JP7516028B2 - Polarizer composite and optical laminate - Google Patents

Description

The present invention relates to a polarizer composite and an optical laminate.

Polarizers are widely used as polarized light supplying elements and polarized light detecting elements in display devices such as liquid crystal display devices and organic electroluminescence (EL) display devices. Display devices equipped with polarizers are also used in mobile devices such as notebook personal computers and mobile phones, and polarizers with regions of different transmittance are required due to the demands for diversifying display purposes, clarifying display divisions, decoration, etc. In particular, in small and medium-sized mobile terminals such as smartphones and tablet terminals, a polarizer may be attached to the entire display surface in order to achieve a seamless design over the entire surface from the perspective of decorativeness. In this case, the polarizer may overlap the area of the camera lens and the area of icon or logo printing at the bottom of the screen, which may result in poor camera sensitivity and poor design.

For example, Patent Document 1 describes a method in which a polarizer contained in a polarizing plate is partially provided with a low-concentration portion of dichroic material, where the content of dichroic material is relatively low, and a camera is positioned corresponding to this low-concentration portion of dichroic material, thereby preventing adverse effects on camera performance.

JP 2015-215609 A

In Patent Document 1, a resin film containing a dichroic material is subjected to a chemical treatment in which a basic solution is brought into contact with the resin film, thereby partially decolorizing the resin film and forming a low-concentration portion of the dichroic material. The basic solution used for decolorization requires time and cost to dispose of as waste liquid. Patent Document 1 also describes that when iodine is used as the dichroic material, the iodine content can be reduced by contacting with a basic solution to form a low-concentration portion of the dichroic material. However, there is no disclosure of a specific method for forming a low-concentration portion of the dichroic material when a dichroic material other than iodine is used.

The present invention aims to provide a polarizer composite and an optical laminate that include a novel polarizer that can replace polarizers that have regions with a low content of dichroic material formed by chemical treatment such as bleaching.

The present invention provides the following polarizer composite and optical laminate.
[1] A polarizer composite including a polarizer, a first reinforcing material provided on one surface side of the polarizer, and a second reinforcing material provided on the other surface side of the polarizer,
the polarizer has a polarizing region having a thickness of 15 μm or less and a non-polarizing region surrounded by the polarizing region in a plan view,
a plurality of first cells each having an open end face, the first cells being arranged so that each open end face faces a surface of the polarizer;
a cell region in which the first cell is present and which is located in a region corresponding to the polarizing region, and a non-cell region in which the first cell is not present and which is located in a region corresponding to the non-polarizing region,
The second reinforcing material is
a plurality of second cells each having an open end face, the second cells being arranged so that each open end face faces a surface of the polarizer;
the second cell is present at least in an area corresponding to the non-polarizing area,
the non-polarizing region and the non-cell region contain a cured product of an active energy ray-curable resin,
A polarizer composite, wherein the cured material contained in the non-polarizing region is provided in a through hole surrounded by the polarizing region in a plan view.
[2] The polarizer composite according to [1], wherein the thickness of the cured product is equal to the total thickness of the polarizing region and the cell region.
[3] The polarizer composite according to [1], wherein a thickness of the cured product is smaller than a total thickness of a thickness of the polarizing region and a thickness of the cell region.
[4] The polarizer composite according to [1], wherein the thickness of the cured product is greater than the total thickness of the polarized polarization region and the cell region.
[5] The polarizer composite according to any one of [1] to [4], wherein the non-polarizing region has light-transmitting properties.
[6] The polarizer composite according to any one of [1] to [5], wherein the non-polarizing region has a diameter in a planar view of 0.5 mm or more and 20 mm or less.
[7] The polarizer composite according to any one of [1] to [6], wherein the active energy ray-curable resin contains an epoxy compound.
[8] The polarizer composite according to [7], wherein the epoxy compound includes an alicyclic epoxy compound.
[9] The polarizer composite according to any one of [1] to [8], wherein the shapes of the openings of the opening end faces of the first cell and the second cell are each independently polygonal, circular, or elliptical.
[10] The polarizer composite according to any one of [1] to [9], further comprising a light-transmitting filler in an internal space of the first cell.
[11] The polarizer composite according to any one of [1] to [10], further comprising a light-transmitting filler in an internal space of the second cell.
[12] An optical laminate comprising the polarizer composite according to any one of [1] to [11], and a protective layer on one or both sides of the polarizer composite.

