JP3692384B2 - Optical laminate - Google Patents

Description

ここで、ｎは１〜２０の整数、Ｒは水素又は炭素数１〜４のアルキル基、フェニル基である。
【００１１】
即ち、本発明においては上記化１で示されるシリケートオリゴマーからなる層を光学フィルムの少なくとも片面に設けることが最大の特徴であり、これにより、光学積層体の耐湿熱性及び耐熱性が向上し、更に保護層を必要としないので薄膜化が可能となるのである。
尚、本発明においては、上記の如く光学フィルムと非晶質酸化ケイ素層が積層されていればよく、各層間に任意に接着剤層等の層が介在されてもよい。
又、本発明においては、上記光学積層体に、更に粘着剤層を設けることができ、これにより、光学積層体の強度、耐久性が向上したり、又、液晶表示体作製時のガラス基板、又は偏光フィルムや位相差フィルム等への貼合が簡便となり、一段と実用性に富んだ光学積層体が得られる。
【００１２】
【発明の実施の形態】
以下、本発明について具体的に説明する。
本発明の光学フィルムとしては、偏光フィルム、位相差フィルム、楕円偏光フィルムのいずれかが使用される。
偏光フィルムとしては特に制限されないが、好ましくは、ポリビニルアルコール系フィルムの一軸延伸フィルムである。ポリビニルアルコールは通常、酢酸ビニルを重合したポリ酢酸ビニルをケン化して製造されるが、本発明では必ずしもこれに限定されるものではなく、少量の不飽和カルボン酸（塩、エステル、アミド、ニトリル等を含む）、オレフィン類、ビニルエーテル類、不飽和スルホン酸塩等、酢酸ビニルと共重合可能な成分を含有していても良い。又、ポリビニルアルコール系樹脂を酸の存在下でアルデヒド類と反応させたポリビニルブチラール樹脂、ポリビニルホルマール樹脂等のいわゆるポリビニルアセタール樹脂及びその他ポリビニルアルコール系樹脂誘導体も挙げられるが、これらに限定されるものではない。これらのうちでは、耐熱性が良好であるという点から、高ケン化度で高重合度のポリビニルアルコールが好ましい。即ちケン化度は８５〜１００モル％、好ましくは９８〜１００モル％、特に好ましくは９９〜１００モル％であり、又、重合度としては任意のものが使用可能であるが、１０００〜１００００、好ましくは２０００〜８０００、より好ましくは２５００〜５０００が有利である。
【００１３】
本発明の偏光フィルムの製造法としては、ポリビニルアルコールを水又は有機溶媒に溶解した原液を流延製膜して、該フィルムを延伸してヨウ素あるいは二色性染料の水溶液に浸漬し染色するか、延伸と染色を同時に行うか、ヨウ素あるいは二色性染料により染色して延伸するかした後、ホウ素化合物処理する方法が挙げられる。又、染色した後ホウ素化合物の溶液中で延伸する方法等もあり、適宜選択して用いることができる。原液調製に際して使用される溶媒としては、例えば水はもちろん、ジメチルスルホキシド（ＤＭＳＯ）、Ｎ−メチルピロリドン、グリセリン、エチレングリコール、プロピレングリコール、ジエチレングリコール、トリエチレングリコール、テトラエチレングリコール、トリメチロールプロパン等の多価アルコール、エチレンジアミン、ジエチレントリアミン等のアミン類及びこれらの混合物が用いられる。
【００１４】
上記有機溶媒中には少量、例えば５〜３０重量％の水を含有させても差し支えない。原液中のポリビニルアルコールの濃度は４〜５０重量％が実用的である。該溶剤を用いて得られたポリビニルアルコール製膜原液は、キャスト法、押出法等任意の方法で製膜される。製膜方法としては乾・湿式製膜法にて、即ち、該溶液を口金スリットから一旦空気中、又は窒素、ヘリウム、アルゴン等の不活性雰囲気中に吐出し次いで凝固浴中に導いて未延伸フィルムを形成せしめる。又は口金から吐出された製膜溶液は一旦ローラー、あるいはベルトコンベアー等の上で溶剤を一部乾燥した後で凝固浴中に導入しても差し支えない。
【００１５】
又、凝固浴に用いる溶媒には前記ポリビニルアルコールの溶剤と混和性を有するもので、例えばメタノール、エタノール、プロパノール、ブタノール等のアルコール類、アセトン、ベンゼン、トルエン等が挙げられる。
ポリビニルアルコール系フィルムを得る方法としては、その他ポリビニルアルコールの溶液を凝固浴中に導入してフィルム化するいわゆるゲル製膜法等も実施可能である。
【００１６】
原反フィルムとしてはその膜厚は３０〜１００μｍ、好ましくは５０〜９０μｍが必要である。３０μｍ以下では延伸不能となり、１００μｍ以上では膜厚精度が低下し不適当である。
前記の如くして得られるポリビニルアルコール未延伸フィルムは次に延伸及び染色、ホウ素化合物処理が施される。延伸と染色更にホウ素化合物処理は別々に行っても同時に行っても良いが、本発明では染色工程、ホウ素化合物処理工程の少なくとも一方の工程中に一軸延伸を実施することが望ましい。
【００１７】
延伸は一軸方向に３．５〜１０倍、好ましくは４．５〜７倍延伸することが望ましい。この際、前記と直角方向にも若干の延伸（幅方向の収縮を防止する程度あるいはそれ以上の延伸）を行っても差し支えない。延伸時の温度条件は４０〜１３０℃から選ぶのが望ましい。更に、かかる延伸倍率は最終的に上記の範囲に設定されれば良く、延伸操作は一段階のみならず、製造工程の任意の範囲の段階に実施すれば良い。
【００１８】
フィルムへの染色つまり偏光素子の吸着はフィルムに偏光素子を含有する液体を接触させることによって行われる。通常はヨウ素−ヨウ化カリの水溶液が用いられ、ヨウ素の濃度は０．１〜２ｇ／ｌ、ヨウ化カリの濃度は１０〜５０ｇ／ｌ、ヨウ化カリ／ヨウ素の重量比は２０〜１００が適当である。染色時間は３０〜５００秒程度が実用的である。処理浴の温度は５〜５０℃、好ましくは５〜４０℃が好ましい。水溶媒以外に水と相溶性のある有機溶媒を少量含有させても差し支えない。
接触手段としては浸漬、塗布、噴霧等の任意の手段が適用できる。
【００１９】
染色処理されたフィルムは次いでホウ素化合物によって処理される。ホウ素化合物としてはホウ酸、ホウ砂が実用的である。
ホウ素化合物は水溶液又は水−有機溶媒混合液の形で濃度０．５〜２モル／ｌ程度で用いられ、液中には少量のヨウ化カリを共存させるのが実用上望ましい。処理法は浸漬法が望ましいが勿論塗布法、噴霧法も実施可能である。処理時の温度は５０〜７０℃程度、処理時間は５〜２０分程度が好ましく、又必要に応じて処理中に延伸操作を行っても良い。
【００２０】
尚、該ホウ素化合物による処理は、ポリビニルアルコール系樹脂溶液にあらかじめホウ素化合物を添加して製膜することにより代替することも可能である。
このようにして、本発明に用いられるヨウ素染色されたポリビニルアルコール系偏光フィルムが得られるわけであるが、本発明では特に該偏光フィルムが８０℃、９０％ＲＨの雰囲気中で２００時間放置処理後のラマン分光法による励起波長５１４．５ｎｍのＡｒ⁺レーザー照射時の１０５ｃｍ^-1及び１５７ｃｍ^-1のスペクトル強度をａ₁及びｂ₁とし、該放置処理前の該スペクトル強度をａ₀及びｂ₀とした時、（ｂ₁／ａ₁）／（ｂ₀／ａ₀）＞０．７、好ましくは１．５＞（ｂ₁／ａ₁）／（ｂ₀／ａ₀）＞０．７を満足することが好ましく、かかる偏光フィルムは上述した偏光フィルムの製造条件をコントロールすることによって上式を満足させることができる。
【００２１】
例えば、原反として高重合度のポリビニルアルコール系樹脂を選択したり、偏光フィルムの製造時の延伸工程において垂直方向の延伸を付加したり、２段階以上の多段階に分けて延伸したり、製造工程上三酢酸セルロース等の保護層を積層する場合は該保護層を積層後乾燥処理を施したりする方法等を単独又は適宜組み合わせることによって実現することができるが、これらに限定されるものではない。
尚、上記の偏光フィルムの、８０℃、９０％ＲＨの雰囲気中で２００時間放置処理に当たっては、処理前の偏光フィルムの両面に接着剤としてポリビニルアルコール水溶液を（塗布乾燥厚み０．０１μｍ）を用いて、表面がアルカリケン化し中和させた三酢酸セルロースフィルム（８０μｍ）を貼着した積層体を試料とし、該試料を上記の条件で放置処理を行った後、該試料をシクロヘキサノン中に２０℃で１２時間浸漬させて両面の三酢酸セルロースフィルムを溶解して完全に取り除き、風乾等により表面付着溶剤を完全に除去した後の偏光フィルム単体のスペクトル強度を放置処理後のスペクトル強度とした。（上記三酢酸セルロースフィルムの除去に当たっては、該フィルムを削り取る等して物理的に除去する方法も可能である。）
【００２２】
又、上記の放置処理前の偏光フィルムのスペクトル強度測定においては偏光フィルムの製造上等の都合により、該偏光フィルムに三酢酸セルロースフィルム等の保護フィルムが積層されているときは、上記等の方法により該保護フィルムを剥がして偏光フィルム単体のスペクトル強度を測定するのである。（保護フィルムがアクリル系樹脂の場合はアセトン、ベンゼン、トルエン等の溶剤を用いることもある。）
【００２３】
更に詳しく説明すると、先ず、前述の如き方法で得られた偏光フィルムをラマン分光測定器（例えば、日本分光社製、Ｊａｓｃｏ ＮＲ−１８００Ｍ）を用いて、励起波長として５１４．５ｎｍのＡｒ⁺レーザーを照射（出力２ｍＷ）し、この時の１０５ｃｍ^-1及び１５７ｃｍ^-1のスペクトル強度ａ₀及びｂ₀を室温で測定（測定時間；１６ｓｅｃ×５回、測定径；２００μｍ、測定モード；後方散乱）する。次に上記の如く該偏光フィルムの両面に三酢酸セルロースフィルムを貼着後、８０℃、９０％ＲＨの雰囲気中で２００時間放置した後取り出してシクロヘキサノン中で該三酢酸セルロースフィルムを剥離した後、上記と同様にラマン分光測定器により、再度偏光フィルム単体の１０５ｃｍ^-1及び１５７ｃｍ^-1のスペクトル強度ａ₁及びｂ₁を測定するのである。
【００２４】
上記のスペクトル強度の決定に当たっては、上記の測定方法により得られたチャートのピークからそれぞれのスペクトル強度を読み取るのであるが、該スペクトル強度の決定は最小自乗法を用いた波形分離法により行い、その際各ピークは３変数（スペクトル位置、スペクトル強度、半価幅）を含むローレンツ関数を、ベースラインは２変数（切片、傾き）を含む直線関数と仮定して波形分離を行い、各スペクトル強度を決定するのである。
そして、上記のａ₀、ｂ₀、ａ₁及びｂ₁からなる（ｂ₁／ａ₁）／（ｂ₀／ａ₀）の値が０．７を越える偏光フィルムが本発明で有効な偏光フィルムであり、好ましくは０．７〜１．５である。該値が０．７以下では偏光フィルムの耐久性が劣ることとなる。更に本発明では、上記の（ｂ₀／ａ₀）の値が１．１より少ないとき、即ち（ｂ₀／ａ₀）＜１．１の条件を満たすとき、高温・高湿時の耐久性に優れており、特に有用である。
【００２５】
又、本発明で用いる偏光フィルムにおいて、偏光フィルムがポリビニルアルコール系フィルムからなり、かつ、波長４６０ｎｍ及び６４０ｎｍでの平行透過率（Ａ）と直交透過率（Ｂ）の比がともに２０００以上、好ましくは２０００〜５０００である偏光フィルム、より好ましくは更に直交透過率（Ｂ）が可視光全般にわたって０．０２％以下、好ましくは０．０００１〜０．０１５％である偏光フィルムも好ましく用いられる。
尚、平行透過率（Ａ）と直交透過率（Ｂ）の比の測定に当たり、上記平行透過率（Ａ）とは２枚の偏光フィルムをその配向方向が同一になるように重ね合わせた場合の透過率（％）を、直交透過率（Ｂ）とは２枚の偏光フィルムをその配向方向が垂直になるように重ね合わせた場合の透過率（％）をそれぞれ意味する。（尚、偏光フィルムの両面に保護フィルムが設けられた偏光板により測定を行っても上記と同様の値となる。）
【００２６】
上記偏光フィルム、即ち波長４６０ｎｍ及び６４０ｎｍでの平行透過率（Ａ）と直交透過率（Ｂ）の比がともに２０００以上の偏光フィルムの製造方法としては特に制限されないが、例えば下記の方法が採用され得る。
即ち、前述と同様に、ポリビニルアルコール系樹脂を水又は有機溶媒に溶解した原液を流延製膜して、該フィルムを延伸してヨウ素化合物あるいは二色性染料の水溶液に浸漬し染色するか、延伸と染色を同時に行うか、ヨウ素化合物あるいは二色性染料により染色して延伸するかした後、ホウ素化合物処理する。又、染色した後ホウ素化合物の溶液中で延伸することも可能であり、適宜選択して用いることができる。しかる後に、水洗処理を行い、その後再度ヨウ素化合物又は二色性染料で再染色を行うことが重要で、これにより特定の偏光フィルムが得られるのである。
【００２７】
かかる水洗処理については、５〜３０℃、好ましくは１０〜２０℃で、２分間以下、好ましくは１分間以下浸漬することにより行われる。勿論浸漬に限らず、噴霧、塗布等も可能である。又、再染色処理については、ヨウ素−ヨウ化カリウムの水溶液が用いられ、ヨウ素の濃度は０．００１〜１ｇ／ｌ、好ましくは０．０１〜１ｇ／ｌ、ヨウ化カリウムの濃度は１０〜５０ｇ／ｌ、好ましくは１０〜３０ｇ／ｌ、染色時間は１０〜５００秒、好ましくは３０〜３００秒程度が実用的である。処理浴の温度は５〜３０℃が好ましい。水溶媒以外に水と相溶性のある有機溶媒を少量含有させても差し支えない。接触手段としては浸漬が好ましいが、塗布、噴霧等、任意の手段が適用できる。再染色処理後は、３０〜８０℃で３０〜５００秒間乾燥を行うことにより、ポリビニルアルコール系偏光フィルムが得られる。
