JP4488793B2 - Polarizing plate, liquid crystal display device using the same, and manufacturing method of polarizing plate - Google Patents

Description

  The present invention relates to a polarizing plate that can be used in a liquid crystal display device and the like and a method for manufacturing the same.

  In recent years, liquid crystal display devices have been remarkably developed as display devices for various displays. With the thinning of the liquid crystal display devices, the polarizing plates used in the liquid crystal display devices have also been reduced in thickness and production efficiency. There are various demands such as improvement.

  As a polarizing plate generally used conventionally, a polyvinyl alcohol-based resin film is uniaxially stretched, and the surface thereof is obtained by adsorbing and orienting iodine, a dichroic direct dye, etc. For the purpose of protection from moisture and the like, it is used by being bonded to a transparent protective film such as a triacetyl cellulose film on both surfaces of the polarizing plate.

  However, the above polarizing plate usually has a problem that it is difficult to reduce the thickness of the film after stretching because the film has a thickness of about 30 μm.

  In order to solve such a problem, for example, after the substrate is rubbed, a corona treatment is performed, a dichroic direct dye is applied thereon, and the dichroic direct dye is oriented in the rubbing direction to form a polarizing layer. There has been proposed a polarizing plate that forms a film (Patent Document 1). However, since the polarizing plate obtained by the above method has insufficient polarization performance, it has not been put into practical use, and further improvement in transmittance and contrast is required.

JP-A-3-54506

  From the above, it is desired to provide a polarizing plate that has good polarization performance, can be thinned, and has high production efficiency.

  In order to achieve the above object, the present invention is formed on a base material, a resin layer formed on the base material, and a concave or convex portion formed in a pattern on the surface, and the resin layer, And a polarizing plate comprising a polarizing layer containing a flat pigment.

  According to the present invention, since the resin layer having a concave portion or a convex portion is formed, for example, by applying a polarizing layer-forming coating solution containing the above-mentioned flat pigment on the resin layer, With the pattern of the recesses on the surface of the resin layer, the flat pigment can be easily aligned and oriented in a certain direction to form a polarizing layer. Therefore, since the polarizing layer can be formed without stretching the substrate, the thickness of the polarizing plate can be reduced, and the polarizing plate can be produced efficiently.

  In the above invention, the flat dye is an anthraquinone dye, phthalocyanine dye, porphyrin dye, naphthalocyanine dye, quinacridone dye, dioxazine dye, indanthrene dye, acridine dye, perylene dye, pyrazolone. A dye selected from the group consisting of a dye, an acridone dye, a pyranthrone dye, and an isoviolanthrone dye is preferable. This is because these flat pigments have light absorption anisotropy in the visible light region.

  Further, in the present invention, the flat dye forms a column structure in which the normal direction of the flat dye is directed to a certain direction of the substrate, and the column structure extends along the concave portion of the resin layer. It is preferably oriented. This is because a column structure made of a plate-like dye is oriented along the concave portion of the resin layer, so that a polarizing layer having good polarization characteristics and excellent heat resistance can be easily formed.

  Furthermore, in the present invention, it is preferable that the above-mentioned tabular dye exhibits a lyotropic liquid crystal phase in a solution. The plate-like dye forms a column structure by self-organization in a solution and exhibits a lyotropic liquid crystal phase. Therefore, by applying a polarizing layer-forming coating solution containing such a plate-like dye, the column structure This is because can be easily oriented.

  In the present invention, it is preferable that the resin layer surface is subjected to a hydrophilic treatment. Usually, when such a concavo-convex structure is replicated, the formed surface has high water repellency, and the flat pigment may not be well oriented.

  The present invention also provides a liquid crystal display device in which the polarizing plate described above and a liquid crystal cell are laminated. According to the present invention, the use of the polarizing plate makes it possible to reduce the thickness of the liquid crystal display device, and to make the liquid crystal display device preferable in terms of manufacturing efficiency and cost. .

In addition, the present invention provides a coating step of applying a curable resin composition on a substrate or a substrate for forming recesses in which convex portions are formed in a pattern on the surface, the substrate and the substrate for forming recesses, and the curable resin composition. Arrangement step of placing the resin composition on top of each other, a curing step of curing the curable resin composition to make a curable resin, and peeling the substrate for forming the recesses from the curable resin composition or the curable resin A resin layer forming step of forming a resin layer by performing a recess forming step of forming the recess into a pattern,
A coating film forming step for applying a polarizing layer-forming coating solution containing a flat pigment on the resin layer and orienting the flat pigment by the concave portions of the resin layer to form a coating film, There is provided a method for producing a polarizing plate, comprising: a drying step of drying, and a polarizing layer forming step of forming a polarizing layer by performing an immobilizing step of immobilizing an orientation state of the flat pigment. .

  According to the present invention, for example, by having the curable resin composition sandwiched between the substrate for forming the recesses in which the projections are formed in a pattern and the base material, the surface has the recesses in the pattern. A resin layer can be formed. Subsequently, by applying a coating solution for forming a polarizing layer containing the above-mentioned plate-like dye on this resin layer, it becomes possible to align the plate-like dye in a certain direction and to be oriented by the pattern of the above-mentioned recesses, It can be a polarizing layer. Thereby, it becomes possible to manufacture a polarizing plate efficiently and without limiting the kind and film thickness of a base material.

  In the above invention, the flat dye forms a column structure in which the normal direction of the flat dye is stacked so as to face a certain direction of the substrate, and the lyotropic liquid crystal phase is formed in the polarizing layer forming coating solution. The column structure is preferably oriented along the recess of the resin layer. Such a flat dye forms a column structure by self-organization in a solution and exhibits a lyotropic liquid crystal phase. Therefore, by applying a polarizing layer-forming coating solution containing this flat dye, the resin layer This is because the column structure can be easily oriented along the recesses.

  In the present invention, it is preferable that a coating method in which shear stress is not applied to the polarizing layer forming coating solution is used in the coating layer forming step of the polarizing layer forming step. This is because if a coating method requiring a shearing stress is used, the flat pigment may be oriented in the coating direction, and it may be difficult to align due to the concave portion of the resin layer.

  Furthermore, in this invention, it is preferable that the method of bridge | crosslinking the said flat pigment | dye is used in the fixing process of the said polarizing layer formation process. This is because a polarizing layer having a high degree of polarization and excellent heat resistance can be formed by crosslinking the flat pigment.

  Moreover, in this invention, it is preferable that the hydrophilic treatment process of hydrophilizing the resin layer surface in which the recessed part was formed is performed after the resin layer formation process mentioned above. Usually, when such a resin layer forming step is performed, the surface of the formed resin layer has high water repellency, and the liquid crystal may not be well aligned.

