invention, particularly because the
occurrence of the minor irregularities on the outer surface
(surface on the opposite side of polarizing layer 5) of second
protective film 20 can be suppressed or prevented more effectively,
the organic EL display device is preferably configured such that
polarizing plate 1 is bonded to the viewing side of organic EL
display element 9 on the first protective film 10 side and the
outer surface of second protective film 20 faces the side opposite
to organic EL display element 9 (i.e., the viewing side).
[0252] In the case where the glass substrate surface of organic EL
display element 9 on which polarizing plate 1 is stacked with
transparent pressure sensitive adhesive layer 3 being interposed,
the poor appearance caused by the minor irregularities present on
the surface of the protective film is easily noticeable when the
organic EL display device is viewed from the polarizing plate 1
side. However, according to the present invention, the organic EL
display device with good appearance can be provided even when the
glass substrate surface is flat.
[0253] In the case where a surface treatment layer, particularly a
hard coat layer, an antireflective layer, an electroconductive
layer or the like, is formed on the surface of second protective
film 20 constituting polarizing plate 1, the minor irregularities
are further easily noticeable when the minor irregularities are
present on the surface of second protective film 20. Therefore, the
configuration of the present invention is preferably applied in
such a case.
[0254] When the image display device has, for example, any of the
following configurations, the poor appearance caused by the minor
irregularities present on the surface of the protective film on the
viewing side is easily noticeable. Therefore, the polarizing plate
according to the present invention is preferably applied in any of
the following configulations.
[0255] [A] The case in which the image display device is portable
(mobile). In this case, a screen is stared from a relatively close
distance, and thus, even slight minor irregularities are easily
recognized as the poor appearance. A shape and a size of the
polarizing plate applied to the portable image display device are,
for example, a rectangular shape having a diagonal length of 3 to
32 cm, and preferably a rectangular shape having a diagonal length
of 7 to 15 cm.
[0256] [B] The case in which a resolution of the display screen of
the image display device is high or the case in which the display
screen of the image display device is capable of color display. In
these cases as well, a displayed image is clean, and thus, the
minor irregularities are easily noticeable. The case of the
resolution being high refers to, for example, the case of the
resolution being not lower than 300 dpi.
[0257] [C] The case in which the image display device is a liquid
crystal display device using a normally black-type liquid crystal
cell in which an image is displayed in black color when a voltage
is not applied. In this case, completely black display is obtained
when an image is turned off, and thus, the minor irregularities are
easily noticeable.
[0258] [D] The case in which the hard coat layer or the
antireflective layer is provided on the outer surface (surface on
the opposite side of the polarizing layer) of the protective film
on the viewing side in the polarizing plate arranged on the front
surface (viewing) side of the image display element. In this case
as well, the minor irregularities are easily noticeable.
[0259] [E] The case in which the viewing side of the polarizing
plate arranged on the front surface (viewing) side of the image
display element is an air layer. In this case as well, the minor
irregularities are easily noticeable. Examples of the image display
device having such a configuration include an image display device
configured such that the viewing side of the aforementioned
polarizing plate is exposed to the atmosphere, and an image display
device configured such that a transparent plate such as a cover
glass and a touch panel is arranged on the viewing side of the
aforementioned polarizing plate with the air layer being
interposed.
[0260] [F] The case in which the electroconductive layer is
provided on the outer surface (surface on the opposite side of the
polarizing layer) of the protective film on the viewing side in the
polarizing plate arranged on the front surface (viewing) side of
the image display element. In this case as well, an optical
reflectivity of many electroconductive layers is relatively high
due to a refractive index thereof, and thus, the minor
irregularities are easily noticeable. Examples of the
electroconductive layer include a layer formed of ATO (antimony tin
oxide), ITO (indium tin oxide) or the like, and others.
EXAMPLES
[0261] The present invention will be further specifically described
with reference to Examples. However, the present invention is not
limited by these Examples.
Reference Example
(1) Fabrication of Polarizing Layer (Polarizing Film)
[0262] A polyvinyl alcohol film having an average degree of
polymerization of about 2400, a degree of saponification of not
lower than 99.9 mol % and a thickness of 75 .mu.m was uniaxially
stretched by dry stretching with a stretching magnification of
about 5, and was further immersed in purified water at 60.degree.