【００２８】
又、本発明において、位相差フィルムも有効であり、位相差フィルムには特に制限されることなく、ポリビニルアルコール、ポリカーボネート、ポリエステル、ポリアリレート、ポリイミド、ポリオレフィン、ポリスチレン、ポリサルホン、ポリエーテルサルホン、ポリビニリデンフルオライド／ポリメチルメタアクリレート、液晶ポリマー、トリアセチルセルロース系樹脂、環状ポリオレフィン、エチレン−酢酸ビニル共重合体ケン化物、ポリ塩化ビニル等のフィルムが採用されるが、主としてポリカーボネート、ポリビニルアルコール系樹脂のフィルムが用いられる。
【００２９】
ポリビニルアルコール系樹脂としては通常酢酸ビニルを重合したポリ酢酸ビニルをケン化して製造されるが、少量の不飽和カルボン酸（塩、エステル、アミド、ニトリル等を含む）、オレフィン類、ビニルエーテル類、不飽和スルホン酸塩等、酢酸ビニルと共重合可能な成分を含有していても良い。又、ポリビニルアルコールを酸の存在下でアルデヒド類と反応させた、例えばポリブチラール樹脂、ポリビニルホルマール樹脂等のいわゆるポリビニルアセタール樹脂及びポリビニルアルコール誘導体が挙げられる。平均重合体は５００〜１００００、好ましくは１０００〜５０００、ケン化度は８０〜１００モル％、好ましくは９０〜１００モル％のもので、無延伸フィルムのものでもよいが、１．０１〜４倍、好ましくは１．０１〜３倍程度に一軸延伸されたものであることが望まれる。
【００３０】
かかる光学フィルムと積層される非晶質酸化ケイ素層としては、前記の化１で示されるシリケートオリゴマーからなる層であることが必要である。該化１で示されるシリケートオリゴマーとしては、特に制限はなく任意の方法で調製され得る。例えば、下記の方法で調製される。
【００３１】
該シリケートオリゴマーは、例えばテトラメトキシシラン、テトラエトキシシラン、テトラプロピオキシシラン、テトラブトキシシラン等のテトラアルコキシシラン、又はテトラフェノキシシランを加水分解することにより得られる。ｎはこの場合の加水分解率を制御することにより調整できる。
加水分解反応自体は、公知の方法によることができ、例えば、上記テトラアルコキシシランに所定量の水を加えて酸触媒の存在下に、副生するアルコールを留去しながら、通常室温程度〜１００℃で反応させる。この反応によりアルコキシシランは加水分解し、更に縮合反応によりヒドロキシル基を２以上有する液状のシリケートオリゴマー（通常平均重合度２〜８程度、好ましくは３〜６）が加水分解物として得られる。加水分解の程度は、使用する水の量により適宜調節することができるが、本発明においては通常４０〜９０％程度、好適には６０〜８０％程度から選ばれる。
【００３２】
ここで、加水分解の程度は、加水分解可能な基、即ちテトラアルコキシシランにおいてはアルコキシ基を全て加水分解縮合するために必要な理論水量即ちアルコキシ基の数の１／２の水を添加したときを加水分解率１００％とし、
加水分解率（％）＝（実際の添加水量／加水分解理論水量）×１００
として求める。
【００３３】
こうして得られたシリケートオリゴマーにはモノマーが通常２〜１０％程度含有されている。このモノマーが含有されていると貯蔵安定性に欠け、保存中に増粘し、膜形成が困難となるので、モノマー含有量が１重量％以下、好ましくは０．３重量％以下になるように、このモノマー除去をフラッシュ蒸留、真空蒸留で行う。
【００３４】
本発明では、上記の如くテトラアルコキシシランに触媒、水を添加して得られる部分加水分解物が用いられるが、特に好ましくは、完全加水分解物が用いられる。該完全加水分解物は、例えば上記の部分加水分解物に溶媒を配合し、次いで硬化触媒と水を添加する等の方法により得られる。かかる溶媒としては、メチルアルコール、エチルアルコールを１種又は２種使用するのが安価であること、及び得られる皮膜の特性が優れ硬度が良好であることから好適である。イソプロピルアルコール、ｎ−ブタノール、イソブタノール、オクタノール等も用いることができるが、得られた皮膜の硬度が低くなる傾向にある。溶媒量は部分加水分解物１００重量部に対して５０〜４００重量部、好ましくは１００〜２５０重量部がよい。
【００３５】
硬化触媒としては酸、アルカリ、有機金属、金属アルコキシド等があるが、好ましくは酸、特に酢酸、マレイン酸、シュウ酸、フマル酸等が用いられる。添加量は部分加水分解物１００重量部に対して１〜１０重量部、好ましくは１〜５重量部がよい。
又、水添加量については部分加水分解物が理論上１００％加水分解し得る量以上の量であればよく、１００〜３００％相当量、好ましくは１００〜２００％相当量を添加するのがよい。
更に、本発明ではこれら成分を配合した後、熟成させることが好ましく、かかる熟成工程により、テトラアルコキシシランの加水分解、縮合による架橋が充分に進み、得られた皮膜の特性が優れたものとなる。
【００３６】
液の熟成は、液を放置すればよく、放置する時間は、上述の架橋が所望の膜特性を得るのに充分な程度進行するのに充分な時間であり、具体的には用いる触媒の種類にもよるが、塩酸では室温で１時間以上、マレイン酸では数時間以上、特に好ましくは８時間〜１週間程度で充分であり、通常３日前後である。熟成を要する時間はまた周囲の温度にも影響を与え、極寒地では２０℃付近まで加熱する手段を採ったほうがよいこともある。一般に高温では熟成が速く進むが１００℃以上にも加熱するとゲル化が起こるので、せいぜい５０〜６０℃までの加熱が適切である。
【００３７】
又、本発明で用いるシリケートオリゴマーについては、上記の他に、例えばエポキシ基、アミノ基、イソシアネート基、カルボキシル基等の官能基を有する有機化合物（モノマー、オリゴマー、ポリマー）等により変性した変性物であっても差し支えなく、単独又は上記シリケートオリゴマーと併用することも可能である。
かくして上記化１で示されるシリケートオリゴマーが得られるが、該シリケートオリゴマー中のＳｉＯ₂含有量は１〜１００％、好ましくは１０〜９９％であることが望まれる。かかるＳｉＯ₂含有量が１％未満では耐久性の向上が見られなくなり本発明の効果を発揮しない。
【００３８】
かかるシリケートオリゴマーより上記非晶質酸化ケイ素層を形成させる方法については特に制限されないが、例えば上記シリケートオリゴマーを光学フィルムの光学性能を阻害しない溶剤、例えばアルコール（メタノール、エタノール、イソプロピルアルコール等）、酢酸エチル、酢酸ブチル、酢酸セロソルブ、メチルグリコールアセテート、エチレングリコールアセテート、メトキシブチルアセテート、メチルエチルケトン、メチルイソブチルケトン、シクロヘキサノン、メチレンクロライド、トルエン、キシレン、ミネラムスピリット、クレゾール、キシレノール、フラフラール、ナフサ等にて希釈し、バーコーター、ロールコーター、グラビアコーター、リバースコーター、リップコーター等、公知の方法により基材に塗工、加熱処理することで可能である。
【００３９】
本発明においては、上記の如き光学フィルムの少なくとも片面に、上記シリケートオリゴマーからなる非晶質酸化ケイ素層が積層されていればよく、その積層方法については限定されず任意の方法が採用され得る。光学フィルムにかかる非晶質酸化ケイ素層を形成するには、光学フィルム表面に、例えば前記のシリケートオリゴマーからなる溶液を塗布したり、あるいは該溶液に光学フィルムを浸漬したりした後に、加熱処理させる方法や、予め該シリケートオリゴマーからなる溶液から皮膜を作製しておき、かかる皮膜を接着剤で貼着する方法等が採用することができる。
【００４０】
かかる接着剤としては特に制限なくポリビニルアルコール、カルボキシメチルセルロース、ウレタン系、アクリル系、エポキシ系等の親水性高分子の水溶液、上記化１で示されるシリケートオリゴマー等が用いられる。中でも本発明では特に上記シリケートオリゴマーからなる溶液を接着剤として用いるとき、本発明の効果が顕著に発揮される。
【００４１】
本発明では前記したように、該シリケートオリゴマーからなる溶液を光学フィルムに塗布し、次いで加熱処理を施し積層するわけであるが、勿論、浸漬、噴霧等の方法も可能で、いずれの方法により積層されてもよい。該加熱処理は２０〜２００℃、好ましくは５０〜２００℃、更に好ましくは５０〜１８０℃の条件で行われる。又、該非晶質酸化ケイ素層の層厚みは乾燥後の厚みで０．００１〜５０μ、好ましくは０．０１〜５０μである。
【００４２】
更に本発明では、必要に応じて非晶質酸化ケイ素層中に紫外線吸収剤を含有させたり、本発明の光学積層体の外側に反射防止層を設けたりすることもできる。該紫外線吸収剤としては前記のサリチル酸エステル系化合物、ベンゾフェノール系化合物、ベンゾトリアゾール系化合物、シアノアクリレート系化合物、ニッケル錯塩系化合物等が挙げられ、反射防止層としては高屈折率の物質（例えばチタン、セリウム、タンタル等の金属酸化物等）と低屈折率の物質（例えば酸化ケイ素、フッ化マグネシウム等）を交互に積層して得られる層あるいは低屈折率の物質（例えば酸化ケイ素、フッ化マグネシウム、フッ素含有ポリマー等）からなる単層のものが挙げられる。
【００４３】
又、本発明の光学積層体については、必要に応じて更に粘着剤層を設けることができ、液晶表示体作製時のガラス基板、又は偏光フィルムと位相差フィルムの貼合等が簡便となり、一段と実用性に富んだ光学積層体が得られる。
粘着剤層の積層に際して、光学積層体の層構成により適宜選択されるが、例えば、光学フィルム層の片面に非晶質酸化ケイ素層が形成されている場合は、該粘着剤層は耐湿熱性向上の点で光学フィルム層表面に設けることが好ましい。又、光学フィルム層の両面に非晶質酸化ケイ素層が形成されている場合は、該粘着剤層はいずれかの非晶質酸化ケイ素層表面のみでも良い。但し、これらに限定されない。
【００４４】
かかる粘着剤層としてはアクリル酸エステル、例えばアクリル酸ブチル、アクリル酸エチル、アクリル酸メチル、アクリル酸２−エチルヘキシル等とα−モノオレフィンカルボン酸、例えばアクリル酸、マレイン酸、イタコン酸、メタクリル酸、クロトン酸等との共重合物（アクリルニトリル、酢酸ビニル、スチロールの如きビニル単量体を添加したものも含む。）を主体とするものが、光学フィルムの光学特性を阻害することがないので特に好ましいが、これに限定されることなく、透明性を有する粘着剤であれば使用可能で、例えばポリビニルエーテル系、ゴム系等でもよい。
【００４５】
更に、本発明においては、光学フィルムとして偏光フィルム、位相差フィルムの他に偏光フィルムと位相差フィルムとを組み合わせた楕円偏光フィルムを用いることもでき、該楕円偏光フィルムの少なくとも片面に、上記化１で示されるシリケートオリゴマーからなる非晶質酸化ケイ素層を設けることで本発明の効果が得られる。該楕円偏光フィルムの具体的な層構成としては、例えば、偏光フィルム／（保護フィルム／）粘着剤層／（保護フィルム／）位相差フィルム、偏光フィルム／非晶質酸化ケイ素層／粘着剤層／非晶質酸化ケイ素層／位相差フィルム、偏光フィルム／非晶質酸化ケイ素層／粘着剤層／保護フィルム／位相差フィルム、偏光フィルム／保護フィルム／粘着剤層／非晶質酸化ケイ素層／位相差フィルム、偏光フィルム／非晶質酸化ケイ素層／粘着剤層／非晶質酸化ケイ素層／位相差フィルム／非晶質酸化ケイ素層／粘着剤層、等が挙げられる。但し、これらに限定されない。
【００４６】
本発明の光学積層体は、偏光フィルム、位相差フィルム、楕円偏光フィルムのいずれかである光学フィルムの少なくとも片面に、上記化１で示されるシリケートオリゴマーからなる非晶質酸化ケイ素層を設けているため、高光学特性はもとより耐湿熱性及び耐熱性に非常に優れ、更に粘着剤層を設けることにより非常に実用的な偏光フィルム、位相差フィルム、楕円偏光フィルムといった光学積層体となる。
かかる特性を利用して液晶表示体の用途に用いられ、特に車両用途、各種工業計器類、家庭用電化製品の表示等に有用である。
【００４７】
【実施例】
以下、本発明について実施例を挙げて具体的に説明する。
尚、実施例中「部」、「％」とあるのは特に断りのない限り重量基準である。又、本発明でいう偏光度は
［（Ｈ₁₁−Ｈ₁）／（Ｈ₁₁＋Ｈ₁）］^1/2×１００（％）
で示され、Ｈ₁₁は２枚の偏光フィルムサンプルの重ね合わせ時において、偏光フィルムの配向方向が同一方向になるように重ね合わせた状態で分光光度計を用いて測定した透過率（％）、Ｈ₁は２枚のサンプルの重ね合わせ時において、偏光フィルムの配向方向が互いに直交する方向になるように重ね合わせた状態で測定した透過率（％）である。
【００４８】
非晶質酸化ケイ素層としては、下記のシリケートオリゴマー（Ａ）〜（Ｃ）を用いた。
［シリケートオリゴマー（Ａ）の調製］
撹拌機と還流用コンデンサー及び温度計を付けた５００ｍｌの３つ口丸底フラスコに、テトラメトキシシラン２３４ｇとメタノール７４ｇを加えて混合した後、０．０５％塩酸２２．２ｇを加え、内温度６５℃、２時間加水分解反応を行った。次いで、コンデンサーを抽出管に切り替え、内温度が１５０℃になるまで昇温し、メタノールで抽出させ更に１５０℃、３時間加熱し縮合して加水分解物を得た。（重合度は３〜６でヒドロキシル基１０以上、テトラメトキシシランオリゴマー中のモノマー量は５％であった。）