  According to the present invention, since the resin layer having the recesses is formed, for example, by applying a polarizing layer-forming coating solution containing the plate-like pigment on the resin layer, the resin layer The flat dye can be easily aligned in a certain direction and oriented by the pattern of the concave portions on the surface to form a polarizing layer. Therefore, compared with a conventional polarizing plate formed by stretching a substrate and impregnating it with iodine, the polarizing plate can be made thinner, and the polarizing plate is efficiently manufactured. Can do it.

  The present invention relates to a polarizing plate that can be used for a liquid crystal display device and the like, a liquid crystal display device using the polarizing plate, and a method for manufacturing the polarizing plate. Each will be described separately below.

A. Polarizing plate First, the polarizing plate of the present invention will be described. The polarizing plate of the present invention comprises a base material, a resin layer formed on the base material and having concave or convex portions formed on the surface thereof in a pattern, a resin layer formed on the resin layer, and a flat pigment. And a polarizing layer to be contained.

  The polarizing plate of the present invention will be described with reference to the drawings. FIG. 1 is a schematic sectional view showing an example of the polarizing plate of the present invention. As shown in FIG. 1, the polarizing plate of the present invention comprises a base material 1, a resin layer 2 formed on the base material 1 and having concave or convex portions formed on the surface in a pattern, and the resin layer. 2 and a polarizing layer 3 containing a flat pigment.

According to the present invention, since the resin layer having a concave portion or a convex portion is formed, by applying, for example, a polarizing layer forming coating solution containing the above-described flat pigment on the resin layer, Due to the unevenness of the surface, it becomes possible to easily align the flat pigments in a certain direction. Therefore, when the polarizing layer is formed, it is not necessary to stretch the base material, so that the thickness of the polarizing plate is not affected by the thickness of the base material and can be a thin film. Since there is no limitation on the type of the substrate, various types of substrates can be used. As a result, various properties such as strength and resistance can be imparted to the polarizing plate. Furthermore, since the polarizing layer can be formed by applying the polarizing layer forming coating solution, the polarizing plate can be produced efficiently.
Hereinafter, each configuration in the polarizing layer of the present invention will be described.

1. Resin Layer First, the resin layer used in the present invention will be described. The resin layer used for this invention is formed on the base material mentioned later, and the recessed part or convex part is formed in the pattern shape on the surface. In the present invention, since the resin layer has concave portions or convex portions, by applying a polarizing layer forming coating solution containing a flat pigment, the flat pigment is aligned in a certain direction by the pattern of the concave portions. It can be oriented and can be a polarizing layer to be described later.

  The shape of the pattern of the concave portion or convex portion of the resin layer in the present invention is not particularly limited as long as it is a shape capable of forming a polarizing layer when the flat pigment is oriented. In particular, a pattern that is regularly formed in a stripe at regular intervals is preferable. This is because the plate-like dye can be easily oriented by the stripe-shaped recess.

  In the present invention, the width of such a concave portion varies depending on the type of the flat pigment described in the section of the polarizing layer described later, but is usually in the range of 0.1 μm to 100 μm, preferably 0.1 μm. It is preferable to be within a range of 10 μm, particularly within a range of 0.2 μm to 1 μm. Forming the width of the concave portion narrower than the above range is difficult in terms of the manufacturing method, and conversely, if the width of the concave portion is too wide, it may be difficult to arrange a column structure made of a flat pigment. It is. Here, the width of the concave portion is, for example, the width indicated by a in FIG. 2 and refers to the width of the portion formed in a concave shape.

  Further, the depth of the concave portion is preferably within a range of 0.05 μm to 1 μm, and more preferably within a range of 0.1 μm to 0.2 μm. If the depth of the concave portion is too shallow, the ability to orient the column structure made of a flat pigment will be low, and conversely if the depth of the concave portion is too deep, a polarizing layer forming coating solution containing the flat pigment will be applied on the resin layer. This is because there is a possibility that uneven coating occurs when it is applied to the surface. Here, the depth of the recess is, for example, the depth indicated by b in FIG. 2 and refers to the height from the deepest portion in the recess to the end of the recess.

  Furthermore, when the pattern of the concave portion or the convex portion is striped, the interval between the concave portions is different depending on the type of the flat pigment to be described later, but usually the interval between the end of the adjacent concave portion and the end of the concave portion, that is, The width of the convex portion is set to be half or less of the wavelength of visible light, preferably in the range of 0.05 μm to 2 μm, more preferably in the range of 0.1 μm to 1 μm, particularly in the range of 0.1 μm to 0.2 μm. It is preferred that It is difficult to make the interval between the ends of the adjacent recesses narrower than the above range, and conversely, if the interval between the ends of the adjacent recesses is too wide, a column structure made of a plate-like dye is arranged. This may be difficult. Further, if the distance between the end of the adjacent recess and the end of the recess is a value close to the wavelength of visible light, there is a possibility that problems such as optical coloring may occur due to light diffraction. Here, the space | interval of the edge of an adjacent recessed part and the edge of a recessed part is a space | interval shown by c of FIG. 2, for example.

  Further, the pitch of the recesses is appropriately selected depending on the type of the flat pigment to be described later and the like, but is usually in the range of 0.1 μm to 10 μm, preferably in the range of 0.2 μm to 1 μm, and particularly preferably 0.8. It is preferable to be in the range of 2 μm to 0.4 μm. It is difficult to make the pitch of the recesses narrower than the above range because the manufacturing method is difficult, and conversely, if the pitch of the recesses is too wide, it may be difficult to arrange the column structure made of flat pigments. It is. Here, the pitch of the recesses is, for example, the pitch indicated by d in FIG. 2 and refers to the distance from the center of the adjacent recesses to the center of the recesses.

  The cross-sectional shape of the concave portion of the resin layer is not particularly limited. For example, as shown in FIG. 1, the cross-sectional shape of the concave portion may be rectangular, and the cross-sectional shape of the concave portion may be other shapes such as a trapezoid. There may be. In the present invention, it is particularly preferable that the cross-sectional shape of the concave portion is rectangular in view of the ability to easily align and align a column structure made of a flat dye described later in a certain direction.

  The resin layer having the recesses as described above prepares a recess forming substrate having convex portions symmetrical to the shape of the target recess, and is cured between the recess forming substrate and a base material to be described later. It can be formed by sandwiching and curing the conductive resin composition. Examples of the curable resin used in such a resin composition include unsaturated polyester, melamine, epoxy, polyester (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, polyether (meth) acrylate, and polyol. A curable resin such as (meth) acrylate, melamine (meth) acrylate, or triazine acrylate can be used alone or in combination. The resin composition may be a thermosetting resin or an ultraviolet curable resin, or may be a combination of these.