C. for 1 minute with the tension state being maintained, and
thereafter, was immersed at 28.degree. C. for 60 seconds in an
aqueous solution in which a weight ratio of iodine/potassium
iodide/water was 0.05/5/100. Thereafter, the polyvinyl alcohol film
was immersed at 72.degree. C. for 300 seconds in an aqueous
solution in which a weight ratio of potassium iodide/boric
acid/water was 8.5/8.5/100. Subsequently, the polyvinyl alcohol
film was cleaned with purified water at 26.degree. C. for 20
seconds, and thereafter, was dried at 65.degree. C. Thus, a
polarizing film having iodine adsorbed and oriented in the
uniaxially stretched polyvinyl alcohol film was fabricated. A
thickness of the polarizing film was 28 .mu.m.
(2) Preparation of Ultraviolet Curing Adhesive
[0263] The following components were mixed and defoamed to prepare
an ultraviolet curing resin adhesive in a liquid state:
TABLE-US-00001 3,4-epoxycyclohexylmethyl 75 parts
3,4-epoxycyclohexanecarboxylate 1,4-butanediol diglycidyl ether 20
parts 2-ethylhexyl glycidyl ether 5 parts triarylsulfonium
hexafluorophosphate-based 2.25 parts. photocationic polymerization
initiator
[0264] A photocationic polymerization initiator obtained in a form
of 50% propylene carbonate solution was used as the photocationic
polymerization initiator. The blending amount (2.25 parts)
described above was an amount of solid content.
(3) Bonding of Protective Film
[0265] A second protective film [trade name: "KC4UY" which is a TAC
film manufactured by Konica Minolta Optics, Inc.] having a
thickness of 40 .mu.m was prepared, and the ultraviolet curing
adhesive prepared in the above was applied to one surface of the
second protective film by using a micro gravure coater, and this
was bonded to one surface of the aforementioned polarizing film.
Thereafter, by using an ultraviolet ray irradiation device with a
belt conveyor to which an ultraviolet lamp, "D Valve", manufactured
by Fusion UV Systems Inc. was attached, irradiation with an
ultraviolet ray was performed such that a multiplied quantity of
light became 250 mJ/cm.sup.2, to harden the ultraviolet curing
adhesive. Next, a first protective film [trade name: "ZEONOR Film
ZF14-023", which is a cyclic polyolefin-based resin film
manufactured by ZEON Corporation, having a bonding surface thereof
subjected to corona treatment] having a thickness of 23 .mu.m was
prepared, and the same ultraviolet curing adhesive was applied to
the corona-treated surface by using the micro gravure coater, and
this was bonded to the other surface of the polarizing film.
Thereafter, irradiation with an ultraviolet ray was similarly
performed to harden the ultraviolet curing adhesive. Thus, a
polarizing plate having a layer configuration of second protective
film (40 .mu.m)/ultraviolet curing adhesive layer/polarizing film
(28 .mu.m)/ultraviolet curing adhesive layer/first protective film
(23 .mu.m) was obtained. A thickness of each adhesive layer
subjected to curing was 1.0 .mu.m.
Comparative Example 1
(1) Primer Layer Formation Step
[0266] Polyvinyl alcohol powders [trade name: "Z-200" manufactured
by The Nippon Synthetic Chemical Industry Co., Ltd., an average
degree of polymerization of 1100, a degree of saponification of
99.5 mol %] were dissolved in hot water at 95.degree. C., to
prepare a polyvinyl alcohol aqueous solution having a concentration
of 3 weight %. A cross-linker [trade name: "Sumirez Resin 650"
manufactured by Taoka Chemical Company, Ltd.] was mixed in the
obtained aqueous solution by 5 parts by weight with respect to 6
parts by weight of the polyvinyl alcohol powders, to obtain a
coating liquid for formation of a primer layer.
[0267] A substrate film [unstretched polypropylene film having a
thickness of 110 .mu.m, melting point of 163.degree. C.] was
prepared, and one surface of the substrate film was subjected to
corona treatment. Then, the aforementioned coating liquid for
formation of a primer layer was applied to the corona-treated
surface by using the micro gravure coater, and was dried at
80.degree. C. for 10 minutes, to form a primer layer having a
thickness of 0.2 .mu.m. A tensile elastic modulus at 80.degree. C.
of the substrate film was measured by using a universal testing
machine, "Autograph AG-I", manufactured by Shimadzu Corporation
including a thermostatic bath. The tensile elastic modulus was 200
MPa.