引き続き１００〜１５０℃に加熱したジャケットでテトラメトキシシランオリゴマーを煮沸させて、気化したモノマーを不活性ガスと共に系外に排出し、こうしてテトラメトキシシランオリゴマーを得た。得られたテトラメトキシシランオリゴマー中のモノマー量は０．２％であった。
【００４９】
［シリケートオリゴマー（Ｂ）の調製］
上記で得られたテトラメトキシシランオリゴマー３３．７８ｇにエタノール１９．１６ｇ配合し、次いでマレイン酸０．３５ｇ及び脱塩素水７．２８ｇを添加した。水添加量はテトラメトキシシランオリゴマーを理論上１００％加水分解し得る量に対し１１３％である。その後室温で２日放置し熟成し、（Ｂ）を得た。
【００５０】
［シリケートオリゴマー（Ｃ）の調製］
前記のテトラメトキシシランに代えてテトラエトキシシランを使用し、上記（Ｂ）の調製と同様にして、シリケートオリゴマー（Ｃ）を得た。
【００５１】
実施例１
平均重合度１７００、平均ケン化度９９．５モル％のポリビニルアルコールを水に溶解し、５．０重量％濃度の水溶液を得た。該液をポリエチレンテレフタレートフィルム上に流延後、乾燥して膜厚６０μのフィルムを得た。このフィルムを１０ｃｍ巾に切断しチャックに装着した。該フィルムをヨウ素０．２ｇ／ｌ、ヨウ化カリ６０ｇ／ｌよりなる水溶液中に３０℃にて４分間浸漬した。次いでホウ酸７０ｇ／ｌ、ヨウ化カリ３０ｇ／ｌの組成の水溶液に５５℃にて５分間浸漬すると共に、先ず２．２倍に延伸し、次いで１．７倍に延伸して、更に１．５倍に延伸した後、２０℃で１０秒間水洗し、風乾で２４時間乾燥を行って偏光フィルムを得た。そして、予め表面をアルカリ処理し酸で中和した三酢酸セルロースフィルム（８０μｍ厚）をポリビニルアルコール接着剤（３％水溶液、乾燥塗布厚０．０１μｍ）を用いて該偏光フィルムの両面に貼着後１００℃で１分間乾燥させて偏光板を得た。次に該偏光板をシクロヘキサノン中に２０℃で１２時間浸漬させて該三酢酸セルロースフィルムを完全に取り除いて偏光フィルム（Ｆ−１）を得た。
【００５２】
尚、該偏光フィルム（Ｆ−１）（２０ｍｍ×２０ｍｍ）をラマン分光測定器（日本分光社製、Ｊａｓｃｏ ＮＲ−１８００Ｍ）を用いて、励起波長として５１４．５ｎｍのＡｒ⁺レーザーを照射して本文中に記載の条件にて１０５ｃｍ^-1及び１５７ｃｍ^-1のスペクトル強度を室温で測定したところ、３７．８１（ａ₀）及び２９．８８（ｂ₀）であった。更に該偏光フィルムの両面に保護フィルムとして上記の三酢酸セルロースフィルムを再度ポリビニルアルコール接着剤で上記の方法と同様に接着して三酢酸セルロース／偏光フィルム／三酢酸セルロースの３層積層体（偏光板）を得、次に該３層積層体を８０℃、９０％ＲＨの雰囲気中で２００時間放置して処理後の３層積層体を得た後、該積層体をシクロヘキサノン中に２０℃で１２時間浸漬させて該保護層を取り除いて偏光フィルム単体として、同様にラマン分光測定器により、再度該偏光フィルムの１０５ｃｍ^-1及び１５７ｃｍ^-1のスペクトル強度を測定したところ、３０．９４（ａ₁）及び２８．３８（ｂ₁）で、これらの測定値より（ｂ₀／ａ₀）及び（ｂ₁／ａ₁）／（ｂ₀／ａ₀）の値を算出すると０．７９及び１．１６であった。
【００５３】
上記偏光フィルム（Ｆ−１）の両面にシリケートオリゴマー（Ａ）のメタノールとエタノールの混合溶液（濃度１０％）をバーコーターにより塗布し、その後１５０℃で１時間加熱処理し、偏光フィルムとシリケートオリゴマー（Ａ）の積層体（シリケートオリゴマー（Ａ）層の厚み：乾燥後の厚みで３．０μｍ）を得た。更にその一方の外面にアクリル系粘着剤（組成：アクリル酸ｎ−ブチル／アクリル酸＝９５／５（重量比）１００部に対してコロネートＬ（日本ポリウレタン社製）１部を添加したもの）層を設け、ガラス板に貼合した。（初期偏光度は９９．６％であった。）
【００５４】
これより得られた偏光板を８０℃、９０％ＲＨに３５０時間放置した後、該偏光板の偏光度変化及び外観変化を測定することで耐湿熱性を評価した。
又、該偏光板を５０℃の条件下で２時間放置した後、直ちに８０℃の条件下で２時間放置し、その後再び５０℃の条件下にさらし、同様の操作を計５回行った後、偏光度変化及び外観変化を測定することで耐熱性を評価した。
尚、外観変化については、上記耐久試験後の偏光板の色抜けを目視により４段階（◎〜×）で評価した。
【００５５】
実施例２
実施例１において、平均重合度２６００、平均ケン化度９９．５モル％のポリビニルアルコールを用い、延伸工程において最初の延伸倍率を２倍に変更して得られる偏光フィルム（Ｆ−２）を用い、又、シリケートオリゴマー（Ａ）を（Ｂ）に代え、シリケートオリゴマー（Ｂ）層の厚みを２．０μｍに代えた以外は、実施例１と同様の操作を行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
尚、ラマン分光測定器によりａ₀、ｂ₀、ａ₁及びｂ₁を測定したところ、ａ₀＝４２．２３、ｂ₀＝３６．３２、ａ₁＝２７．４２、ｂ₁＝２２．５３でこれらの測定値より（ｂ₀／ａ₀）及び（ｂ₁／ａ₁）／（ｂ₀／ａ₀）の値を算出すると０．８６及び０．９５であった。
【００５６】
実施例３
実施例２において、シリケートオリゴマー（Ｂ）を（Ｃ）に代え、シリケートオリゴマー（Ｃ）層の厚みを３．０μｍに代えた以外は同様の操作を行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
【００５７】
実施例４
実施例１において、平均重合度４０００、平均ケン化度９９．５モル％のポリビニルアルコールを用い、延伸工程において先ず３倍に延伸し、次いで１．７倍に延伸する２段のみの延伸処理とし、三酢酸セルロースフィルム積層後の乾燥温度を６０℃に変更して得られる偏光フィルム（Ｆ−３）を用い、シリケートオリゴマー（Ａ）層の厚みを２．０μｍに代えた以外は、実施例１と同様の操作を行い、偏光板を得、耐湿熱性及び外観変化を評価した。
尚、ラマン分光測定器によりａ₀、ｂ₀、ａ₁及びｂ₁を測定したところ、ａ₀＝３５．２７、ｂ₀＝３１．６９、ａ₁＝３９．６３、ｂ₁＝２７．０５でこれらの測定値より（ｂ₀／ａ₀）及び（ｂ₁／ａ₁）／（ｂ₀／ａ₀）の値を算出すると０．９０及び０．７６であった。
【００５８】
実施例５
実施例４において、シリケートオリゴマー（Ａ）を（Ｂ）に代え、シリケートオリゴマー（Ｂ）層の厚みを３．０μｍに代えた以外は同様の操作を行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
【００５９】
実施例６
実施例４において、シリケートオリゴマー（Ａ）を（Ｃ）に代え、シリケートオリゴマー（Ｃ）層の厚みを２．０μｍに代えた以外は同様の操作を行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
【００６０】
実施例７
実施例１において、下記偏光フィルム（Ｆ−４）を用いた以外は同様に行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
平均重合度３８００、ケン化度９９．５モル％のポリビニルアルコールを水に溶解し、５．０％の溶液を得た。該溶液をポリエチレンテレフタレートフィルム上に流延後乾燥し原反フィルム（８０μｍ）を得た。該フィルムをチャックに装着し、ヨウ素０．２ｇ／ｌ、ヨウ化カリウム６０ｇ／ｌよりなる水溶液中に３０℃にて２４０秒浸漬し、次いでホウ酸７０ｇ／ｌ、ヨウ化カリウム３０ｇ／ｌの組成の水溶液に浸漬すると共に、同時に６．０倍に一軸延伸しつつ５分間にわたってホウ酸処理を行った。次に、２０℃の水洗槽に２０秒間浸漬した後、ヨウ素０．０５ｇ／ｌ、ヨウ化カリウム２０ｇ／ｌよりなる水溶液中に２０℃にて２０秒間浸漬し、最後に室温で２４時間乾燥し、偏光フィルム（Ｆ−４）を得た。
【００６１】
尚、該偏光フィルム（Ｆ−４）の波長４６０ｎｍ及び６４０ｎｍにおける平行透過率（Ａ）と直交透過率（Ｂ）とを高速多波長複屈折測定装置（大塚電子（株）製：ＲＥＴＳ−２０００）により測定し、各々の波長における（Ａ）／（Ｂ）の値を算出したところ４６０ｎｍでは２４８３（３２．２９／０．０１３）、６４０ｎｍでは４３６６（３４．９３／０．００８）であった。
【００６２】
実施例８
実施例７において、シリケートオリゴマー（Ａ）を（Ｂ）に代え、シリケートオリゴマー（Ｂ）層の厚みを２．０μｍに代えた以外は同様の操作を行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
【００６３】
実施例９
実施例７において、シリケートオリゴマー（Ａ）を（Ｃ）に代え、シリケートオリゴマー（Ｃ）層の厚みを３．０μｍに代えた以外は同様の操作を行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
【００６４】
実施例１０
実施例７において、平均重合度１７００、ケン化度９９．７モル％のポリビニルアルコールに代えて得られる偏光フィルム（Ｆ−５）を用い、又、シリケートオリゴマー（Ａ）を（Ｃ）に代え、シリケートオリゴマー（Ｃ）層の厚みを２．０μｍに代えた以外は同様の操作を行い、偏光板を得、耐湿熱性及び耐熱性を評価した。
【００６５】
尚、偏光フィルム（Ｆ−５）の波長４６０ｎｍ及び６４０ｎｍにおける平行透過率（Ａ）と直交透過率（Ｂ）とを高速多波長複屈折測定装置（大塚電子（株）製：ＲＥＴＳ−２０００）により測定し、各々の波長における（Ａ）／（Ｂ）の値を算出したところ４６０ｎｍでは２０１４（３０．２２／０．０１５）、６４０ｎｍでは４１７８（３３．４３／０．００８）であった。
【００６６】
比較例１〜５
表１に示す如き偏光フィルム（Ｆ−１〜５）を用いて、シリケートオリゴマーの層の代わりに、三酢酸セルロースフィルム（厚み８０μｍ）をポリビニルアルコール系接着剤（４％水溶液）により積層した以外は実施例１と同様に行い、耐湿熱性及び耐熱性を評価した。
【００６７】
比較例６
実施例１において、シリケートオリゴマー（Ａ）層の代わりにポリエステルポリオールとヘキサメチレンジイソシアネートからなるウレタン樹脂塗膜層（乾燥後の厚みで３．０μ）を設けた以外は同様に行い、耐湿熱性及び耐熱性を評価した。
【００６８】
実施例１１
実施例１において、偏光フィルムを、平均重合度１７００、平均ケン化度９９．５モル％、２倍延伸のポリビニルアルコールフィルム（膜厚５０μｍ）からなる位相差フィルムに代えた以外は同様に行った。
これより得られた位相差板を５５℃、９５％ＲＨに３００時間放置した後、該位相差板の光学特性変化及び外観変化を測定することで耐湿熱性を評価した。
又、該位相差板を４０℃の条件下で２時間放置した後、直ちに６０℃の条件下で２時間放置し、その後再び４０℃の条件下にさらし、同様の操作を計５回行った後、光学特性変化及び外観変化を測定することで耐熱性を評価した。
【００６９】
尚、位相差板の光学特性については、レターデーション値（ＲＤ）を測定した。位相差フィルムのレターデーション値（ＲＤ）とは、主延伸方向（ＭＤ方向）及びこれに垂直な方向（ＴＤ方向）における屈折率（II_MD−II_TD）と位相差フィルムの厚さ（ｄ）との積で定義され、バビネ型コンペンサーター付の偏光顕微鏡（ニコンＰＯＨ−１型）を用い補償法にて測定した（光源は白色光）。
【００７０】
実施例１２
実施例２において、偏光フィルムを、平均重合度３８００、平均ケン化度９９．５モル％、２．２倍延伸のポリビニルアルコールフィルム（膜厚５０μｍ）からなる位相差フィルムに代えた以外は同様に行った。
これより得られた位相差板を実施例１１と同様に光学特性変化及び外観変化を測定することで耐湿熱性及び耐熱性を評価した。
【００７１】
実施例１３
実施例３において、偏光フィルムを、平均重合度２６００、平均ケン化度９９．５モル％、２．１倍延伸のポリビニルアルコールフィルム（膜厚５０μｍ）からなる位相差フィルムに代えた以外は同様に行った。
これより得られた位相差板を実施例１１と同様に光学特性変化及び外観変化を測定することで耐湿熱性及び耐熱性を評価した。
【００７２】
比較例７
実施例１１において、シリケートオリゴマー（Ａ）からなる層の代わりに三酢酸セルロースフィルム（厚み８０μｍ）をポリビニルアルコール系接着剤（４％水溶液）により設けた以外は同様に行い、光学特性変化及び外観変化を測定することで耐湿熱性及び耐熱性を評価した。
【００７３】
実施例１４
実施例１で用いた偏光フィルム及び実施例１１で用いた位相差フィルムを用いて、シリケートオリゴマー（Ｃ）層／偏光フィルム／シリケートオリゴマー（Ｃ）層／粘着剤層／シリケートオリゴマー（Ｃ）層／位相差フィルム／シリケートオリゴマー（Ｃ）層／粘着剤層の構成をもった楕円偏光板を作製し、該楕円偏光板を６２℃、９３％ＲＨに２９０時間放置した後、光学特性変化（ＲＤ値で評価）及び外観変化を測定し、耐湿熱性を評価した。
又、該楕円偏光板を４０℃の条件下で２時間放置した後、直ちに６０℃の条件下で２時間放置し、その後再び４０℃の条件下にさらし、同様の操作を計５回行った後、光学特性変化（ＲＤ値で評価）及び外観変化を測定することで耐熱性を評価した。
実施例、比較例の結果をまとめて表１〜４に示す。
【００７４】
【表１】