  In addition, the resin composition may be added with various additives such as a curing agent and a photopolymerization initiator, if necessary, and may be applied on a substrate described later or a substrate described later. And the viscosity may be adjusted using a solvent, a monomer, or the like.

  Moreover, although the film thickness of the said resin layer changes with kinds of polarizing plate, the thickness of a recessed part shall be 1 micrometer or less normally, Preferably it is 0.2 micrometer or less. It is because the polarizing plate of this invention may become heavy when the thickness of a recessed part is too thick. In consideration of the reduction in thickness of the polarizing plate, the thickness of the concave portion is preferably thin. However, since it is difficult to form a concave portion, the thickness of the concave portion is usually 0.1 μm or more. Here, the thickness of the recess means the thickness of the portion where the recess as shown by e in FIG. 2 is formed.

  In addition, since the formation method of the said resin layer is demonstrated in the term of the "C. manufacturing method of a polarizing plate" mentioned later, description here is abbreviate | omitted.

  In the present invention, usually, when such a concavo-convex structure is replicated, the surface of the formed resin layer has high water repellency, and the liquid crystal may not be well aligned. Since a polarizing layer forming coating solution for forming a polarizing layer described later is applied on this resin layer, the resin layer is preferably hydrophilic, and a hydrophilic layer is provided on the resin layer. The surface of the resin layer may be subjected to a hydrophilic treatment. Examples of the surface treatment so as to make the surface of the resin layer lyophilic include lyophilic surface treatment by plasma treatment using argon or water, and the lyophilic property formed on the resin layer. Examples of the layer include a silica film formed by a sol-gel method of tetraethoxysilane.

2. Next, the polarizing layer used in the present invention will be described. The polarizing layer used in the present invention is a layer containing a flat dye, and if the flat dye is aligned and aligned in a certain direction by the pattern of the recesses of the resin layer, in particular, It is not limited.

  The flat pigment used for such a polarizing layer is particularly limited as long as it is oriented by the concave portions of the resin layer and can form a polarizing layer by orientation. Rather than, for example, anthraquinone dyes, phthalocyanine dyes, porphyrin dyes, naphthalocyanine dyes, quinacridone dyes, dioxazine dyes, indanthrene dyes, acridine dyes, perylene dyes, pyrazolone dyes, acridone dyes And dyes selected from the group consisting of pyranthrone dyes and isoviolanthrone dyes.

  Moreover, it is preferable that the flat pigment | dye used for this invention forms the column structure where the normal line direction of the flat pigment | dye was piled up facing the fixed direction of the base material. This is because the column structure formed by the self-organization of the flat pigment is easily oriented in a certain direction along the concave portion of the resin layer, so that a polarizing layer having good polarization characteristics can be obtained.

  FIG. 3 is a schematic perspective view of the polarizing layer used in the present invention. As shown in FIG. 3, in this polarizing layer, the flat pigment 13 is laminated along the concave portion of the resin layer 2 so that the normal direction n of the flat pigment 13 is directed to a certain direction of the substrate 1. A column structure 13 'is formed, and a plurality of such column structures 13' are arranged to constitute a polarizing layer. In the polarizing layer configured by arranging the flat pigments 13 in this manner, the axial direction of the columns of the plurality of column structures 13 ′ is directed to a certain direction of the base material 1, so that the polarizing layer is a polarizing layer. be able to.

  Such a flat pigment is not particularly limited as long as it can form a column structure by stacking in a columnar shape. Examples of the plate-like dye forming the column structure include a plate-like dye having a hydrophilic group such as a sulfonic acid group or a plate-like dye having a hydrophobic group such as a long-chain alkyl group. Among them, it is preferable to use a flat pigment having a hydrophilic group. This is because the flat pigment having a hydrophilic group has a small hydrophilic group and the distance between adjacent column structures is short, so that the column structures can be easily arranged. Moreover, it is because an immobilization process becomes easy by neutralizing hydrophilic parts, such as a sulfonic acid group, and making it hardly soluble or insoluble in water. Examples of the hydrophilic group include a sulfonic acid group such as a sulfonic acid group, a sodium sulfonate group, an ammonium sulfonate group, a lithium sulfonate group, and a potassium sulfonate group, a carboxyl group, a sodium carboxylate group, and a carboxylic acid. Examples thereof include carboxylic acid-based hydrophilic groups such as ammonium group, lithium carboxylate group, and potassium carboxylate group, hydroxyl groups, and amino groups. Among these, a sulfonic acid-based hydrophilic group is preferable.

  Here, it can be confirmed that the tabular pigment forms a column structure by measurement using an X-ray diffractometer.

  Among the above, the flat pigment used in the present invention preferably exhibits a lyotropic liquid crystal phase in a solution. Since the above flat dye forms a column structure in a solution and exhibits a lyotropic liquid crystal phase, the column structure can be easily oriented by applying a polarizing layer forming coating solution containing such a flat dye. It is because it can be made.

  Examples of the plate-like dye that exhibits a lyotropic liquid crystal phase in such a solution include a plate-like dye that exhibits a lyotropic liquid crystal phase in an aqueous solution, or a plate-like dye that exhibits a lyotropic liquid crystal phase in an organic solvent. The type of the solution differs depending on the substituent of the flat dye, and when the flat dye has a hydrophilic group such as a sulfonic acid group, an aqueous solution is used, and a hydrophobic property such as a long-chain alkyl group. When it has a group, an organic solvent is used. Among these, it is preferable to use a flat pigment that exhibits a lyotropic liquid crystal phase in an aqueous solution. This is because the plate-like dye has a hydrophilic group and exhibits a lyotropic liquid crystal phase in an aqueous solution, so that the treatment for fixing the alignment state of the plate-like dye described later becomes simple.

  Specific examples of the tabular dye that forms the column structure described above and exhibits a lyotropic liquid crystal phase in an aqueous solution include substances represented by the following chemical formula.

The alkyl group in each chemical formula is preferably one having 1 to 4 carbon atoms. The halogen in each chemical formula is preferably Cl or Br. Further, as the cation in the above ^{formula, H +, Li +, Na} +, K +, Cs + or _NH ^{4 +} and the like. These substances can be used alone or in combination of two or more.

  In the present invention, among the above, substances represented by the above chemical formulas I to V are preferably used.

  Further, the flat pigment is not limited to those showing the lyotropic liquid crystal phase as described above, and may show the thermotropic liquid crystal phase.