The present invention provides a polarizer composite and an optical laminate that include a novel polarizer.

FIG. 1A is a schematic cross-sectional view showing an example of a polarizer composite of the present invention, FIG. 1B is a schematic plan view of the first reinforcing member side of the polarizer composite shown in FIG. 1A, and FIG. 1C is a schematic plan view of the second reinforcing member side of the polarizer composite shown in FIG. 4A and 4B are schematic cross-sectional views illustrating another example of a polarizer composite of the present invention. 1A and 1B are schematic diagrams illustrating an example of a cross section around a non-polarizing region and a non-cell region of a polarizer composite, and are explanatory diagrams for explaining a method of determining the thickness of a cured material provided in the non-polarizing region and the non-cell region. 1A to 1D are schematic cross-sectional views illustrating an example of a method for producing a polarizer composite of the present invention. 5A and 5B are schematic cross-sectional views showing a continuation of the method for producing the polarizer composite shown in FIG. 4 . FIG. 1 is a schematic cross-sectional view showing an example of an optical laminate of the present invention.

Below, preferred embodiments of the polarizer, polarizer composite, and optical laminate of the present invention will be described with reference to the drawings. In all of the drawings below, the scale of each component has been appropriately adjusted to make it easier to understand, and the scale of each component shown in the drawings does not necessarily match the scale of the actual component.

<Polarizer Composite>
Fig. 1(a) is a schematic cross-sectional view showing an example of the polarizer composite of this embodiment, Fig. 1(b) is a schematic plan view of the first reinforcing member side of the polarizer composite shown in Fig. 1(a), and Fig. 1(c) is a schematic plan view of the second reinforcing member side of the polarizer composite shown in Fig. 1(a). Figs. 2(a) and (b) are schematic cross-sectional views showing another example of the polarizer composite of this embodiment. The polarizer composite 40 shown in Figs. 1 and 2 has a polarizer 10, a first reinforcing member 50 provided on one surface side of the polarizer 10, and a second reinforcing member 60 provided on the other surface side of the polarizer 10.

As shown in FIG. 1(a), the polarizer 10 in the polarizer composite 40 has a polarizing region 11 and a non-polarizing region 12. The thickness of the polarizing region 11 is 15 μm or less.

The arrangement of the polarized regions 11 and non-polarized regions 12 in the polarizer 10 is not particularly limited as long as the polarized regions 11 are arranged to surround the non-polarized regions 12. In a plan view of the polarizer 10, it is preferable that the total area occupied by the polarized regions 11 is larger than the total area occupied by the non-polarized regions 12. The polarizer 10 may have one non-polarized region 12, or may have two or more non-polarized regions 12. When the polarizer 10 has two or more non-polarized regions 12, the shapes of the non-polarized regions 12 may be the same as each other or may be different from each other.

The first reinforcing member 50 of the polarizer composite 40 has a plurality of first cells 51 having an open end surface, and is arranged so that each open end surface faces the surface of the polarizer 10, as shown in FIG. 1(b) as an example. The first reinforcing member 50 has a cell region 55 in which the first cells 51 exist, and a non-cell region 56 in which the first cells 51 do not exist. The first cells 51 have a hollow columnar (cylindrical) structure surrounded by cell partitions 53 that divide the first cells 51, and both axial ends of the columnar structure are open end surfaces. The non-cell region 56 in which the first cells 51 do not exist is a region in which the cell partitions 53 that constitute the first cells 51 and the hollow columnar (cylindrical) space surrounded by the cell partitions 53 do not exist.