(2) Resin Layer Formation Step
[0268] Polyvinyl alcohol powders [trade name: "PVA124" manufactured
by Kuraray Co., Ltd., an average degree of polymerization of 2400,
a degree of saponification of 98.0 to 99.0 mol %] were dissolved in
hot water at 95.degree. C., to prepare a polyvinyl alcohol aqueous
solution having a concentration of 8 weight %. This was used as a
coating liquid for formation of a polyvinyl alcohol-based resin
layer.
[0269] By using a lip coater, the aforementioned coating liquid for
formation of a polyvinyl alcohol-based resin layer was applied to a
primer layer surface of the substrate film having the primer layer
fabricated in (1) above, and was dried at 80.degree. C. for 2
minutes. Thus, a three-layer laminated film composed of substrate
film/primer layer/polyvinyl alcohol-based resin layer was
fabricated.
(3) Stretching Step
[0270] By using a tenter device, free-end uniaxial stretching was
performed at 160.degree. C. with a stretching magnification of 5.8
to the laminated film fabricated in (2) above, to obtain a
stretched film. A thickness of the polyvinyl alcohol-based resin
layer subjected to stretching was 6.1 .mu.m.
(4) Coloring Step
[0271] The stretched film fabricated in (3) above was immersed in a
coloring aqueous solution including iodine and potassium iodide
(including 0.35 parts by weight of iodine and 10 parts by weight of
potassium iodide with respect to 100 parts by weight of water) at
30.degree. C., and coloring treatment of the polyvinyl
alcohol-based resin layer was performed. Then, an excessive
coloring solution was washed away with purified water at 10.degree.
C. Subsequently, the film was immersed for 300 seconds in a
cross-linking aqueous solution including boric acid and potassium
iodide (including 9.5 parts by weight of boric acid and 5 parts by
weight of potassium iodide with respect to 100 parts by weight of
water) at 76.degree. C., and cross-linking treatment was performed.
Thereafter, the film was cleaned for 10 seconds with purified water
at 10.degree. C. and dried at 80.degree. C. for 200 seconds. Thus,
a polarizing laminated film having a polarizing layer on one
surface of the substrate film was obtained.
(5) First Bonding Step
[0272] The same ultraviolet curing adhesive as that used in
Reference Example was applied to one surface of the same second
protective film as that used in Reference Example by using the
micro gravure coater, and the second protective film was bonded to
a surface of the polarizing layer of the polarizing laminated film
fabricated in (4) above, wherein the surface is a surface on the
opposite side of the substrate film. Next, irradiation with an
ultraviolet ray was performed from the substrate film side under
the same conditions as those in Reference Example, to harden the
adhesive layer. Thus, a five-layer film composed of substrate
film/primer layer/polarizing layer/ultraviolet curing adhesive
layer/second protective film was obtained. A thickness of the
polarizing layer was 6.1 .mu.m.
(6) Separation Step and Second Bonding Step
[0273] The substrate film was separated and removed from the
five-layer-structure film fabricated in (5) above, to obtain a
polarizing plate with the protective film on one surface. The
substrate film was able to be separated easily. Next, the same
ultraviolet curing adhesive as that used in Reference Example was
applied to one surface of the same first protective film as that
used in Reference Example by using the micro gravure coater, and
this was bonded to a primer layer surface in the aforementioned
polarizing plate with the protective film on one surface. Next,
irradiation with an ultraviolet ray was performed from the first
protective film side under the same conditions as those in
Reference Example, to harden the adhesive layer. Thus, a polarizing
plate having a configuration similar to that in FIG. 1(a) was
obtained. A thickness of each adhesive layer subjected to curing
was 1.0 .mu.m.
Example 1
(1) Fabrication of Polarizing Laminated Film
[0274] Similarly to Comparative Example 1, a polarizing laminated
film having a polarizing layer on one surface of a substrate film
was obtained.