  Furthermore, the polarizing layer used in the present invention may contain a liquid crystal material in addition to the above-mentioned flat pigment. For example, even if the flat pigment is difficult to align due to the concave portion of the resin layer, the flat pigment can be aligned along the alignment direction of the liquid crystal material by aligning the liquid crystal material along the concave portion. Because it can. As the liquid crystal material, a liquid crystal material that can be generally used for a polarizing layer can be used. In addition, the liquid crystal composition of the liquid crystal material and the flat pigment may exhibit a lyotropic liquid crystal phase or a thermotropic liquid crystal phase, but usually exhibits a thermotropic liquid crystal phase. Is used.

  The thickness of the polarizing layer formed in the present invention varies depending on the kind of the above-mentioned flat pigment and the intended transmittance of the polarizing plate, etc., but is usually 50 nm to 2000 nm, and particularly within the range of 100 nm to 1000 nm. It is preferable that

  In addition, since it forms in the term of the "C. manufacturing method of a polarizing plate" mentioned later regarding the formation method of a polarizing layer, description here is abbreviate | omitted.

3. Next, the substrate used in the present invention will be described. In this invention, if the said resin layer can be formed, it will not specifically limit. In this invention, since the said polarizing layer is formed using the recessed part of the said resin layer, a base material does not need to be extended and a base material is not limited. Therefore, for example, it is possible to use a substrate having various functionalities such as strength and resistance, and can be appropriately selected depending on the type of polarizing plate to be formed. Moreover, what has flexibility, for example, a resin film, etc. may be sufficient, and what does not have flexibility, for example, a glass substrate etc., may be sufficient.

  In the present invention, as described above, the curable resin composition is applied on the base material, and the concave portion is formed by sandwiching the curable resin composition between the base material and the concave portion forming substrate having the convex portion. Thus, the resin layer can be formed, so that the polarizing plate can be continuously produced by a roll-to-roll process. In this case, the substrate is preferably a transparent resin film having flexibility and a light transmittance of 80% or more. As such a resin film, films such as cellulose resin, norbornene resin, and cycloolefin resin, and films such as polycarbonate, polyarylate, polysulfone, and polyethersulfone can be used.

  Moreover, when forming the said resin layer, when irradiating an ultraviolet-ray, for example from a base material side, and hardening a curable resin, the said base material needs to have ultraviolet-ray permeability.

  Furthermore, when the polarizing plate of the present invention is used as a transmissive polarizing plate, the base material usually needs transparency, but for example, a reflective layer made of metal or the like is formed on the surface of the base material. In the case of a reflective polarizing plate or a semi-transmissive polarizing plate, the substrate does not necessarily need transparency.

  The film thickness of the substrate used in the present invention varies depending on the type and use of the polarizing plate, but can usually be in the range of 100 to 1000 μm.

  Moreover, in order to improve the adhesiveness of a base material and a resin layer, you may surface-treat a base material. Specifically, glow discharge treatment, corona discharge treatment, UV treatment, saponification treatment, or the like can be used. Moreover, you may form a primer layer on a base material. Further, a primer layer (barrier layer) may be provided for the purpose of protecting the substrate from the curable resin. Examples of such a primer layer include silane-based and titanium-based coupling agents.

  Furthermore, a functional layer may be formed on the substrate. The functional layer used in the present invention is not particularly limited as long as it is generally used in a liquid crystal display device, and examples thereof include a color filter layer. The color filter layer is not particularly limited as long as it is generally used as a color filter layer of a liquid crystal display device, and a layer using a pigment or a resin can be used. A black matrix may be formed between the colors.

4). Next, the polarizing plate of the present invention will be described. In the polarizing plate of the present invention, the above resin layer is formed on the substrate described above, and the polarizing layer is formed by aligning and aligning the flat pigments in a certain direction by the concave portions on the surface of the resin layer. If there is, it will not be specifically limited.

  Although the film thickness of the polarizing plate of this invention is suitably selected by the use and kind of the polarizing plate, it can usually be in the range of 50 micrometers-1000 micrometers.

  In the present invention, it may be a reflective polarizing plate in which a reflective layer made of metal or the like is formed on the substrate, and has a certain degree of transparency to visible light on the substrate. As described above, a transflective polarizing plate on which the reflective layer is formed may be used.

  As such a reflective layer, for example, a highly reflective metal such as aluminum or silver can be formed by, for example, a vacuum deposition method, a sputtering method, an ion plating method, or the like. For example, a reflective polarizing plate is formed. In the case of forming a transflective polarizing plate, the film thickness can usually be in the range of 10 nm to 30 nm. In addition, when the reflective layer made of the metal is formed, a protective layer such as an acrylic resin, an epoxy resin, a polyester resin, a urethane resin, or an alkyd resin may be formed to prevent the reflective layer from being deteriorated. preferable. Further, a light diffusion layer or the like may be formed as necessary.

B. Next, the liquid crystal display device of the present invention will be described. The liquid crystal display device of the present invention is not particularly limited as long as the above polarizing plate and the liquid crystal cell are laminated. For example, the above polarizing plate is laminated on both surfaces of the liquid crystal cell. Alternatively, it may be laminated on one side of the liquid crystal cell as a front polarizing plate or a rear polarizing plate of the liquid crystal cell. Furthermore, when the liquid crystal cell is a plastic liquid crystal cell or the like in which two polymer films are arranged to face each other, the above polarizing plate is used as the polymer film constituting the liquid crystal film cell. May be.

  Since the liquid crystal display device of the present invention uses the polarizing plate, the liquid crystal display device can be made thin, and can also be made preferable in terms of manufacturing efficiency and cost.

  As the liquid crystal cell used in the present invention, those usually used in a liquid crystal display device can be used.

C. Next, the manufacturing method of the polarizing plate of this invention is demonstrated.
The method for producing a polarizing plate of the present invention comprises a coating step of applying a curable resin composition on a substrate or a substrate for forming recesses having convex portions formed in a pattern on the surface, the substrate and the substrate for forming recesses. Are arranged with the curable resin composition interposed therebetween, a curing step in which the curable resin composition is cured to form a curable resin, and the concave portion from the curable resin composition or the curable resin. A resin layer forming step of forming a resin layer by performing a recess forming step of peeling the forming substrate to form a recess in a pattern;
A coating film forming step for applying a polarizing layer-forming coating solution containing a flat pigment on the resin layer and orienting the flat pigment by the concave portions of the resin layer to form a coating film, A drying step of drying, and a polarizing layer forming step of forming a polarizing layer by performing an immobilizing step of immobilizing the alignment state of the flat pigment.