In the first reinforcing member 50, the cell region 55 exists in a region corresponding to the polarized region 11 present in the polarizer 10, and the non-cell region 56 exists in a region corresponding to the non-polarized region 12 of the polarizer 10. Here, the cell region 55 exists in a region corresponding to the polarized region 11 means that the cell region 55 and the polarized region 11 have approximately the same shape and approximately the same size in the planar viewing direction, and similarly, the non-cell region 56 exists in a region corresponding to the non-polarized region 12 means that the non-cell region 56 and the non-polarized region 12 have approximately the same position, approximately the same shape, and approximately the same size (diameter) in the planar viewing direction. In other words, when the non-cell region 56 is projected onto the polarizer 10 in the planar viewing direction, the projection region of the non-cell region 56 and the non-polarized region 12 in the polarizer 10 are approximately the same. According to the manufacturing means of the polarizer composite described later, a polarizer composite in which the cell region 55 exists in a region corresponding to the polarized region 11 can be efficiently manufactured. When the polarizer 10 included in the polarizer composite 40 has two or more non-polarized regions 12, as long as a non-cell region 56 is present in a region corresponding to at least one of the non-polarized regions 12, a cell region 55 may be present in a region corresponding to the other non-polarized regions 12.

The second reinforcing member 60 of the polarizer composite 40 has a plurality of second cells 61 having an open end surface, as shown in FIG. 1(c), and is arranged so that each open end surface faces the surface of the polarizer 10. The second reinforcing member 60 has a hollow columnar (tubular) structure surrounded by cell partitions 63 that divide the second cells 61, similar to the first cells 51, and both axial ends of the columnar structure are open end surfaces. Unlike the first reinforcing member 50, the second reinforcing member 60 also has second cells 61 in the region corresponding to the non-polarized region 12 (the portion shown by the wavy line in FIG. 1(c)). It is preferable that the second reinforcing member 60 has second cells 61 in both the polarized region 11 and the non-polarized region 12, and it is more preferable that the second cells 61 are present on the entire surface of the polarizer 10.

The non-polarized region 12 of the polarizer 10 and the non-cell region 56 of the first reinforcing member 50 contain a cured product of an active energy ray curable resin (hereinafter, sometimes referred to as "curable resin (X)"). The non-polarized region 12 is a region in which a cured product of the curable resin (X) is provided in a through hole 22 surrounded by the polarized region 11 in a planar view. The non-cell region 56 is a region in which a cured product of the curable resin (X) is provided in a through hole 52 provided in a region corresponding to the through hole 22 described above, which is provided so as to cut out all or a part of the multiple first cells 51. The through hole 22 of the polarizer 10 and the through hole 52 of the first reinforcing member 50 can have the same shape in a planar view. The through hole 22 and the through hole 52 can be connected in the thickness direction of the polarized region 11, and the cured product of the curable resin (X) can be provided across the through holes 22, 52 that are connected to each other.

The polarizer 10 in the polarizer composite 40 has a non-polarizing region 12, as shown in FIG. 1(a). Therefore, when the polarizer composite 40 is applied to a display device such as a liquid crystal display device or an organic EL display device deployed in a smartphone or tablet terminal, etc., a camera lens, an icon, a logo, or other printed part is arranged corresponding to the non-polarizing region 12, thereby preventing a decrease in the camera sensitivity and a decrease in the design.

In the polarizer composite 40, since the polarizer 10 has a non-polarizing region 12, it is believed that cracks are likely to occur around the non-polarizing region 12 due to the shrinkage of the polarizer 10 caused by temperature changes when applied to a display device, etc. Furthermore, since the polarizing region 11 of the polarizer 10 is thin, at 15 μm or less, it is believed that cracks are likely to occur when the polarizer 10 is subjected to impact. In the polarizer composite 40, since the first reinforcing material 50 and the second reinforcing material 60 are provided on both sides of the polarizer 10 as described above, it is believed that it is possible to suppress the occurrence of cracks when subjected to temperature changes or impacts, and the progression of fine cracks to large cracks.