【００７５】

【００７６】
【表２】

【００７７】
注）比較例において、耐熱性については優れているものの、耐湿熱性については実施例に比べかなり劣っており、又、比較例１〜５では薄膜化されていない偏光板である。実施例においては、耐湿熱性及び耐熱性にともに優れており、薄膜化された偏光板である。
【００７８】
【表３】

【００７９】
【表４】

【００８０】
【発明の効果】
本発明の光学積層体は、偏光フィルム、位相差フィルム、楕円偏光フィルムのいずれかである光学フィルムの少なくとも片面に、上記化１で示されるシリケートオリゴマーからなる非晶質酸化ケイ素層を設けたことにより、高光学性能に加えて、耐久性、耐湿熱性及び耐熱性に非常に優れた光学積層体であり、更に三酢酸セルロースフィルム等の保護層を必要としないので薄膜化に優れたものである。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an optical laminate that can be thinned and is excellent in optical performance, moisture and heat resistance, and heat resistance.
[0002]
[Prior art]
In recent years, liquid crystal display devices have been used in desktop electronic calculators, electronic watches, word processors, automobile and machinery instruments, etc., and demand for optical laminates such as polarizing plates, retardation plates, and elliptically polarizing plates has increased. Yes. In particular, since instruments are often used under severe conditions, optical laminates having high durability and high degree of polarization are required.
Among them, as for the polarizing plate, as a typical known polyvinyl alcohol polarizing film, there are a polyvinyl alcohol film dyed with iodine and a dichroic dye dyed. An aqueous solution is formed and dyed by stretching it uniaxially, or after being dyed and uniaxially stretched, preferably subjected to a durability treatment with a boron compound, and transparent on the surface of the polarizing film. A plastic film is bonded as a protective film. As the protective film, cellulose acetate films such as cellulose diacetate and cellulose triacetate are widely used as surface protective films because they are excellent in optical transparency, non-orientation and the like.
[0003]
However, since the cellulose acetate film has a large water absorption rate and moisture permeability, there is a problem that the polarizing plate having the above constitution does not satisfy the durability under the conditions of high temperature and high humidity. For this reason, various alternatives to the cellulose acetate film have been studied as protective films for polarizing films.
For example, in Japanese Patent Application Laid-Open No. 53-82433, the polarizing film and the urethane resin coating layer are firmly bonded by applying and curing a urethane resin on the surface of the polarizing film without using cellulose triacetate as a protective film. A polarizing plate has been proposed.
[0004]
Japanese Patent Application Laid-Open No. 56-80001 also discloses a compound having two or more isocyanate groups in the molecule without using cellulose triacetate and an active hydrogen and a polymerizable unsaturated group that react with the isocyanate group in one molecule. A composition in which a resin having active hydrogen capable of reacting with an isocyanate group is added to a so-called urethane acrylic compound produced by reacting a compound having an acrylic monomer, for example, an acrylic monomer, is applied to the polarizing film, and the active energy is applied to the polarizing film. A polarizing plate with improved moisture resistance and adhesion has been proposed by irradiating a wire to cure the coating film.
[0005]
Further, JP-A-59-151109, JP-A-59-151110, JP-A-59-151111, JP-A-59-151112, and the like disclose polarization for the purpose of improving durability. It has been proposed to form a cured film layer composed of a composition containing various additives (silica sol, cohesive silica gel, etc.) on an ultraviolet curable resin (polyester acrylate resin, acrylic urethane resin, etc.) on the film surface. Yes.
[0006]
In addition, the present applicant also disclosed in Japanese Patent Application Laid-Open No. 7-77608, in place of cellulose triacetate as a protective film, a water vapor transmission rate of 80 g and 90% RH at 200 g / m. ² ・ 24hr ・ 100μ or less and photoelastic coefficient is 1 × 10 ^-11 cm ² It has been proposed to use a film of less than / dyne, for example, a film made of a thermoplastic saturated norbornene resin.
[0007]
[Problems to be solved by the invention]
However, the polarizing plates disclosed in JP-A-53-82433 and JP-A-56-80001 are only durable under conditions of 40 to 60 ° C. and 90 to 95% RH in terms of performance. It has not been realized and provides a so-called medium-durability and high-polarization-type polarizing plate, and the recent high demand performance is still not satisfactory in terms of moisture and heat resistance. In addition, regarding the techniques disclosed in JP-A-59-151109, JP-A-59-151110, JP-A-59-151111, and JP-A-59-151112, the surface strength immediately after the production of the polarizing plate is Although it has been improved, the durability test has not been evaluated, and the durability has not been examined in detail.
[0008]
Further, in the technology disclosed in Japanese Patent Application Laid-Open No. 7-77608, the present invention and the like have been examined in detail. Thus, it was found that there is still room for improvement in durability at high temperatures, that is, heat resistance.
Therefore, in the present invention, under such a background, an optical laminate such as a polarizing plate, a retardation plate, an elliptical polarizing plate having excellent durability such as moist heat resistance and heat resistance, and a highly durable high optical performance type optical It aims at providing a laminated body.
[0009]
[Means for Solving the Problems]
However, the present inventors have conducted extensive research to solve such problems, Either a polarizing film, a retardation film, or an elliptical polarizing film On at least one side of the optical film The silicate oligomer represented by the following chemical formula 1 The present inventors have found that an optical layered body provided with an amorphous silicon oxide layer is excellent in optical performance, moist heat resistance and heat resistance, and completed the present invention.
In the present invention Good Preferably, when the silicate oligomer is a partial hydrolyzate obtained by adding a catalyst and water to tetraalkoxysilane and hydrolytic condensation, more preferably the silicate oligomer is added with a solvent, a curing catalyst and water. When it is a complete hydrolyzate obtained by hydrolysis and condensation, the effects of the present invention are remarkably exhibited.
[0010]
[Chemical 1]