  The manufacturing method of the polarizing plate of this invention is demonstrated referring drawings. FIG. 4 is a process diagram showing an example of a method for producing a polarizing plate of the present invention. As shown in FIG. 4, in the manufacturing method of the polarizing plate of this invention, first, the curable resin composition 12 is apply | coated on the base material 1 (FIG. 4 (a)), and the base material 1 and a convex part are patterns. The substrate 4 for forming recesses is overlapped with the curable resin composition 12 interposed therebetween, and the curable resin composition 12 is cured by irradiating with ultraviolet rays 21 (FIG. 4B). Further, the resin layer 2 having the recesses is formed by peeling off the recess forming substrate 4 (FIG. 4C) (FIG. 4D). In this way, the resin layer forming step is performed. Next, a polarizing layer-forming coating solution containing a flat dye is applied onto the resin layer 2, and the flat dye is aligned by the recesses of the resin layer 2, thereby fixing the alignment state of the flat dye. Thus, the polarizing layer 3 is formed (FIG. 4E). In this way, the polarizing layer forming step is performed.

According to the present invention, the resin layer forming step forms a resin layer having recesses formed in a pattern on the surface. Therefore, the plate-like dye is easily oriented in a certain direction by the recess pattern of the resin layer. Can be aligned and aligned to form a polarizing layer. Thereby, it becomes possible to manufacture a polarizing plate efficiently and without limiting the kind and film thickness of a base material.
Hereinafter, each process of the manufacturing method of the polarizing plate of this invention is demonstrated.

1. Resin Layer Forming Step First, the resin layer forming step in the present invention will be described. The resin layer forming step in the present invention includes a coating step of applying a curable resin composition on a substrate or a substrate for forming a recess having convex portions formed in a pattern on the surface, the substrate, and forming the recess. Arrangement step of superposing substrates on both sides of the curable resin composition, a curing step of curing the curable resin composition to obtain a curable resin, and the curable resin composition or the curable resin A recess forming step of peeling the recess forming substrate and forming a recess.
Hereinafter, each process of such a resin layer formation process is demonstrated.

(1) Application process In the resin layer formation process of the present invention, first, an application process is performed in which a curable resin composition is applied on a substrate or a substrate for forming recesses having protrusions formed in a pattern on the surface. Is called.

  In addition, about the curable resin composition used for this process, a base material, etc., since it is the same as that of what was described in the term of the "A. polarizing plate" mentioned above, description here is abbreviate | omitted. Hereinafter, the method for applying the recess forming substrate and the curable resin composition will be described.

(Substrate forming substrate)
First, the recess forming substrate used in this step will be described. The substrate for forming recesses used in this step has protrusions formed in a pattern on the surface, and the shape and pattern of the protrusions are symmetrical to the shape of the recess pattern of the target resin layer. It is formed as follows.

  In addition, since the width and height of the convex part, the shape of the pattern, etc. correspond to the shape of the concave part formed on the resin layer described in the section of the resin layer in “A. Polarizing plate” described above, The description here is omitted.

  Such a substrate for forming recesses is not particularly limited as long as the above-described pattern is formed, and is a flexible substrate such as a resin film. It may be a non-flexible material such as glass. In the present invention, since the recess forming substrate is used repeatedly, a material having a predetermined strength is preferably used. Specific examples include glass, ceramic, metal, and plastic. Such a material is appropriately selected depending on a method for forming a convex portion described later. Furthermore, the substrate for forming recesses is appropriately selected depending on the method of irradiation with ultraviolet rays when curing the curable resin composition in the curing step described later. That is, when irradiating ultraviolet rays from the concave portion forming substrate side, it is necessary to have ultraviolet transparency, but when irradiating ultraviolet rays from the base material side, it is not particularly limited.

  Further, the recess forming substrate may be moved by the concave / convex cylindrical drum, and the concave forming substrate itself constitutes the concave / convex cylindrical drum, that is, the convex portion is formed on the surface of the concave / convex cylindrical drum. It may be formed. It is because a recessed part can be continuously replicated on a base material and a manufacturing efficiency improves by passing through a roll to roll process. In addition, since it is possible to produce a large number of polarizing plates having good polarization characteristics by only once producing an original plate of such a recess formation substrate, the production efficiency can be further improved.

  As a method for forming such a pattern-like convex portion, for example, a method of patterning glass or a resin film, a method of coating a photosensitive resin layer or the like on the surface of glass or the like, and a method of patterning the photosensitive resin layer, etc. Can be used. As the patterning method, a general method can be used, and examples thereof include a photolithography method, a sputtering method, and a mechanical cutting method. Furthermore, an oblique vapor deposition method, a rubbing method, etc. can also be used.

(Coating method of curable resin composition)
In this step, the curable resin composition 12 may be applied on the base material 1 as shown in FIG. 4A, for example, or may be applied on a recess forming substrate (not shown). Further, the base material and the recess forming substrate may be fixed with a predetermined gap, and the curable resin composition may be poured and applied between them.

  Examples of the method for applying the curable resin composition include spin coating, roll coating, printing, dip coating, curtain coating (die coating), and the like.

  The film thickness of the applied curable resin composition is preferably in the range of 0.1 to 30 μm, and more preferably in the range of 0.2 to 10 μm. This is because if the film thickness of the curable resin composition is too thin, there is a possibility that the recesses are not sufficiently replicated in the curable resin composition. Moreover, when the film thickness is too thick, it is difficult to reduce the thickness of the polarizing plate produced according to the present invention, and when the substrate is a film, the coated surface may be easily curled.

  Moreover, it may apply | coat by the method mentioned above, controlling application quantity so that the said curable resin composition may become a desired film thickness, and after apply | coating, you may remove an excess curable resin composition. Examples of a method for removing excess curable resin composition include a method for removing using a roller, a method for scraping using a doctor, and the like. Moreover, the process of removing such an excessive curable resin composition may be performed after an application | coating process, and may be performed after the arrangement | positioning process mentioned later.

(2) Arrangement Step Next, the arrangement step of the resin layer forming step in the present invention will be described. The disposing step in the present invention is a step of overlapping the base material and the concave portion forming substrate with the curable resin composition interposed therebetween.

  The method for arranging the substrate and the recess forming substrate is not particularly limited as long as the applied curable resin composition is arranged so as to be in contact with the substrate and the recess forming substrate. It is preferable to arrange so as to be in close contact with the substrate. This is because the resin layer made of the curable resin obtained by curing the curable resin composition is formed on the substrate, and therefore, the curable resin composition is preferably in close contact with the substrate. Moreover, it is preferable that the said base material and the said board | substrate for recessed part formation are arrange | positioned with a gap | interval so that a curable resin composition may become the target film thickness.

  Moreover, in order to improve the adhesiveness of the said base material and the said curable resin composition, it is preferable to surface-treat to a base material. Specifically, glow discharge treatment, corona discharge treatment, UV treatment, saponification treatment, or the like can be used. Moreover, you may form a primer layer on a base material. Further, a primer layer (barrier layer) may be provided for the purpose of protecting the substrate from the curable resin. Examples of such a primer layer include silane-based and titanium-based coupling agents.