(2) First Bonding Step
[0275] Polyvinyl alcohol powders [trade name: "KL-318" manufactured
by Kuraray Co., Ltd., an average degree of polymerization of 1800]
were dissolved in hot water at 95.degree. C., to prepare a
polyvinyl alcohol aqueous solution having a concentration of 3
weight %. A cross-linker [trade name: "Sumirez Resin 650"
manufactured by Taoka Chemical Company, Ltd.] was mixed in the
obtained aqueous solution by 1 part by weight with respect to 2
parts by weight of the polyvinyl alcohol powders, to prepare a
water-soluble adhesive.
[0276] By using the gravure coater, the aforementioned
water-soluble adhesive was applied to a surface of the polarizing
layer of the polarizing laminated film fabricated in (1) above,
wherein the surface is a surface on the opposite side of the
substrate film. Then, the same second protective film as that used
in Reference Example was bonded to the applied surface. Thereafter,
drying treatment was performed at 80.degree. C. for 5 minutes.
Thus, a five-layer film composed of substrate film/primer
layer/polarizing layer/water-soluble adhesive layer/second
protective film was obtained. A thickness of the polarizing layer
was 6.1 .mu.m.
(3) Separation Step and Second Bonding Step
[0277] The substrate film was separated and removed from the
five-layer-structure film fabricated in (2) above, to obtain a
polarizing plate with the protective film on one surface. The
substrate film was able to be separated easily. Next, the same
ultraviolet curing adhesive as that used in Reference Example was
applied to one surface of the same first protective film as that
used in Reference Example by using the micro gravure coater, and
this was bonded to the primer layer surface in the aforementioned
polarizing plate with the protective film on one surface. Next,
irradiation with an ultraviolet ray was performed from the first
protective film side under the same conditions as those in
Reference Example, to harden the adhesive layer. Thus, a polarizing
plate having a configuration similar to that in FIG. 1(a) was
obtained. A thickness of each adhesive layer subjected to curing
was 1.0 .mu.m.
Example 2
(1) Fabrication of Polarizing Layer (Polarizing Film)
[0278] A polyvinyl alcohol film having an average degree of
polymerization of about 2400, a degree of saponification of not
lower than 99.9 mol % and a thickness of 30 .mu.m was uniaxially
stretched by dry stretching with a stretching magnification of
about 4, and was further immersed in purified water at 40.degree.
C. for 1 minute with the tension state being maintained, and
thereafter, was immersed at 28.degree. C. for 60 seconds in an
aqueous solution in which a weight ratio of iodine/potassium
iodide/water was 0.05/10/100. Thereafter, the polyvinyl alcohol
film was immersed at 68.degree. C. for 300 seconds in an aqueous
solution in which a weight ratio of potassium iodide/boric
acid/water was 8.5/7.5/100. Subsequently, the polyvinyl alcohol
film was cleaned with purified water at 10.degree. C. for 20
seconds, and thereafter, was dried at 65.degree. C. Thus, a
polarizing film having iodine adsorbed and oriented in the
uniaxially stretched polyvinyl alcohol film was fabricated. A
thickness of the polarizing film was 11 .mu.m.
(2) Bonding of Second Protective Film
[0279] The same water-soluble adhesive as that used in Example 1
was applied to one surface of the aforementioned polarizing film by
using the gravure coater. Then, a second protective film [trade
name: "ZEONOR Film ZF14-023", which is a cyclic polyolefin-based
resin film manufactured by ZEON Corporation, having a bonding
surface thereof subjected to corona treatment] having a thickness
of 23 .mu.m was bonded to the applied surface. Thereafter, drying
treatment was performed at 40.degree. C. for 1 minute. Thus, a
polarizing plate with the protective film on one surface composed
of polarizing film/water-soluble adhesive layer/second protective
film was obtained.
(3) Bonding of First Protective Film
[0280] A first protective film [polyethylene terephthalate film
manufactured by Mitsubishi Plastics, Inc., having a bonding surface
thereof subjected to corona treatment] having a thickness of 25
.mu.m was prepared, and the same ultraviolet curing adhesive as
that used in Reference Example was applied to the corona-treated
surface by using the micro gravure coater, and this was bonded to a
polarizing film surface of the polarizing plate with the protective
film on one surface fabricated in (2) above. Next, irradiation with
an ultraviolet ray was performed from the second protective film
side under the same conditions as those in Reference Example, to
harden the adhesive layer. Thus, a polarizing plate having a
configuration similar to that in FIG. 1(a) was obtained. A
thickness of the ultraviolet curing adhesive layer subjected to
curing was 1.0 .mu.m.