Here, n is an integer of 1 to 20, and R is hydrogen, an alkyl group having 1 to 4 carbon atoms, or a phenyl group.
[0011]
That is, in the present invention, the greatest feature is to provide a layer composed of the silicate oligomer represented by the above chemical formula 1 on at least one side of the optical film, thereby improving the heat and heat resistance and heat resistance of the optical laminate, Since a protective layer is not required, it is possible to reduce the thickness.
In the present invention, it is sufficient that the optical film and the amorphous silicon oxide layer are laminated as described above, and layers such as an adhesive layer may be arbitrarily interposed between the respective layers.
In the present invention, a pressure-sensitive adhesive layer can be further provided on the optical layered body, thereby improving the strength and durability of the optical layered body. Or the lamination | stacking to a polarizing film, retardation film, etc. becomes simple, and the optical laminated body which was further rich in practicality is obtained.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be specifically described.
As an optical film of the present invention, ,side Optical film, retardation film, elliptical polarizing film Any of used.
Although it does not restrict | limit especially as a polarizing film, Preferably, it is a uniaxially stretched film of a polyvinyl alcohol-type film. Polyvinyl alcohol is usually produced by saponifying polyvinyl acetate obtained by polymerizing vinyl acetate, but is not necessarily limited to this in the present invention, and a small amount of unsaturated carboxylic acid (salt, ester, amide, nitrile, etc.) A component copolymerizable with vinyl acetate, such as olefins, vinyl ethers, and unsaturated sulfonates. In addition, examples include polyvinyl butyral resins obtained by reacting polyvinyl alcohol resins with aldehydes in the presence of acid, so-called polyvinyl acetal resins such as polyvinyl formal resins, and other polyvinyl alcohol resin derivatives. Absent. Among these, polyvinyl alcohol having a high degree of saponification and a high degree of polymerization is preferable from the viewpoint of good heat resistance. That is, the saponification degree is 85 to 100 mol%, preferably 98 to 100 mol%, particularly preferably 99 to 100 mol%, and any degree of polymerization can be used. Preferably it is 2000-8000, More preferably, it is 2500-5000.
[0013]
As a method for producing the polarizing film of the present invention, a stock solution obtained by dissolving polyvinyl alcohol in water or an organic solvent is cast into a film, and the film is stretched and immersed in an aqueous solution of iodine or a dichroic dye for dyeing. And a method of treating with a boron compound after stretching and dyeing at the same time or dyeing with iodine or a dichroic dye and drawing. There is also a method of drawing in a solution of a boron compound after dyeing, etc., which can be appropriately selected and used. Examples of the solvent used for preparing the stock solution include water, dimethyl sulfoxide (DMSO), N-methylpyrrolidone, glycerin, ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, and trimethylolpropane. Amines such as monohydric alcohol, ethylenediamine, diethylenetriamine and mixtures thereof are used.
[0014]
The organic solvent may contain a small amount, for example, 5 to 30% by weight of water. The concentration of polyvinyl alcohol in the stock solution is practically 4 to 50% by weight. The polyvinyl alcohol film-forming stock solution obtained using the solvent is formed by an arbitrary method such as a casting method or an extrusion method. The film forming method is a dry / wet film forming method, that is, the solution is once discharged from the base slit into the air or into an inert atmosphere such as nitrogen, helium, argon, etc., and then introduced into the coagulation bath and unstretched. Form a film. Alternatively, the film-forming solution discharged from the die may be introduced into the coagulation bath after the solvent is partially dried on a roller or a belt conveyor.
[0015]
The solvent used in the coagulation bath is miscible with the polyvinyl alcohol solvent, and examples thereof include alcohols such as methanol, ethanol, propanol and butanol, acetone, benzene and toluene.
As a method for obtaining a polyvinyl alcohol-based film, a so-called gel film forming method in which a solution of polyvinyl alcohol is introduced into a coagulation bath to form a film can be performed.
[0016]
The film thickness of the raw film is 30-100 μm, preferably 50-90 μm. If the thickness is 30 μm or less, the film cannot be stretched. If the thickness is 100 μm or more, the film thickness accuracy is lowered, which is inappropriate.
The polyvinyl alcohol unstretched film obtained as described above is then subjected to stretching, dyeing, and boron compound treatment. Stretching and dyeing Further, the boron compound treatment may be performed separately or simultaneously. In the present invention, it is desirable to carry out uniaxial stretching during at least one of the dyeing step and the boron compound treatment step.
[0017]
Stretching is desirably performed 3.5 to 10 times, preferably 4.5 to 7 times in a uniaxial direction. At this time, the film may be slightly stretched in the direction perpendicular to the above (stretching to prevent shrinkage in the width direction or more). The temperature condition during stretching is desirably selected from 40 to 130 ° C. Furthermore, the draw ratio may be finally set in the above range, and the drawing operation may be performed not only in one stage but also in any stage of the manufacturing process.
[0018]
The film is dyed, that is, the polarizing element is adsorbed by bringing the liquid containing the polarizing element into contact with the film. Usually, an iodine-potassium iodide aqueous solution is used, and the iodine concentration is 0.1 to 2 g / l, the potassium iodide concentration is 10 to 50 g / l, Potassium iodide / iodine A weight ratio of 20 to 100 is appropriate. The dyeing time is practically about 30 to 500 seconds. The temperature of the treatment bath is 5 to 50 ° C, preferably 5 to 40 ° C. In addition to the water solvent, a small amount of an organic solvent compatible with water may be contained.
Any means such as dipping, coating, spraying, etc. can be applied as the contact means.
[0019]
The dyed film is then treated with a boron compound. As the boron compound, boric acid and borax are practical.
The boron compound is used in the form of an aqueous solution or a water-organic solvent mixture at a concentration of about 0.5 to 2 mol / l, and it is practically desirable that a small amount of potassium iodide coexists in the solution. The treatment method is preferably an immersion method, but of course, a coating method and a spraying method can also be implemented. The temperature during the treatment is preferably about 50 to 70 ° C., and the treatment time is preferably about 5 to 20 minutes. If necessary, the stretching operation may be performed during the treatment.
[0020]
The treatment with the boron compound may be replaced by adding a boron compound to the polyvinyl alcohol resin solution in advance to form a film.
In this way, the iodine-stained polyvinyl alcohol polarizing film used in the present invention is obtained. In the present invention, the polarizing film is particularly treated after being left for 200 hours in an atmosphere of 80 ° C. and 90% RH. Of excitation wavelength 514.5nm by Raman spectroscopy ⁺ 105cm at the time of laser irradiation ^-1 And 157 cm ^-1 The spectral intensity of a ₁ And b ₁ And the spectral intensity before the standing treatment is a ₀ And b ₀ (B ₁ / A ₁ ) / (B ₀ / A ₀ )> 0.7, preferably 1.5> (b ₁ / A ₁ ) / (B ₀ / A ₀ )> 0.7 is preferably satisfied, and the polarizing film can satisfy the above formula by controlling the manufacturing conditions of the polarizing film described above.
[0021]
For example, select a polyvinyl alcohol-based resin with a high degree of polymerization as the raw fabric, add vertical stretching in the stretching process when manufacturing a polarizing film, stretch in two or more stages, and manufacture In the case where a protective layer such as cellulose triacetate is laminated in the process, it can be realized by alone or appropriately combining methods such as applying a drying treatment after laminating the protective layer, but is not limited thereto. .
When the polarizing film is left to stand for 200 hours in an atmosphere of 80 ° C. and 90% RH, an aqueous polyvinyl alcohol solution (coating dry thickness: 0.01 μm) is used as an adhesive on both surfaces of the polarizing film before the processing. Then, a laminate with a cellulose triacetate film (80 μm) pasted with alkali saponified and neutralized was used as a sample, the sample was left standing under the above conditions, and then the sample was placed in cyclohexanone at 20 ° C. For 12 hours to dissolve and completely remove the cellulose triacetate films on both sides, and the spectral intensity of the polarizing film alone after completely removing the surface adhering solvent by air drying or the like was taken as the spectral intensity after standing treatment. (When removing the cellulose triacetate film, a method of physically removing the film by scraping the film is also possible.)
[0022]
In addition, in the measurement of the spectral intensity of the polarizing film before the standing treatment, when a protective film such as a cellulose triacetate film is laminated on the polarizing film for the convenience of manufacturing the polarizing film, the above method is used. The protective film is peeled off to measure the spectral intensity of the polarizing film alone. (When the protective film is an acrylic resin, a solvent such as acetone, benzene, or toluene may be used.)
[0023]
More specifically, first, the polarizing film obtained by the method as described above is used with a Raman spectrophotometer (for example, Jasco NR-1800M, manufactured by JASCO Corporation), and the excitation wavelength is 514.5 nm Ar. ⁺ Laser irradiation (output 2mW), 105cm at this time ^-1 And 157 cm ^-1 Spectral intensity a ₀ And b ₀ Is measured at room temperature (measurement time: 16 sec × 5 times, measurement diameter: 200 μm, measurement mode: backscattering). Next, after adhering the cellulose triacetate film on both sides of the polarizing film as described above, after leaving for 200 hours in an atmosphere of 80 ° C. and 90% RH, it was taken out and the cellulose triacetate film was peeled off in cyclohexanone, In the same manner as described above, the Raman spectrophotometer is used again, and the polarizing film alone is 105 cm. ^-1 And 157 cm ^-1 Spectral intensity a ₁ And b ₁ Is measured.
[0024]
In determining the above spectrum intensity, each spectrum intensity is read from the peak of the chart obtained by the above measurement method. The spectrum intensity is determined by a waveform separation method using the least square method, At the same time, each peak is assumed to be a Lorentz function including three variables (spectral position, spectral intensity, half width), and the baseline is a linear function including two variables (intercept, slope). To decide.
And above a ₀ , B ₀ , A ₁ And b ₁ (B ₁ / A ₁ ) / (B ₀ / A ₀ ) Is a polarizing film effective in the present invention, preferably 0.7 to 1.5. When the value is 0.7 or less, the durability of the polarizing film is inferior. Furthermore, in the present invention, the above (b ₀ / A ₀ ) Is less than 1.1, ie (b ₀ / A ₀ ) When satisfying the condition of <1.1, it is excellent in durability at high temperature and high humidity and is particularly useful.
[0025]
In the polarizing film used in the present invention, the polarizing film is made of a polyvinyl alcohol film, and the ratio of the parallel transmittance (A) and the orthogonal transmittance (B) at wavelengths of 460 nm and 640 nm is both 2000 or more, preferably A polarizing film having 2000 to 5000, more preferably a polarizing film having orthogonal transmittance (B) of 0.02% or less, preferably 0.0001 to 0.015% over the entire visible light is also preferably used.
In the measurement of the ratio of the parallel transmittance (A) and the orthogonal transmittance (B), the parallel transmittance (A) is a value obtained by superposing two polarizing films so that their orientation directions are the same. The transmittance (%) and the orthogonal transmittance (B) mean the transmittance (%) when two polarizing films are superposed so that their orientation directions are perpendicular to each other. (In addition, even if it measures with the polarizing plate in which the protective film was provided on both surfaces of the polarizing film, it will become the same value as the above.)
[0026]
The method for producing the polarizing film, that is, the polarizing film in which the ratio of the parallel transmittance (A) and the orthogonal transmittance (B) at wavelengths of 460 nm and 640 nm is both 2000 or more is not particularly limited. For example, the following method is adopted. obtain.
That is, in the same manner as described above, a casting solution in which a polyvinyl alcohol-based resin is dissolved in water or an organic solvent is cast into a film, and the film is stretched and immersed in an aqueous solution of an iodine compound or a dichroic dye to be dyed. After drawing and dyeing at the same time, or dyeing with an iodine compound or a dichroic dye and drawing, a boron compound treatment is performed. Further, after dyeing, it can be stretched in a solution of a boron compound, and can be appropriately selected and used. After that, it is important to carry out a water washing treatment, and then re-dyeing again with an iodine compound or a dichroic dye, whereby a specific polarizing film is obtained.
[0027]
About this water washing process, it is 5-30 degreeC, Preferably it is carried out by immersing at 10-20 degreeC for 2 minutes or less, Preferably it is 1 minute or less. Of course, not only immersion but spraying, application, etc. are possible. For the re-dyeing treatment, an aqueous solution of iodine-potassium iodide is used, the iodine concentration is 0.001 to 1 g / l, preferably 0.01 to 1 g / l, and the potassium iodide concentration is 10 to 50 g. / L, preferably 10 to 30 g / l, and the dyeing time is 10 to 500 seconds, preferably about 30 to 300 seconds. The temperature of the treatment bath is preferably 5 to 30 ° C. In addition to the water solvent, a small amount of an organic solvent compatible with water may be contained. Immersion is preferred as the contact means, but any means such as coating and spraying can be applied. After the re-dyeing treatment, a polyvinyl alcohol polarizing film is obtained by drying at 30 to 80 ° C. for 30 to 500 seconds.