(3) Curing step In the resin layer forming step in the present invention, a curing step is performed in which the curable resin composition is cured to obtain a curable resin.

  The method for curing the curable resin composition is appropriately selected depending on the type of the curable resin composition, and when the curable resin in the curable resin composition is a thermosetting resin. It can be carried out at room temperature or by heating and leaving it for a predetermined time. Moreover, when curable resin in the said curable resin composition is ultraviolet curable resin, it can carry out by irradiating an ultraviolet-ray. In this case, it is required that either the base material or the substrate for forming a recess has ultraviolet transparency.

  Moreover, as a film thickness of curable resin obtained by hardening | curing curable resin composition, it is preferable to exist in the range of 0.1-30 micrometers, especially in the range of 0.2-10 micrometers. This is because when the film thickness is larger than the above range, it may be difficult to reduce the thickness of the polarizing plate produced according to the present invention. Moreover, it is because toughness is inferior when a film thickness is thinner than the said range.

  In the present invention, the curing step may be performed after the coating step, after the placement step, or during the recess formation step. That is, after the curable resin composition is applied on the base material or the recess forming substrate and then cured (after the coating process), the base material and the recess forming substrate are disposed so as to overlap each other with the curable resin composition interposed therebetween. It may be carried out in any case of curing (after the placement step) or curing after peeling off the recess forming substrate from the curable resin composition (during the recess forming step). Hereinafter, each aspect will be described.

(First aspect)
In the present invention, the first aspect of the curing step is obtained by applying the curable resin composition on a substrate or a substrate for forming recesses, curing the curable resin composition by heating or ultraviolet irradiation, and curing the composition. The base material and the concave portion forming substrate are arranged so as to overlap each other with the curable resin sandwiched therebetween, and the concave portion forming substrate is peeled from the curable resin to form the concave portion. In this embodiment, for example, as shown in FIG. 5, after the curable resin composition 12 is applied on the substrate 1, the ultraviolet curable resin composition 12 is cured by irradiation with ultraviolet rays 21. In FIG. 5, the curable resin composition 12 is applied on the base material 1, but may be applied on a substrate for forming recesses.

  At this time, the irradiation direction of the ultraviolet rays for curing the curable resin composition may be from the substrate or the concave-forming substrate side or from the curable resin composition side. However, when the curable resin composition is applied onto the base material or the concave portion forming substrate and irradiated from the base material or the concave portion forming substrate side, the base material or the concave portion forming substrate has ultraviolet transparency. There is a need.

  In addition, when the curable resin composition is applied and cured on the base material, the concave portion forming substrate is placed on the surface of the curable resin obtained by curing, and the concave portion is duplicated. The curable resin needs to have a predetermined viscosity. Therefore, it is preferable not to completely cure the curable resin composition, and after the recess forming substrate is disposed on the surface of the curable resin, or after the recess forming substrate is peeled from the curable resin, it may be cured again. Good.

(Second aspect)
In the present invention, in the second aspect of the curing step, the curable resin composition is applied onto a substrate or a recess forming substrate, and the substrate and the recess forming substrate are overlapped with the curable resin composition interposed therebetween. The curable resin composition is cured by heating or ultraviolet irradiation, and the recess forming substrate is peeled from the curable resin obtained by curing to form the recess. In this embodiment, for example, as shown in FIG. 4B, after the base material 1 and the concave portion forming substrate 4 are arranged so as to overlap each other with the curable resin composition 12 interposed therebetween, the above-described curing is performed by irradiating the ultraviolet ray 21. The functional resin composition 12 is cured.

  At this time, the irradiation direction of the ultraviolet rays for curing the curable resin composition may be from the concave portion forming substrate side or from the base material side. However, when irradiating from the base material side, the base material needs to have ultraviolet transparency, and when irradiating from the concave portion forming substrate side, the concave portion forming substrate has ultraviolet transmittance. Need to be.

(Third aspect)
In this invention, the 3rd aspect of a hardening process apply | coats curable resin composition on the base material or the board | substrate for recessed part formation, and laminate | stacks the base material and the board | substrate for recessed part formation on both sides of the said curable resin composition. And disposing the substrate for forming recesses from the curable resin composition, curing the curable resin composition by heating or ultraviolet irradiation, and forming recesses. In this embodiment, for example, as shown in FIG. 6, after the recess forming substrate 4 is peeled from the curable resin composition 12, the ultraviolet curable resin composition 12 is cured by irradiating with ultraviolet rays 21.

  At this time, the irradiation direction of the energy ray for curing the curable resin composition may be from the curable resin composition side or from the substrate side. However, when irradiating from the base material side, the base material needs to have ultraviolet transmittance.

  In addition, since the curable resin composition is cured after peeling the recess forming substrate from the curable resin composition, the curable resin composition needs to maintain the recess even after peeling the recess forming substrate. There is. Therefore, the curable resin composition may have a semi-cured state in advance before peeling the recess forming substrate from the curable resin composition so that the curable resin composition has a predetermined viscosity.

(4) Recess formation process In the resin layer formation process in this invention, the recessed part formation process which peels the said board | substrate for recessed part formation from the said curable resin composition or the said curable resin, and forms a recessed part in a pattern shape is performed. . As a result, for example, as shown in FIG. 4C, the resin layer 2 having a concave pattern corresponding to the convex pattern of the concave-forming substrate 4 can be formed.

  As a method of peeling the concave portion forming substrate from the curable resin composition or the curable resin, the curable resin composition or the curable resin is peeled off from the concave portion forming substrate and is in close contact with the base material, and the concave portion is formed. If it is formed, it will not specifically limit.

  Further, in the present invention, the recess forming substrate is moved by the concave and convex cylindrical drum, and the base material is moved by the base cylindrical drum, and the curable resin composition or the curable resin is moved on the two cylindrical drums. By overlapping the base material and the concave portion forming substrate across the substrate, peeling the concave portion forming substrate from the curable resin composition or the curable resin, and continuously replicating the concave portion on the base material, A resin layer having a recess may be formed. Furthermore, the concave-convex forming substrate may be a concave-convex cylindrical drum. This is because by passing through the roll-to-roll process, the concave portions can be continuously replicated on the base material, and the production efficiency is improved. Moreover, it is because it is possible to manufacture a large number of polarizing plates having good polarization characteristics only by once producing an original plate of such a substrate for forming recesses.

2. Next, the polarizing layer forming step in the present invention will be described. In the polarizing layer forming step in the present invention, a polarizing layer-forming coating solution containing a flat dye is applied on the resin layer, and the flat dye is oriented by the concave portion of the resin layer to form a coating film. It is a step of forming a polarizing layer by performing a coating film forming step, a drying step of drying the coating film, and an immobilization step of immobilizing the orientation state of the flat pigment.