In the polarizer composite 40, the non-polarized region 12 and the non-cell region 56 contain a cured product of the curable resin (X), so that the through-hole 22 of the polarizer 10 and the through-hole 52 of the first reinforcement member 50 can be made solid. Since the polarizer 10 of the polarizer composite 40 has a thickness of 15 μm or less, if the non-polarized region 12 does not have a cured product of the curable resin (X) and the through-hole 22 is hollow, there is a risk of problems such as cracks occurring around the through-hole 22 due to shrinkage of the polarizer caused by temperature changes when applied to a display device. In contrast, as in the polarizer 10 of the polarizer composite 40, the non-polarized region 12 and the non-cell region 56 can be made solid by providing a cured product of the curable resin (X) in the through-hole 22 and the through-hole 52, so that the occurrence of the above problems can be suppressed.

The thickness of the cured product of the curable resin (X) provided in the polarizer composite 40 may be the same as the total thickness of the polarizing region 11 and the cell region 55 (FIG. 1(a)), may be smaller than the total thickness (FIG. 2(a)), or may be larger than the total thickness (FIG. 2(b)). The cured product of the curable resin (X) provided in the polarizer composite 40 may be provided so as to fill at least a part of the through hole 22 of the polarizer 10 and at least a part of the through hole 52 of the first reinforcement member 50. The cured product of the curable resin (X) is preferably provided so as to fill the entire through hole 22 of the polarizer 10, and more preferably provided so as to fill the entire through hole 22 of the polarizer 10 and the entire through hole 52 of the first reinforcement member 50.

The thickness of the cured material provided in the polarizer composite 40 is determined as follows. First, in the polarizer composite 40, a first plane including the surface of the polarizing region 11 of the polarizer 10 (the surface opposite to the first reinforcing material 50 side) and a second plane including the opening end face of the cell region 55 of the first reinforcing material 50 (the opening end face opposite to the polarizer 10 side) are assumed. Next, in the non-polarizing region 12, a first position is determined as a position where the shortest distance between the surface of the cured material on the polarizer 10 side and the first plane is maximized, and a second position is determined as a position where the shortest distance between the surface of the cured material on the first reinforcing material 50 side and the second plane is maximized. Then, the sum (dm+dn+D) of the shortest distance (dm) at the first position, the shortest distance (dn) at the second position, and the distance (D) between the first plane and the second plane is determined as the thickness of the cured material provided in the polarizer composite 40.

A method for determining the thickness when the thickness of the cured material provided in the non-polarized region 12 and the non-cell region 56 differs from the total thickness of the polarized region 11 and the cell region 55 is specifically described with reference to FIG. 3. FIGS. 3(a) and (b) are schematic diagrams showing an example of a cross section of the non-polarized region and the periphery of the non-cell region of a polarizer composite, and are explanatory diagrams for explaining a method for determining the thickness of the cured material provided in the non-polarized region and the non-cell region.

3(a), when the cured material is provided in the non-polarized region 12 and the non-cell region 56, a straight line in the non-cell region 56 along the surface side opposite to the polarizer 10 side of the first reinforcement 50 is assumed to be the first plane 11m. Among the straight lines that connect an arbitrary point on this first plane 11m and an arbitrary point on the surface of the cured material provided in the non-cell region 56 with the shortest distance, the position when the length of the straight line ("dm" in FIG. 3(a)) is maximum is taken as the first position. Next, as shown in FIG. 3(a), a straight line shown by a dashed line in the non-polarized region 12 along the surface side opposite to the first reinforcement 50 side of the polarizer 10 is assumed to be the second plane 11n. Among the straight lines that connect an arbitrary point on this second plane 11n and an arbitrary point on the surface of the cured material provided in the non-polarized region 12 with the shortest distance, the position when the length of the straight line ("dn" in FIG. 3(a)) is maximum is taken as the second position. Here, as shown in FIG. 3(a), when the surface of the cured material provided in the non-polarizing region 12 and the non-cell region 56 is present on the inner side (polarizer 10 and first reinforcing material 50 side) of the first plane 11m and the second plane 11n in the thickness direction of the polarizer composite 40, dm and dn are shown as negative values. Also, the distance between the first plane 11m and the second plane 11n is D. Then, the thickness of the cured material provided in the non-polarizing region 12 and the non-cell region 56 shown in FIG. 3(a) can be determined as D + dm + dn (dm and dn are negative values).