[0028]
In the present invention, a retardation film is also effective. The retardation film is not particularly limited, and is not limited to polyvinyl alcohol, polycarbonate, polyester, polyarylate, polyimide, polyolefin, polystyrene, polysulfone, polyethersulfone, polysulfone. Films such as vinylidene fluoride / polymethyl methacrylate, liquid crystal polymer, triacetyl cellulose resin, cyclic polyolefin, saponified ethylene-vinyl acetate copolymer, polyvinyl chloride, etc. are mainly used. Polycarbonate, polyvinyl alcohol resin The film is used.
[0029]
Polyvinyl alcohol resins are usually produced by saponifying polyvinyl acetate obtained by polymerizing vinyl acetate, but small amounts of unsaturated carboxylic acids (including salts, esters, amides, nitriles, etc.), olefins, vinyl ethers, A component copolymerizable with vinyl acetate, such as a saturated sulfonate, may be contained. Moreover, what is called polyvinyl acetal resin and polyvinyl alcohol derivatives, such as polybutyral resin, polyvinyl formal resin, etc. which reacted polyvinyl alcohol with aldehyde in presence of an acid is mentioned. The average polymer is 500 to 10000, preferably 1000 to 5000, the degree of saponification is 80 to 100 mol%, preferably 90 to 100 mol%, and may be an unstretched film, but 1.01 to 4 times It is desirable that the film is uniaxially stretched preferably about 1.01 to 3 times.
[0030]
As an amorphous silicon oxide layer laminated with such an optical film, ,Previous It is a layer composed of a silicate oligomer represented by Chemical Formula 1 is necessary . The silicate oligomer represented by Chemical Formula 1 is not particularly limited and can be prepared by any method. For example, it is prepared by the following method.
[0031]
The silicate oligomer can be obtained, for example, by hydrolyzing tetraalkoxysilane such as tetramethoxysilane, tetraethoxysilane, tetrapropoxysilane, tetrabutoxysilane, or tetraphenoxysilane. n can be adjusted by controlling the hydrolysis rate in this case.
The hydrolysis reaction itself can be carried out by a known method. For example, while adding a predetermined amount of water to the tetraalkoxysilane and distilling off the alcohol produced as a by-product in the presence of an acid catalyst, it is usually from about room temperature to about React at ℃. By this reaction, the alkoxysilane is hydrolyzed, and further, a liquid silicate oligomer (generally having an average degree of polymerization of about 2 to 8, preferably 3 to 6) having two or more hydroxyl groups is obtained as a hydrolyzate by a condensation reaction. The degree of hydrolysis can be appropriately adjusted depending on the amount of water used, but is usually selected from about 40 to 90%, preferably about 60 to 80% in the present invention.
[0032]
Here, the degree of hydrolysis is such that when a hydrolyzable group, that is, tetraalkoxysilane, the amount of theoretical water necessary for hydrolytic condensation of all alkoxy groups, that is, half the number of alkoxy groups, is added. With a hydrolysis rate of 100%,
Hydrolysis rate (%) = (actual amount of added water / theoretical amount of hydrolysis) × 100
Asking.
[0033]
The silicate oligomer thus obtained usually contains about 2 to 10% of monomers. If this monomer is contained, it will lack storage stability, thicken during storage, and film formation will be difficult, so that the monomer content will be 1% by weight or less, preferably 0.3% by weight or less. The monomer removal is performed by flash distillation or vacuum distillation.
[0034]
In the present invention, a partial hydrolyzate obtained by adding a catalyst and water to tetraalkoxysilane as described above is used, and a complete hydrolyzate is particularly preferably used. The complete hydrolyzate can be obtained by, for example, a method of adding a solvent to the partial hydrolyzate and then adding a curing catalyst and water. As such a solvent, it is preferable to use one or two kinds of methyl alcohol and ethyl alcohol because it is inexpensive and the properties of the resulting film are excellent and the hardness is good. Isopropyl alcohol, n-butanol, isobutanol, octanol and the like can be used, but the hardness of the obtained film tends to be low. The amount of the solvent is 50 to 400 parts by weight, preferably 100 to 250 parts by weight, based on 100 parts by weight of the partial hydrolyzate.
[0035]
Examples of the curing catalyst include acids, alkalis, organic metals, metal alkoxides, and the like, and acids such as acetic acid, maleic acid, oxalic acid, and fumaric acid are preferably used. The addition amount is 1 to 10 parts by weight, preferably 1 to 5 parts by weight based on 100 parts by weight of the partial hydrolyzate.
Further, the amount of water added may be an amount that is at least the amount that the partial hydrolyzate can theoretically hydrolyze to 100%, and an amount equivalent to 100 to 300%, preferably an amount equivalent to 100 to 200% should be added. .
Furthermore, in the present invention, it is preferable to ripen after blending these components, and the ripening step sufficiently proceeds the hydrolysis and condensation of the tetraalkoxysilane, and the resulting film has excellent properties. .
[0036]
The ripening of the liquid may be allowed to stand, and the standing time is sufficient for the above-mentioned crosslinking to proceed to a sufficient extent to obtain the desired film characteristics. Specifically, the type of catalyst used However, for hydrochloric acid, 1 hour or more at room temperature, for maleic acid, several hours or more, particularly preferably about 8 hours to 1 week is sufficient, usually about 3 days. The time required for aging also affects the ambient temperature, and in extremely cold regions it may be better to take measures to heat to around 20 ° C. In general, ripening proceeds rapidly at high temperatures, but when heated to 100 ° C. or higher, gelation occurs. Therefore, heating to 50 to 60 ° C. is appropriate at most.
[0037]
In addition to the above, the silicate oligomer used in the present invention is a modified product modified with an organic compound (monomer, oligomer, polymer) having a functional group such as an epoxy group, an amino group, an isocyanate group, or a carboxyl group. It can be used alone or in combination with the above silicate oligomer.
Thus, the silicate oligomer represented by the above chemical formula 1 is obtained, and the SiO in the silicate oligomer is obtained. ₂ The content is desired to be 1 to 100%, preferably 10 to 99%. Such SiO ₂ When the content is less than 1%, the durability is not improved and the effect of the present invention is not exhibited.
[0038]
The method for forming the amorphous silicon oxide layer from the silicate oligomer is not particularly limited. For example, the silicate oligomer is a solvent that does not impair the optical performance of the optical film, such as alcohol (methanol, ethanol, isopropyl alcohol, etc.), acetic acid, and the like. Diluted with ethyl, butyl acetate, cellosolve acetate, methyl glycol acetate, ethylene glycol acetate, methoxybutyl acetate, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, methylene chloride, toluene, xylene, mineram spirit, cresol, xylenol, furfural, naphtha, etc. Then, it is applied to the substrate by a known method such as bar coater, roll coater, gravure coater, reverse coater, lip coater, and heat treatment. It is possible in Rukoto.
[0039]
In the present invention, at least one side of the optical film as described above. , Composed of the above silicate oligomer The amorphous silicon oxide layer only needs to be laminated, and the lamination method is not limited and any method can be adopted. Optical film Take In order to form the amorphous silicon oxide layer, for example, a method of applying a solution made of the above-described silicate oligomer on the surface of the optical film or immersing the optical film in the solution, followed by a heat treatment, For example, a method of preparing a film from a solution composed of the silicate oligomer and sticking the film with an adhesive can be employed.
[0040]
Examples of such an adhesive include polyvinyl alcohol, carboxymethyl cellulose, urethane-based, acrylic-based, and epoxy-based hydrophilic polymer aqueous solutions, silicate oligomers represented by Chemical Formula 1 above, and the like. In particular, in the present invention, when the solution composed of the silicate oligomer is used as an adhesive, the effects of the present invention are remarkably exhibited.
[0041]
In the present invention, as described above, the solution composed of the silicate oligomer is applied to the optical film and then subjected to heat treatment for lamination. Of course, methods such as immersion and spraying are also possible, and lamination is performed by any method. May be. The heat treatment is performed at 20 to 200 ° C, preferably 50 to 200 ° C, more preferably 50 to 180 ° C. The amorphous silicon oxide layer has a thickness after drying of 0.001 to 50 μm, preferably 0.01 to 50 μm.
[0042]
Furthermore, in the present invention, if necessary, an ultraviolet absorber may be contained in the amorphous silicon oxide layer, or an antireflection layer may be provided outside the optical laminate of the present invention. Examples of the ultraviolet absorber include the aforementioned salicylic acid ester compounds, benzophenol compounds, benzotriazole compounds, cyanoacrylate compounds, nickel complex compounds, and the like, and the antireflection layer has a high refractive index (for example, titanium). , Cerium, tantalum and other metal oxides) and low refractive index substances (eg, silicon oxide, magnesium fluoride, etc.) or layers obtained by alternately laminating or low refractive index substances (eg, silicon oxide, magnesium fluoride, etc.) , Fluorine-containing polymers, etc.).
[0043]
In addition, the optical layered body of the present invention can be further provided with an adhesive layer as necessary, making it easier to bond a glass substrate or a polarizing film and a retardation film at the time of liquid crystal display production. An optical laminate having a high level of practicality can be obtained.
When laminating the pressure-sensitive adhesive layer, it is appropriately selected depending on the layer structure of the optical laminate. For example, when an amorphous silicon oxide layer is formed on one side of the optical film layer, the pressure-sensitive adhesive layer has improved heat and moisture resistance. It is preferable to provide on the surface of an optical film layer at this point. Moreover, when the amorphous silicon oxide layer is formed on both surfaces of the optical film layer, the pressure-sensitive adhesive layer may be only on the surface of any amorphous silicon oxide layer. However, it is not limited to these.
[0044]
As such an adhesive layer, acrylic acid esters such as butyl acrylate, ethyl acrylate, methyl acrylate, 2-ethylhexyl acrylate and the like and α-monoolefin carboxylic acids such as acrylic acid, maleic acid, itaconic acid, methacrylic acid, Especially those which are mainly composed of copolymers with crotonic acid (including those added with vinyl monomers such as acrylonitrile, vinyl acetate and styrene) do not interfere with the optical properties of the optical film. Although it is preferred, the present invention is not limited to this, and any pressure-sensitive adhesive having transparency can be used. For example, a polyvinyl ether type or a rubber type may be used.
[0045]
Further, in the present invention, an elliptical polarizing film in which a polarizing film and a retardation film are combined in addition to a polarizing film and a retardation film can be used as an optical film, and the elliptical polarizing film is provided on at least one surface of the elliptical polarizing film. The silicate oligomer represented by the above chemical formula 1 The effects of the present invention can be obtained by providing an amorphous silicon oxide layer. As a specific layer structure of the elliptically polarizing film, for example, polarizing film / (protective film /) adhesive layer / (protective film /) retardation film, polarizing film / amorphous silicon oxide layer / adhesive layer / Amorphous silicon oxide layer / retardation film, polarizing film / amorphous silicon oxide layer / adhesive layer / protective film / retardation film, polarizing film / protective film / adhesive layer / amorphous silicon oxide layer / position Examples thereof include phase difference films, polarizing films / amorphous silicon oxide layers / adhesive layers / amorphous silicon oxide layers / retardation films / amorphous silicon oxide layers / adhesive layers. However, it is not limited to these.
[0046]
The optical laminate of the present invention is Either a polarizing film, a retardation film, or an elliptical polarizing film On at least one side of the optical film ,Up Since an amorphous silicon oxide layer composed of a silicate oligomer represented by Chemical Formula 1 is provided, it is very practical in terms of high heat resistance and heat resistance as well as high optical properties, and further by providing an adhesive layer. It becomes an optical laminate such as a polarizing film, a retardation film, and an elliptically polarizing film.
Utilizing such characteristics, it is used for liquid crystal display applications, and is particularly useful for displays for vehicles, various industrial instruments, household appliances, and the like.
[0047]
【Example】
Hereinafter, the present invention will be specifically described with reference to examples.
In the examples, “parts” and “%” are based on weight unless otherwise specified. The degree of polarization in the present invention is
[(H ₁₁ -H ₁ ) / (H ₁₁ + H ₁ ]] ^1/2 × 100 (%)
Indicated by H ₁₁ Is the transmittance (%) measured using a spectrophotometer in the state where the polarizing film is superposed so that the orientation direction of the polarizing film is the same direction when the two polarizing film samples are superposed, H ₁ Is the transmittance (%) measured in a state in which the two polarizing films were superposed so that the orientation directions of the polarizing films were orthogonal to each other.
[0048]
As the amorphous silicon oxide layer, the following silicate oligomers (A) to (C) were used.
[Preparation of silicate oligomer (A)]
To a 500 ml three-necked round bottom flask equipped with a stirrer, a condenser for reflux and a thermometer, 234 g of tetramethoxysilane and 74 g of methanol were added and mixed, and then 22.2 g of 0.05% hydrochloric acid was added, and the internal temperature 65 The hydrolysis reaction was carried out at 2 ° C. for 2 hours. Subsequently, the condenser was switched to an extraction tube, the temperature was raised until the internal temperature reached 150 ° C., extracted with methanol, further heated at 150 ° C. for 3 hours and condensed to obtain a hydrolyzate. (The degree of polymerization was 3 to 6, the hydroxyl group was 10 or more, and the amount of monomers in the tetramethoxysilane oligomer was 5%.)