Comparative Example 2
(1) Fabrication of Polarizing Layer (Polarizing Film)
[0281] Similarly to Example 2, a polarizing film was
fabricated.
(2) Bonding of First Protective Film and Second Protective Film
[0282] The same first protective film [polyethylene terephthalate
film manufactured by Mitsubishi Plastics, Inc., having a bonding
surface thereof subjected to corona treatment] and the same second
protective film ("ZEONOR Film ZF14-023" manufactured by ZEON
Corporation, having a bonding surface thereof subjected to corona
treatment) as those used in Example 2 were prepared, and the same
ultraviolet curing adhesive as that used in Reference Example was
applied to each corona-treated surface by using the micro gravure
coater, and the first protective film was bonded to one surface of
the aforementioned polarizing film and the second protective film
was bonded to the opposite surface. Next, irradiation with an
ultraviolet ray was performed from the second protective film side
under the same conditions as those in Reference Example, to harden
the adhesive layer. Thus, a polarizing plate was obtained.
[0283] [Evaluation of Polarizing Plate]
[0284] (1) Appearance Evaluation of Surface of Polarizing Plate
[0285] FIG. 8 is a schematic view for describing a method of
evaluating an appearance of a surface of a polarizing plate, and
FIG. 8(a) is a side view thereof and FIG. 8(b) is a top view
thereof. Referring to FIG. 8, appearance evaluation of the surface
of the polarizing plate was performed as follows. First, the
polarizing plate was cut out into a size of 100 mm in length and
100 mm in width, and this was defined as a sample for evaluation
1a. The first protective film side of this sample for evaluation 1a
was bonded to a flat black acrylic plate 2 having a thickness of 2
mm, with transparent pressure sensitive adhesive layer 3 being
interposed.
[0286] Sample for evaluation 1a bonded to black acrylic plate 2 was
placed in a room where a fluorescent lamp 60 is on. A position of
fluorescent lamp 60 is at a height of 2 m from black acrylic plate
2. In this state, the light from fluorescent lamp 60 is reflected
on a surface of sample for evaluation 1a (the reference numeral 61
represents the incident light incident on the surface of sample for
evaluation 1a, and the reference numeral 62 represents the
reflected light), and thereby, a region of a reflected image A of
the fluorescent lamp appearing on the surface of sample for
evaluation 1a was visually observed. Sample for evaluation 1a was
placed in such an orientation that a direction of an absorption
axis B of a polarizing layer thereof is parallel to a line
connecting fluorescent lamp 60 and an observer X.
[0287] A result of appearance evaluation of the surface of the
polarizing plate is shown in Table 1. In Table 1, A indicates that
no circular recessed patterns were observed and the surface of
sample for evaluation 1a was observed as being flat, and B
indicates that circular recessed patterns were observed. In
Comparative Example 1, flaky uneven circular recessed patterns
having a diameter of about 1 mm were observed over the entire
surface of sample for evaluation 1a.
[0288] (2) Evaluation of Irregularities on Surface of Polarizing
Plate by Measuring Reflection Sharpness
[0289] FIG. 9 is a schematic view for describing a method of
measuring a reflection sharpness of a polarizing plate, and FIG.
9(a) is a side view thereof and FIG. 9(b) is a top view thereof.
Referring to FIG. 9, the reflection sharpness of the polarizing
plate was measured as follows. First, the polarizing plate was cut
out into a size of 100 mm in length and 100 mm in width, and this
was defined as sample for evaluation 1a. The first protective film
side of this sample for evaluation 1a was bonded to flat black
acrylic plate 2 having a thickness of 2 mm, with transparent
pressure sensitive adhesive layer 3 being interposed.