In addition, in the case where the cured material is provided in the non-polarized region 12 and the non-cell region 56 as shown in FIG. 3(b), the thickness of the cured material provided in the non-polarized region 12 and the non-cell region 56 can be determined by assuming the first plane 11m and the second plane 11n in the same manner as described above. Specifically, first, among the straight lines that connect an arbitrary point on the first plane 11m and an arbitrary point on the surface of the cured material provided in the first reinforcement 50, the position at which the length of the straight line ("dm" in FIG. 3(b)) is maximum is set as the first position. Next, among the straight lines that connect an arbitrary point on the second plane 11n and an arbitrary point on the surface of the cured material provided in the non-polarized region 12, the position at which the length of the straight line ("dn" in FIG. 3(b)) is maximum is set as the second position. Here, as shown in FIG. 3(b), when the surface of the cured material provided in the non-polarizing region 12 and the non-cell region 56 is on the outer side (opposite the polarizer 10 and the first reinforcing material 50) of the first plane 11m and the second plane 11n in the thickness direction of the polarizer composite 40, dm and dn are shown as positive values. In this case, the thickness of the cured material provided in the non-polarizing region 12 and the non-cell region 56 shown in FIG. 3(b) can be determined as D+dm+dn (dm and dn are positive values).

In the polarizer composite 40 shown in FIG. 2(a), the second reinforcing material 60 can be provided on the cured product of the curable resin (X) in the through hole 22 by penetrating into the through hole 22 of the polarizer 10. In the polarizer composite 40 shown in FIG. 2(b), the second reinforcing material 60 can be provided on the surface of the cured product of the curable resin (X) provided so as to protrude from the through hole 22 of the polarizer 10.

The first reinforcing member 50 and the second reinforcing member 60 of the polarizer composite 40 may have the same shape and size as the first cell 51 and the second cell 61, respectively, or may differ from each other in at least one of the shape and size. The openings of the first cells 51 of the first reinforcing member 50 and the openings of the second cells 61 of the second reinforcing member 60 provided in the polarizer 10 may be arranged to overlap each other in a plan view, but are preferably arranged to be offset from each other.

The polarizer composite 40 is applied to a display device or the like in a state in which it includes a polarizer 10, a first reinforcing material 50, and a second reinforcing material 60. If the internal space of the first cell 51 of the first reinforcing material 50 and the second cell 61 of the second reinforcing material 60 is hollow, the visibility of the display device may be reduced due to the difference in refractive index between the cell partition 53 and the internal space of the first cell 51, and the difference in refractive index between the cell partition 63 and the internal space of the second cell 61, etc. Therefore, it is preferable that a translucent filler is provided in the internal space of the first cell 51 of the first reinforcing material 50 in the polarizer composite 40 and the internal space of the second cell 61 of the second reinforcing material 60. In the first reinforcing material 50 and the second reinforcing material 60 of the polarizer composite 40, when gaps are provided between the multiple first cells 51 or between the multiple second cells 61 as described below, it is preferable that a translucent filler is also provided in the gaps.

In this specification, translucency refers to the property (transmittance) of transmitting 80% or more of visible light in the wavelength range of 400 nm to 700 nm, with 85% or more being preferred, 90% or more being more preferred, and 92% or more being even more preferred. The definition of "translucency" below and the preferred range of transmittance for visible light are the same as above.

The polarizer composite 40 may be a sheet or a long body having a length that is wound into a roll shape during storage, transportation, etc. The planar shape and size of the polarizer composite 40 are not particularly limited.

(Polarizing Area)
The polarizing region 11 of the polarizer 10 preferably exhibits absorption dichroism in the wavelength range of 380 nm to 780 nm. The polarizer 10 has the property of absorbing linearly polarized light having a vibration plane parallel to its absorption axis and transmitting linearly polarized light having a vibration plane perpendicular to the absorption axis (parallel to the transmission axis), and this property can be obtained mainly by the polarizing region 11.