In the present invention, since the recesses are formed in a pattern on the resin layer, the pattern of the recesses makes it possible to align and align the flat pigments in a certain direction.
Hereinafter, each process in such a polarizing layer formation process is demonstrated.

(1) Coating film formation process The coating film formation process in this invention apply | coats the coating liquid for polarizing layer formation containing a flat pigment | dye on a resin layer, orientates the said flat pigment | dye, and forms a coating film. It is a process.

  The polarizing layer forming coating solution used in this step contains a flat pigment. In addition, about a flat pigment | dye, since it is the same as that of what was described in the term of the polarizing layer of "A. polarizing plate" mentioned above, description here is abbreviate | omitted.

  The solvent used in the polarizing layer forming coating solution is appropriately selected depending on the substituent introduced into the flat pigment. For example, when a hydrophilic group such as a sulfonic acid group is introduced, water is used as the solvent. On the other hand, when a hydrophobic group such as a long-chain alkyl group is introduced, an organic solvent is used. A common thing can be used as such an organic solvent. Moreover, the said polarizing layer forming coating liquid may contain various additives, such as surfactant, such as polyethyleneglycol, as needed.

  In the present invention, among the above, the polarizing layer forming coating solution is preferably aqueous. This is because a flat pigment used in the present invention preferably has a column structure, has a hydrophilic group, and exhibits a lyotropic liquid crystal phase in an aqueous solution.

  The polarizing layer forming coating solution may contain a liquid crystal material in addition to the flat pigment. For example, even when the flat pigment is difficult to align due to the concave portion of the resin layer, the liquid crystal material can be aligned along the concave portion of the resin layer, and the flat pigment can be aligned along the alignment direction of the liquid crystal material. Because it can. Since the liquid crystal material is the same as that described in the section of the polarizing layer of “A. Polarizing plate” described above, description thereof is omitted here.

  As a method for applying such a polarizing layer forming coating solution, if the polarizing layer forming coating solution can be applied and the flat pigment can be arranged in a certain direction by the pattern of the concave portions of the resin layer, Although not particularly limited, a coating method in which shearing stress is not applied is preferable. This is because, when a coating method requiring a shearing stress is used, the flat pigment is oriented in the coating direction, and it may be difficult to orient due to the pattern of the concave portions of the resin layer. Examples of coating methods that do not apply shear stress include spray coating, ink jet methods, flexographic printing methods, and the like. Among these, the ink jet method is preferably used.

(2) Drying process The drying process in this invention is a process of drying the coating film formed in the said coating-film formation process, and is a process of drying the solvent contained in the said polarizing layer formation coating liquid. is there. In the present invention, by providing this drying step, an immobilization step described later is smoothly performed.

  As a method for drying the solvent in the polarizing layer forming coating solution, a method generally used for drying a solvent, for example, heat drying, room temperature drying, freeze drying, far infrared drying, or the like can be used. .

(3) Immobilization step The immobilization step in the present invention is a step of fixing the orientation state of the flat pigment. In the present invention, by performing such an immobilization step, water resistance and heat resistance can be imparted to the polarizing layer, and the orientation of the plate-like dye depends on the usage environment of the polarizing plate produced according to the present invention. Without being disturbed, the alignment stability can be excellent.

  As a method for fixing the orientation state of the tabular dye used in the present invention, a method of crosslinking the tabular dye can be used. The cross-linking method of the flat dye differs depending on the substituent introduced into the flat dye.

  When the flat pigment has a hydrophilic group such as a sulfonic acid group, a crosslinking method is used in which the hydrophilic group is hydrophobized. When the hydrophilic group of the flat dye is hydrophobized, cross-linking is formed between adjacent flat dyes, and the alignment state of the flat dye is fixed. When the above-mentioned tabular dye exhibits a lyotropic liquid crystal phase in an aqueous solution, unless such a hydrophobizing treatment is performed, the water resistance is poor, the orientation state is likely to be disturbed due to moisture in the air, etc. There is a case.

  The hydrophobizing solution used for the hydrophobizing treatment is not particularly limited as long as the hydrophilic group can be hydrophobized, and is different depending on the hydrophilic group of the flat pigment used. However, it is preferable that crosslinks can be formed between adjacent flat pigments. For example, an aqueous solution of a divalent metal salt can be used. Examples of the divalent metal include magnesium, calcium, barium and the like. Specifically, an aqueous barium chloride solution, an aqueous magnesium chloride solution, an aqueous calcium chloride solution, or the like can be used.

The mechanism by which adjacent flat pigments are crosslinked is as follows. For example, when the tabular dye has SO ₃ Na groups and is hydrophobized using an aqueous barium chloride solution, SO ₃ ions of the SO ₃ Na group of the tabular dye, and Ba ions in the barium chloride aqueous solution By bonding, the adjacent flat pigments are cross-linked and the alignment state is fixed. That is, in the state where the normal direction of the flat dyes is stacked in a certain direction, the adjacent flat dyes are cross-linked, so that the column structure is fixed.

  The method for the hydrophobic treatment is not particularly limited as long as the hydrophilic substituent can be hydrophobized. After the polarizing layer forming coating solution is dried, the hydrophobic treatment is performed. Examples thereof include a method of applying a liquid and a method of immersing in the hydrophobizing treatment liquid. After application or immersion of this hydrophobizing treatment liquid, a polarizing layer can be obtained by washing and drying.

  On the other hand, when the flat dye has a hydrophobic group such as a long-chain alkyl group, for example, a polymerizable group is introduced into the core part of the flat dye or a part of the alkyl side chain to polymerize the polymerizable group. Thus, a cross-linking method is used in which the flat pigment is cross-linked in a linear or network form and the alignment state is fixed.

  Further, when the polarizing layer forming coating liquid contains the liquid crystal material described above, the alignment state of the plate-like dye can be fixed also by polymerizing the liquid crystal material. In this case, the liquid crystal material needs to have a polymerizable group.

3. Others In the present invention, it is preferable that after the resin layer forming step, a hydrophilic treatment step of hydrophilizing the resin layer surface on which the recesses are formed is performed. Usually, when the resin layer forming step as described above is performed, the surface of the formed resin layer has high water repellency and the liquid crystal may not be well aligned. The hydrophilic treatment method is the same as that described in the above section “A. Polarizing plate”, and thus the description thereof is omitted here.

  In addition, this invention is not limited to the said embodiment. The above-described embodiment is an exemplification, and the present invention has any configuration that has substantially the same configuration as the technical idea described in the claims of the present invention and exhibits the same function and effect. It is included in the technical scope.