Subsequently, the tetramethoxysilane oligomer was boiled with a jacket heated to 100 to 150 ° C., and the vaporized monomer was discharged out of the system together with an inert gas, thus obtaining a tetramethoxysilane oligomer. The monomer amount in the obtained tetramethoxysilane oligomer was 0.2%.
[0049]
[Preparation of silicate oligomer (B)]
19.33 g of ethanol was added to 33.78 g of the tetramethoxysilane oligomer obtained above, and then 0.35 g of maleic acid and 7.28 g of dechlorinated water were added. The amount of water added is 113% with respect to the amount capable of hydrolyzing 100% of the tetramethoxysilane oligomer. Thereafter, the mixture was aged for 2 days at room temperature to obtain (B).
[0050]
[Preparation of silicate oligomer (C)]
In place of the tetramethoxysilane, tetraethoxysilane was used, and the silicate oligomer (C) was obtained in the same manner as in the preparation of the above (B).
[0051]
Example 1
Polyvinyl alcohol having an average degree of polymerization of 1700 and an average degree of saponification of 99.5 mol% was dissolved in water to obtain a 5.0 wt% aqueous solution. The liquid was cast on a polyethylene terephthalate film and then dried to obtain a film having a thickness of 60 μm. This film was cut to a width of 10 cm and mounted on a chuck. The film was immersed in an aqueous solution consisting of 0.2 g / l iodine and 60 g / l potassium iodide at 30 ° C. for 4 minutes. Next, it was immersed in an aqueous solution having a composition of boric acid 70 g / l and potassium iodide 30 g / l at 55 ° C. for 5 minutes, first stretched 2.2 times, then stretched 1.7 times, and further 1. After stretching 5 times, it was washed with water at 20 ° C. for 10 seconds and then air-dried for 24 hours to obtain a polarizing film. Then, after adhering the cellulose triacetate film (80 μm thickness), which has been previously alkali-treated and neutralized with acid, to both sides of the polarizing film using a polyvinyl alcohol adhesive (3% aqueous solution, dry coating thickness 0.01 μm) A polarizing plate was obtained by drying at 100 ° C. for 1 minute. Next, the polarizing plate was immersed in cyclohexanone at 20 ° C. for 12 hours to completely remove the cellulose triacetate film to obtain a polarizing film (F-1).
[0052]
The polarizing film (F-1) (20 mm × 20 mm) was subjected to an excitation wavelength of 514.5 nm Ar using a Raman spectrophotometer (manufactured by JASCO, Jasco NR-1800M). ⁺ 105cm under the conditions described in the text after laser irradiation ^-1 And 157 cm ^-1 Was measured at room temperature to find 37.81 (a ₀ ) And 29.88 (b ₀ )Met. Further, the above-mentioned cellulose triacetate film as a protective film on both sides of the polarizing film was again adhered with a polyvinyl alcohol adhesive in the same manner as described above, and a three-layer laminate of cellulose triacetate / polarizing film / cellulose triacetate (polarizing plate) Then, the three-layer laminate was allowed to stand in an atmosphere of 80 ° C. and 90% RH for 200 hours to obtain a treated three-layer laminate, and the laminate was then added to cyclohexanone at 20 ° C. for 12 hours. The protective film is removed by immersion for a period of time to form a polarizing film alone. ^-1 And 157 cm ^-1 Of the spectral intensity of 30.94 (a ₁ ) And 28.38 (b ₁ ) From these measurements (b ₀ / A ₀ ) And (b ₁ / A ₁ ) / (B ₀ / A ₀ ) Calculated to be 0.79 and 1.16.
[0053]
A mixed solution of silicate oligomer (A) in methanol and ethanol (concentration: 10%) is applied to both surfaces of the polarizing film (F-1) with a bar coater, and then heat-treated at 150 ° C. for 1 hour. The polarizing film and the silicate oligomer A laminate (A) (thickness of the silicate oligomer (A) layer: 3.0 μm in thickness after drying) was obtained. Furthermore, an acrylic pressure-sensitive adhesive (composition: 1 part of Coronate L (manufactured by Nippon Polyurethane) is added to 100 parts of composition: n-butyl acrylate / acrylic acid = 95/5 (weight ratio)) on one outer surface thereof And bonded to a glass plate. (The initial polarization degree was 99.6%.)
[0054]
The polarizing plate thus obtained was allowed to stand at 80 ° C. and 90% RH for 350 hours, and then the wet heat resistance was evaluated by measuring changes in polarization degree and appearance of the polarizing plate.
The polarizing plate was allowed to stand at 50 ° C. for 2 hours, immediately left at 80 ° C. for 2 hours, then exposed again to 50 ° C., and the same operation was performed a total of 5 times. The heat resistance was evaluated by measuring the change in polarization degree and the change in appearance.
In addition, about the external appearance change, the color loss of the polarizing plate after the said endurance test was evaluated in four steps ((double-circle)-*) visually.
[0055]
Example 2
In Example 1, a polarizing film (F-2) obtained by using polyvinyl alcohol having an average degree of polymerization of 2600 and an average degree of saponification of 99.5 mol% and changing the initial draw ratio to 2 times in the drawing step is used. Further, except that the silicate oligomer (A) was replaced with (B) and the thickness of the silicate oligomer (B) layer was replaced with 2.0 μm, the same operation as in Example 1 was carried out to obtain a polarizing plate, which was heat and heat resistant. And heat resistance was evaluated.
It should be noted that a ₀ , B ₀ , A ₁ And b ₁ Is measured, a ₀ = 42.23, b ₀ = 36.32, a ₁ = 27.42, b ₁ = 22.53, and from these measurements (b ₀ / A ₀ ) And (b ₁ / A ₁ ) / (B ₀ / A ₀ ) Calculated to be 0.86 and 0.95.
[0056]
Example 3
In Example 2, the same operation was performed except that the silicate oligomer (B) was changed to (C) and the thickness of the silicate oligomer (C) layer was changed to 3.0 μm, to obtain a polarizing plate, and the heat and moisture resistance and heat resistance. Evaluated.
[0057]
Example 4
In Example 1, a polyvinyl alcohol having an average degree of polymerization of 4000 and an average degree of saponification of 99.5 mol% was used, and in the stretching step, first, the stretching process was a three-stage stretching process and then a 1.7-fold stretching process. Example 1 except that the polarizing film (F-3) obtained by changing the drying temperature after lamination of the cellulose triacetate film to 60 ° C. was used, and the thickness of the silicate oligomer (A) layer was changed to 2.0 μm. The same operation was performed to obtain a polarizing plate, and the heat and moisture resistance and appearance change were evaluated.
It should be noted that a ₀ , B ₀ , A ₁ And b ₁ Is measured, a ₀ = 35.27, b ₀ = 31.69, a ₁ = 39.63, b ₁ = 27.05, from these measurements (b ₀ / A ₀ ) And (b ₁ / A ₁ ) / (B ₀ / A ₀ ) Were 0.90 and 0.76.
[0058]
Example 5
In Example 4, the same operation was carried out except that the silicate oligomer (A) was replaced with (B) and the thickness of the silicate oligomer (B) layer was changed to 3.0 μm, whereby a polarizing plate was obtained, and heat and heat resistance and heat resistance were obtained. Evaluated.
[0059]
Example 6
In Example 4, the same operation was carried out except that the silicate oligomer (A) was replaced with (C) and the thickness of the silicate oligomer (C) layer was changed to 2.0 μm, whereby a polarizing plate was obtained. Evaluated.
[0060]
Example 7
In Example 1, it carried out similarly except having used the following polarizing film (F-4), the polarizing plate was obtained, and the heat-and-moisture resistance and heat resistance were evaluated.
Polyvinyl alcohol having an average polymerization degree of 3800 and a saponification degree of 99.5 mol% was dissolved in water to obtain a 5.0% solution. The solution was cast on a polyethylene terephthalate film and then dried to obtain a raw film (80 μm). The film was mounted on a chuck and immersed in an aqueous solution consisting of 0.2 g / l iodine and 60 g / l potassium iodide at 30 ° C. for 240 seconds, and then composed of 70 g / l boric acid and 30 g / l potassium iodide. And then boric acid treatment was performed for 5 minutes while uniaxially stretching 6.0 times. Next, after being immersed in a 20 ° C. water-washing tank for 20 seconds, it was immersed in an aqueous solution of 0.05 g / l iodine and 20 g / l potassium iodide for 20 seconds at 20 ° C., and finally dried at room temperature for 24 hours. A polarizing film (F-4) was obtained.
[0061]
The parallel transmittance (A) and orthogonal transmittance (B) at wavelengths of 460 nm and 640 nm of the polarizing film (F-4) are measured with a high-speed multi-wavelength birefringence measuring device (Otsuka Electronics Co., Ltd .: RETS-2000). When the value of (A) / (B) at each wavelength was calculated, it was 2483 (32.29 / 0.013) at 460 nm and 4366 (34.93 / 0.008) at 640 nm.
[0062]
Example 8
In Example 7, the same operation was carried out except that the silicate oligomer (A) was replaced with (B) and the thickness of the silicate oligomer (B) layer was replaced with 2.0 μm, to obtain a polarizing plate, and heat and heat resistance and heat resistance. Evaluated.
[0063]
Example 9
In Example 7, the same operation was performed except that the silicate oligomer (A) was changed to (C) and the thickness of the silicate oligomer (C) layer was changed to 3.0 μm, to obtain a polarizing plate, and the heat and moisture resistance and heat resistance. Evaluated.
[0064]
Example 10
In Example 7, a polarizing film (F-5) obtained in place of polyvinyl alcohol having an average polymerization degree of 1700 and a saponification degree of 99.7 mol% was used, and the silicate oligomer (A) was replaced by (C). A similar operation was performed except that the thickness of the silicate oligomer (C) layer was changed to 2.0 μm to obtain a polarizing plate, and the heat and moisture resistance and heat resistance were evaluated.
[0065]
In addition, the parallel transmittance (A) and orthogonal transmittance (B) at wavelengths of 460 nm and 640 nm of the polarizing film (F-5) are measured with a high-speed multi-wavelength birefringence measuring apparatus (Otsuka Electronics Co., Ltd .: RETS-2000). When measured and the value of (A) / (B) at each wavelength was calculated, it was 2014 (30.22 / 0.015) at 460 nm and 4178 (33.43 / 0.008) at 640 nm.
[0066]
Comparative Examples 1-5
A polarizing film (F-1 to 5) as shown in Table 1 was used except that a cellulose triacetate film (thickness 80 μm) was laminated with a polyvinyl alcohol adhesive (4% aqueous solution) instead of the silicate oligomer layer. It carried out similarly to Example 1 and evaluated the heat-and-moisture resistance and heat resistance.
[0067]
Comparative Example 6
In Example 1, the same procedure was performed except that a urethane resin coating layer (3.0 μm in thickness after drying) composed of polyester polyol and hexamethylene diisocyanate was provided instead of the silicate oligomer (A) layer. Sex was evaluated.
[0068]
Example 11
In Example 1, it carried out similarly except having replaced the polarizing film with the phase difference film which consists of polyvinyl alcohol film (film thickness of 50 micrometers) of 2 times extending | stretching of the average degree of polymerization 1700, average saponification degree 99.5 mol%. .
The retardation plate thus obtained was allowed to stand at 55 ° C. and 95% RH for 300 hours, and then the wet heat resistance was evaluated by measuring changes in optical properties and appearance of the retardation plate.
The retardation plate was allowed to stand at 40 ° C. for 2 hours, immediately left at 60 ° C. for 2 hours, and then exposed again to 40 ° C., and the same operation was performed a total of 5 times. Then, heat resistance was evaluated by measuring changes in optical properties and changes in appearance.
[0069]
In addition, the retardation value (RD) was measured about the optical characteristic of the phase difference plate. The retardation value (RD) of the retardation film is the refractive index (II) in the main stretching direction (MD direction) and the direction perpendicular to this (TD direction). _MD −II _TD ) And the thickness (d) of the retardation film, and measured by a compensation method using a polarizing microscope with a Babinet type compensator (Nikon POH-1 type) (light source is white light).
[0070]
Example 12
In Example 2, the polarizing film was replaced with a retardation film composed of a polyvinyl alcohol film (film thickness: 50 μm) having an average degree of polymerization of 3800, an average degree of saponification of 99.5 mol%, and a 2.2-fold stretch. went.
The retardation plate thus obtained was evaluated for wet heat resistance and heat resistance by measuring changes in optical properties and appearance as in Example 11.
[0071]
Example 13
In Example 3, the polarizing film was replaced with a retardation film composed of a polyvinyl alcohol film (film thickness 50 μm) stretched 2.1 times, with an average degree of polymerization of 2600, an average degree of saponification of 99.5 mol%, and similarly. went.
The retardation plate thus obtained was evaluated for wet heat resistance and heat resistance by measuring changes in optical properties and appearance as in Example 11.
[0072]
Comparative Example 7
In Example 11, the same procedure was followed except that a cellulose triacetate film (thickness 80 μm) was provided with a polyvinyl alcohol-based adhesive (4% aqueous solution) instead of the layer composed of the silicate oligomer (A). The wet heat resistance and heat resistance were evaluated by measuring.
[0073]
Example 14
Using the polarizing film used in Example 1 and the retardation film used in Example 11, silicate oligomer (C) layer / polarizing film / silicate oligomer (C) layer / adhesive layer / silicate oligomer (C) layer / An elliptically polarizing plate having the structure of retardation film / silicate oligomer (C) layer / adhesive layer was prepared, and the elliptically polarizing plate was left at 62 ° C. and 93% RH for 290 hours, and then the optical property change (RD value) And the appearance change was measured, and the heat and humidity resistance was evaluated.
The elliptically polarizing plate was allowed to stand at 40 ° C. for 2 hours, immediately left at 60 ° C. for 2 hours, and then exposed again to 40 ° C., and the same operation was performed a total of 5 times. Thereafter, heat resistance was evaluated by measuring changes in optical characteristics (evaluated by RD value) and changes in appearance.
The results of Examples and Comparative Examples are summarized in Tables 1 to 4.
[0074]
[Table 1]