The polarizing region 11 may be, for example, a hydrophilic polymer film such as a polyvinyl alcohol film, a partially formalized polyvinyl alcohol film, or an ethylene-vinyl acetate copolymer partially saponified film, to which a dichroic substance such as iodine or a dichroic dye is adsorbed and oriented; a polyene-based oriented film or an oriented liquid crystal compound, such as a dehydrated polyvinyl alcohol film or a dehydrochlorinated polyvinyl chloride film, to which a dichroic substance is adsorbed and oriented; or the like. Among these, it is preferable to use a polyvinyl alcohol film dyed with iodine and uniaxially stretched, as it has excellent optical properties.

First, we will briefly explain the manufacturing method of the preferred polarizing region 11, which is obtained by dyeing a polyvinyl alcohol film with iodine and uniaxially stretching it.

Dyeing with iodine is carried out, for example, by immersing a polyvinyl alcohol film in an aqueous iodine solution. The stretching ratio for uniaxial stretching is preferably 3 to 7 times. Stretching may be carried out after the dyeing process or while dyeing. Alternatively, dyeing may be carried out after stretching.

The polyvinyl alcohol film is subjected to a swelling treatment, a crosslinking treatment, a washing treatment, a drying treatment, etc., as necessary. For example, by immersing the polyvinyl alcohol film in water and washing it before dyeing, not only can dirt and anti-blocking agents on the surface of the polyvinyl alcohol film be washed away, but the polyvinyl alcohol film can also be swelled to prevent uneven dyeing, etc.

The stretching, dyeing, crosslinking (boric acid treatment), washing, and drying of the polyvinyl alcohol-based resin film may be performed, for example, in accordance with the method described in JP 2012-159778 A. In the method described in this document, a polyvinyl alcohol-based resin layer that becomes the polarizing region 11 is formed by coating a substrate film with a polyvinyl alcohol-based resin. The substrate film used in this case can also be used as the first support layer 25 described below.

Next, a brief description will be given of the polarizing region 11 in which a dichroic dye is adsorbed and aligned on an oriented liquid crystal compound. As the polarizing region 11 in this case, a dichroic dye may be aligned in a cured film in which a liquid crystal compound is polymerized, as described in, for example, JP-A-2013-37353, JP-A-2013-33249, JP-A-2016-170368, JP-A-2017-83843, etc. As the dichroic dye, one having absorption in the wavelength range of 380 to 800 nm can be used, and it is preferable to use an organic dye. As the dichroic dye, for example, an azo compound can be used. The liquid crystal compound is a liquid crystal compound that can be polymerized while being aligned, and can have a polymerizable group in the molecule. Such a cured film in which a liquid crystal compound is polymerized may be formed on a substrate film, and in that case, the substrate film can also be used as the first support layer 25 described later.

After producing the polarizing film used in the polarizing region 11 as described above, it is also preferable to form the non-polarizing region 12 by drilling to form the polarizer 10. In this specification, such a polarizing film formed only of the polarizing region 11 is sometimes referred to as the raw polarizer 20.

The luminosity-corrected polarization degree (Py) of the polarizing region 11 is preferably 80% or more, more preferably 90% or more, even more preferably 95% or more, and particularly preferably 99% or more. The single transmittance (Ts) of the polarizing region 11 is usually less than 50%, and may be 46% or less. The single transmittance (Ts) of the polarizing region 11 is preferably 39% or more, more preferably 39.5% or more, even more preferably 40% or more, and particularly preferably 40.5% or more.