Hereinafter, the present invention will be specifically described with reference to examples.
Example 1
A UV-curable acrylate resin having the following composition is spin-coated on the cleaned glass substrate, and an original plate having irregularities formed thereon by an electron beam drawing method is placed thereon, and a weight of 100 kg is applied for 1 minute. In this state, the UV light 100 mJ / cm ² was irradiated, further after peeling the original, the UV light 3000 mJ / cm ² was irradiated, the width 1μm of the recess, the pitch of the recesses 2 [mu] m, the recess depth 0.2μm recess Or the convex part pattern was formed. The surface was hydrophilized by adding a plasma treatment thereto.

  Along the groove direction of the concave or convex pattern formed in this way, an aqueous solution containing a flat plate-like dye (manufactured by Optiva; LCPN013) was coated using a Mayer bar, and after drying, 15 wt% barium chloride It was immersed in the aqueous solution for about 1 second. Further, it was washed and dried again to obtain a 300 nm polarizing plate. The degree of polarization was measured and found to be 88%.

<Composition of UV curable acrylate resin>
・ Goserac UV-7500B (manufactured by Nippon Kayaku Co., Ltd.) 40 parts by weight ・ 35 parts by weight of 1,6-hexanediol diacrylate (manufactured by Nippon Kayaku Co., Ltd.) ・ 21 parts by weight of pentaerythritol triacrylate (manufactured by Toagosei Co., Ltd.) 1 hydroxycyclohexyl phenyl ketone (Ciba Geigy) 2 parts by weight • Benzophenone (Nippon Kayaku Co., Ltd.) 2 parts by weight

(Example 2)
A concave or convex pattern is formed in the same manner as in Example 1 except that the concave portion width is 0.2 μm, the concave pitch is 0.4 μm, and the concave depth is 0.2 μm, and plasma treatment is applied thereto. As a result, the surface was hydrophilized.

  Along with the groove direction of the concave or convex pattern formed in this way, an aqueous solution containing a pigment having a flat plate structure (manufactured by Optiba; N015) is coated using an ink jet, and after drying, a 15 wt% barium chloride aqueous solution is coated. For about 1 second. The plate was further washed and dried again to obtain a 300 nm polarizing plate. The degree of polarization was measured and found to be 98%.

(Comparative Example 1)
The washed glass substrate was coated with an aqueous solution containing a flat plate-like dye (manufactured by Optiva; LCPN013) using a Mayer bar, dried, and then immersed in a 15 wt% aqueous barium chloride solution for about 1 second. The plate was further washed and dried again to obtain a 300 nm polarizing plate. The degree of polarization was measured and found to be 83%.

(Comparative Example 2)
The washed glass substrate was coated with an aqueous solution containing a flat plate dye (manufactured by Optiva; N015) using a Mayer bar, dried, and then immersed in a 15 wt% aqueous barium chloride solution for about 1 second. The plate was further washed and dried again to obtain a 300 nm polarizing plate. The degree of polarization was measured and found to be 93%.

It is a schematic sectional drawing which shows an example of the polarizing plate of this invention. It is a schematic sectional drawing which shows an example of the shape of the resin layer used for this invention. It is explanatory drawing for demonstrating a flat pigment | dye. It is process drawing which shows an example of the manufacturing method of the polarizing plate of this invention. It is process drawing which shows an example of the hardening process in the manufacturing method of the polarizing plate of this invention. It is process drawing which shows the other example of the hardening process in the manufacturing method of the polarizing plate of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Base material 2 ... Resin layer 3 ... Polarizing layer 4 ... Substrate formation board 12 ... Curable resin composition 13 ... Flat pigment | dye

Claims (10)

A base material; a resin layer formed on the base material and having concave or convex portions formed on the surface thereof in a pattern; and a polarizing layer formed on the resin layer and containing a flat pigment. And
The resin layer is made of a curable resin, and its film thickness is in the range of 0.1 μm to 1 μm.
The shape of the concave or convex pattern of the resin layer is a stripe shape,
The flat dye forms a column structure in which the normal direction of the flat dye is stacked in a certain direction of the substrate, and the column structure is oriented along the concave portion of the resin layer. A characteristic polarizing plate.   The flat dyes are anthraquinone dyes, phthalocyanine dyes, porphyrin dyes, naphthalocyanine dyes, quinacridone dyes, dioxazine dyes, indanthrene dyes, acridine dyes, perylene dyes, pyrazolone dyes, acridone dyes. The polarizing plate according to claim 1, wherein the polarizing plate is selected from the group consisting of a dye, a pyranthrone dye, and an isoviolanthrone dye.   The polarizing plate according to claim 1, wherein the plate-like dye exhibits a lyotropic liquid crystal phase in a solution.   The polarizing plate according to any one of claims 1 to 3, wherein the resin layer surface is subjected to a hydrophilic treatment.   5. A liquid crystal display device comprising: the polarizing plate according to claim 1; and a liquid crystal cell. An application step of applying a curable resin composition on a substrate or a substrate for forming recesses having convex portions formed on the surface, and sandwiching the curable resin composition between the substrate and the substrate for forming recesses And a step of curing the curable resin composition to form a curable resin, and a step of peeling the substrate for forming the recesses from the curable resin composition or the curable resin to pattern the recesses. A resin layer forming step of forming a resin layer by performing a recess forming step to form a shape;
Applying a polarizing layer-forming coating solution containing a flat pigment on the resin layer, and orienting the flat pigment by the concave portions of the resin layer to form a coating film, the coating film A drying step of drying, and a polarizing layer forming step of forming a polarizing layer by performing an immobilization step of immobilizing the orientation state of the flat pigment,
The shape of the concave pattern of the resin layer is a stripe shape,
The flat dye forms a column structure in which the normal direction of the flat dye is stacked in a certain direction of the substrate, and the column structure is oriented along the concave portion of the resin layer. A method for producing a polarizing plate.   The said flat pigment | dye shows a lyotropic liquid crystal phase in the said coating liquid for polarizing layer formation, The manufacturing method of the polarizing plate of Claim 6 characterized by the above-mentioned.   The polarizing plate according to claim 6 or 7, wherein in the coating film forming step of the polarizing layer forming step, a coating method in which a shear stress is not applied to the polarizing layer forming coating solution is used. Manufacturing method.   The method for producing a polarizing plate according to any one of claims 6 to 8, wherein a method of crosslinking the flat pigment is used in the fixing step of the polarizing layer forming step.   The polarized light according to any one of claims 6 to 9, wherein after the resin layer forming step, a hydrophilization treatment step of hydrophilizing the resin layer surface on which the concave portion is formed is performed. A manufacturing method of a board.

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