[0290] The surface of sample for evaluation 1a was irradiated with
light (incident light 71) at an incidence angle of 45.degree. from
a light source 70 and a quantity of reflected light 72 was measured
through an optical comb 80 by using an image clarity measuring
device, "ICM-1T", manufactured by Suga Test Instruments Co., Ltd.,
in accordance with the section of "Reflection Method" in JIS K7374
[Plastics: Determination of image clarity]. Thus, the reflection
sharpness (%) was determined as to sample for evaluation 1a bonded
to black acrylic plate 2 described above. A width of the optical
comb was 0.125 mm. Sample for evaluation 1a was placed in such an
orientation that a direction of absorption axis B of a polarizing
layer thereof is parallel to a plane including incident light 71
and reflected light 72 to be detected. As a flatness of the surface
of sample for evaluation 1a becomes higher, the reflection
sharpness becomes greater. A result of measurement of the
reflection sharpness is shown in Table 1.
TABLE-US-00002 TABLE 1 Appearance Reflection Evaluation Sharpness
(%) Reference Example A 32.7 Comparative Example 1 B 12.1 Example 1
A 52.7 Example 2 A 27.6 Comparative Example 2 B 3.7
[0291] (3) Evaluation of Irregularities on Surface of Polarizing
Plate by Measuring Surface Shape
[0292] FIG. 10 is a schematic view for describing a method of
measuring a surface shape of a polarizing plate, and FIG. 10(a) is
a side view thereof and FIG. 10(b) is a top view thereof. Referring
to FIG. 10, the surface shape of the polarizing plate was measured
as follows. First, the polarizing plate was cut out into a size of
100 mm in length and 100 mm in width, and this was defined as
sample for evaluation 1a. The first protective film side of this
sample for evaluation 1a was bonded to flat black acrylic plate 2
having a thickness of 2 mm, with transparent pressure sensitive
adhesive layer 3 being interposed.
[0293] By using "Imaging Profiler PL.mu.2300" manufactured by
SENSOFAR Inc., a change in height of a surface of sample for
evaluation 1a was measured over a length of 8000 .mu.m (a
measurement spot R in FIG. 10) by a confocal mode. From the
obtained result, arithmetic average roughness Ra (nm) which is a
parameter of a surface roughness, a maximum valley depth PV (nm) of
a cross section curve, and a root mean square roughness Rms (nm)
were determined. A result of evaluation about the polarizing plates
obtained in Reference Example, Comparative Example 1, Example 1,
and Example 2 is shown in Table 2.
TABLE-US-00003 TABLE 2 Ra PV Rms (nm) (nm) (nm) Reference Example
62 472 80 Comparative Example 1 111 628 133 Example 1 69 422 82
Example 2 74 482 86
[0294] (4) Measurement of Shrinkage Force of Polarizing Layer
Constituting Polarizing Plate
[0295] The first and second protective films of the polarizing
plate obtained in Example 2 was dissolved and only the polarizing
layer was taken out to measure the heat shrinkage force in a
direction of an absorption axis thereof (a direction of
stretching). In measurement, with the direction of the stretching
absorption axis being a longer side, a film of 2 mm in width and 8
mm in length was cut out and was defined as a sample for
measurement. This sample was placed in a thermo-mechanical analyzer
(TMA) ["EXSTAR-6000" manufactured by SII NanoTechnology Inc.], and
the shrinkage force in a direction of the length of 8 mm generated
when the sample was heated at 80.degree. C. for 240 minutes with
the dimension being kept constant was measured. The shrinkage force
was 1.7 N.
REFERENCE SIGNS LIST
[0296] 1 polarizing plate; 1a sample for evaluation; 2 black
acrylic plate; 3 transparent pressure sensitive adhesive layer; 4
substrate; 5 polarizing layer; 6 polyvinyl alcohol-based resin
layer; 6' stretched polyvinyl alcohol-based resin layer; 8 liquid
crystal cell; 9 organic electroluminescence display element; 10
first protective film; 15 first adhesive layer; 20 second
protective film; 25 second adhesive layer; 30 substrate film; 30'
stretched substrate film; 40 back-side polarizing plate; 50
backlight; 60 fluorescent lamp; 61 incident light; 62 reflected
light; 70 light source; 71 incident light; 72 reflected light; 80
optical comb; 100 laminated film; 200 stretched film; 300
polarizing laminated film; 400 bonded film; 500 polarizing plate
with protective film on one surface; A reflected image of
fluorescent lamp; B absorption axis of polarizing layer; R
measurement spot; X observer.
* * * * *