The single transmittance (Ts) is a Y value measured in accordance with JIS Z8701 2-degree visual field (C light source) and subjected to luminosity correction. The luminosity-corrected polarization degree (Py) can be measured, for example, using an ultraviolet-visible spectrophotometer (manufactured by JASCO Corporation, product name: V7100), and is calculated by the following formula based on the luminosity-corrected parallel transmittance Tp and crossed transmittance Tc.
Py [%] = {(Tp-Tc)/(Tp+Tc)} ^1/2 ×100

The thickness of the polarizing region 11 is 15 μm or less, may be 13 μm or less, may be 10 μm or less, may be 8 μm or less, may be 5 μm or less, and is usually 1 μm or more. If the thickness of the polarizing region 11 exceeds the above range, the workability for providing the cured product of the active energy ray curable resin (X) containing the curable resin (X) described later in the non-polarizing region 12 is likely to decrease. Also, if the polarizing region 11 is less than the above range, it becomes difficult to obtain the desired optical characteristics. The thickness of the polarizing region 11 can be measured using, for example, a contact film thickness measuring device (MS-5C, manufactured by Nikon Corporation).

(Non-polarized area)
In general, "non-polarized" refers to light that has no observable regularity in the electric field component. In other words, non-polarized light is random light in which no dominant specific polarization state is observed. In addition, "partially polarized" refers to light that is in an intermediate state between polarized light and non-polarized light, and means light in which at least one of linearly polarized light, circularly polarized light, and elliptically polarized light is mixed with non-polarized light. The non-polarized region 12 in the polarizer 10 means that the light that passes through the non-polarized region 12 (transmitted light) becomes non-polarized or partially polarized. In particular, a non-polarized region in which the transmitted light is non-polarized is preferable.

The non-polarized region 12 of the polarizer 10 is a region surrounded by the polarized region 11 in a planar view. The non-polarized region 12 contains a cured product of a curable resin (X). The non-polarized region 12 is preferably a region in which a cured product of an active energy ray-curable resin composition containing a curable resin (X), which will be described later, is provided in a through hole provided in a polarizer (raw polarizer 20) formed only of the polarized region 11. The non-polarized region 12 is translucent.

The non-polarized region 12 of the polarizer 10 has light transmissivity, so that optical transparency can be ensured in the non-polarized region 12. As a result, when the polarizer composite 40 is applied to a display device, a camera lens, an icon, a logo, or other printed portion can be arranged corresponding to the non-polarized region 12, thereby preventing a decrease in camera sensitivity and a decrease in design.

The planar shape of the non-polarizing region 12 is not particularly limited, but may be a circle; an ellipse; an oval; a polygon such as a triangle or a rectangle; a rounded polygon with at least one corner of the polygon being rounded (a shape having an R), etc.

The diameter of the non-polarized region 12 is preferably 0.5 mm or more, and may be 1 mm or more, 2 mm or more, or 3 mm or more. The diameter of the non-polarized region 12 is preferably 20 mm or less, and may be 15 mm or less, 10 mm or less, or 7 mm or less. The diameter of the non-polarized region 12 refers to the length of the longest straight line connecting any two points on the periphery of the non-polarized region 12.

The thickness of the cured product of the curable resin (X) provided in the non-polarizing region 12 may be the same as the thickness of the polarizing region 11, may be smaller than the thickness of the polarizing region 11, or may be larger than the thickness of the polarizing region 11. As described above, it is preferable that the cured product of the curable resin (X) provided in the non-polarizing region 12 is provided so as to fill the entire through hole 22.

The thickness of the cured material provided in the non-polarizing region 12 may be measured by following the method for measuring the thickness of the cured material provided in the polarizer composite 40 described above. Specifically, in the above measurement method, the first plane is set as the surface of the polarizing region 11 of the polarizer 10 (the surface on the first reinforcing member 50 side), and the thickness of the cured material of the curable resin (X) is determined.

(Cell Region of First Reinforcement)
The cell region 55 is a region in which the first cell 51 of the first reinforcing member 50 exists. As shown in FIG. 1B, the first cell 51 has a hollow columnar (tubular) structure surrounded by cell partitions 53 that divide the first cell 51, and both axial ends of the columnar structure are open end faces. The first cell 51 has, as open end faces, a first open end face arranged on a side relatively closer to the polarizer 10 of the polarizer composite 40, and a second open end face arranged on a side relatively farther away. The cell region 55 may be arranged so that at least one of the first open end face and the second open end face faces the polarizer 10, and it is preferable that both the first open end face and the second open end face face the polarizer 10.