[0075]

[0076]
[Table 2]

[0077]
Note) Although the heat resistance is excellent in the comparative examples, the heat and humidity resistance is considerably inferior to that of the examples, and in Comparative Examples 1 to 5, the polarizing plate is not thinned. In Examples, the polarizing plate is excellent in both moist heat resistance and heat resistance and is made into a thin film.
[0078]
[Table 3]

[0079]
[Table 4]

[0080]
【The invention's effect】
The optical laminate of the present invention is Either a polarizing film, a retardation film, or an elliptical polarizing film On at least one side of the optical film The silicate oligomer represented by the above chemical formula 1 By providing an amorphous silicon oxide layer, in addition to high optical performance, it is an optical laminate that is extremely excellent in durability, moist heat resistance and heat resistance, and further requires a protective layer such as a cellulose triacetate film. Therefore, it is excellent in thinning.

Claims (8)

An optical laminate comprising an amorphous silicon oxide layer comprising a silicate oligomer represented by the following chemical formula 1 on at least one surface of an optical film which is any one of a polarizing film, a retardation film and an elliptically polarizing film. .

Here, n is an integer of 1 to 20, and R is hydrogen, an alkyl group having 1 to 4 carbon atoms, or a phenyl group. 2. The optical laminate according to claim 1, wherein the silicate oligomer represented by Chemical Formula 1 is a partial hydrolyzate obtained by hydrolysis and condensation by adding a catalyst and water to tetraalkoxysilane. 2. The optical laminate according to claim 1, wherein the silicate oligomer represented by Chemical Formula 1 is a complete hydrolyzate obtained by adding a solvent, a curing catalyst, and water to tetraalkoxysilane and hydrolytic condensation. The polarizing film is made of a polyvinyl alcohol film, and has an excitation wavelength of 514.5 nm by Raman spectroscopy after standing for 200 hours in an atmosphere of 80 ° C. and 90% RH. ⁺ 105cm at the time of laser irradiation ^-1 And 157 cm ^-1 (B1 / a1) / (b0 / a0)> 0.7 is satisfied, where a1 and b1 are the spectral intensities of the film, and a0 and b0 are the spectral intensities before the polarizing film leaving treatment, respectively. The optical laminate according to any one of claims 1 to 3. The polarizing film is made of a polyvinyl alcohol film, and the ratio of the parallel transmittance (A) and the orthogonal transmittance (B) at wavelengths of 460 nm and 640 nm is both 2000 or more. Or an optical laminate. The optical laminate according to claim 4 or 5, wherein the polyvinyl alcohol film is a film made of a polyvinyl alcohol resin having a polymerization degree of 2000 to 8000. 6. The optical laminate according to claim 4, wherein the polyvinyl alcohol film is a film made of a polyvinyl alcohol resin having a polymerization degree of 2500 to 5000. The optical layered body according to any one of claims 1 to 7, wherein a pressure-sensitive adhesive layer is provided on at least one outer side of the outermost layer.