The shape of the openings at the open end faces of the first cells 51 in the cell region 55 is not particularly limited, but is preferably polygonal, circular, or elliptical. The shape of the openings at the first open end face and the shape of the openings at the second open end face are preferably the same shape and size, but may be different shapes, or may be the same shape but different sizes. In addition, the shapes of the openings at the open end faces of the multiple first cells 51 in the cell region 55 may be the same as each other, or may be different from each other.

The plurality of first cells 51 in the cell region 55 are preferably arranged such that the openings of the first cells 51 are adjacent to each other in a plan view of the open end surface. The plurality of first cells 51 may be arranged such that the first cells 51 are arranged without gaps between each other, for example, when the shape of the opening of the open end surface of the first cell 51 shown in FIG. 1(b) is a hexagon or the like, in a plan view of the open end surface. Alternatively, the plurality of first cells 51 may be arranged such that parts of the cell partition walls 53 of the plurality of first cells 51 are in contact with each other, and there are gaps between the plurality of first cells 51, for example, when the shape of the opening of the open end surface of the first cell 51 is a circle or the like, in a plan view of the open end surface.

It is preferable that the cell region 55 of the first reinforcing member 50 has a honeycomb structure in which the openings at both the first opening end face and the second opening end face are hexagonal in shape, as shown in FIG. 1(b), and a plurality of first cells 51 are arranged in the planar direction of the polarizer composite 40 so that the openings are adjacent to each other with no gaps.

The size of the opening of the first cell 51 is not particularly limited, but it is preferable that the opening has a diameter smaller than the diameter of the non-polarizing region 12. The diameter of the first cell 51 is preferably 3 mm or less, may be 2 mm or less, may be 1 mm or less, and is usually 0.1 mm or more, and may be 0.5 mm or more. The diameter of the opening of this first cell 51 refers to the length of the longest straight line among the straight lines connecting any two points on the periphery of the opening.

The height of the first cell 51 (the length in the direction perpendicular to the open end surface of the first cell 51) is typically 0.1 μm or more, and may be 0.5 μm or more, 1 μm or more, or 3 μm or more, and is typically 15 μm or less, and may be 13 μm or less, or 10 μm or less.

It is preferable that the cell partitions 53 that separate the first cells 51 in the cell region 55 are translucent.

The line width of the cell partition 53 in the cell region 55 is, for example, 0.05 mm or more, may be 0.1 mm or more, may be 0.5 mm or more, may be 1 mm or more, and is usually 5 mm or less, and may be 3 mm or less.

The cell partitions 53 of the cell region 55 can be formed of, for example, a resin material or an inorganic oxide, and are preferably formed of a resin material. Examples of the resin material include thermoplastic resins, and curable resins such as thermosetting resins and active energy ray curable resins. Examples of the resin material include the above-mentioned curable resin (X) and the thermoplastic resins exemplified as the thermoplastic resins used in the filler. Examples of the inorganic oxide include silicon oxide (SiO ₂ ), aluminum oxide, etc.

(Non-cell region of the first reinforcement)
The non-cell region 56 is a region where the first cells 51 of the first reinforcing member 50 are not present, and as described above, is a region where the cell partitions 53 constituting the first cells 51 and the hollow columnar (cylindrical) spaces surrounded by the cell partitions 53 are not present. The non-cell region 56 is provided so as to cut out all or part of the multiple first cells 51, and has through holes 52 provided in regions corresponding to the through holes 22 of the polarizer 10. The non-cell region 56 can contain a cured product of the curable resin (X) in the through holes 52.

The planar shape and diameter of the non-cell region 56 are not particularly limited, and examples of the planar shape and diameter include those exemplified as the planar shape of the non-polarizing region 12. It is preferable that the planar shape and diameter of the non-cell region 56 are the same as the planar shape and diameter of the non-polarizing region 12.

(Second reinforcing material)
As shown in FIG. 1C, the second cell 61 of the second reinforcing member 60 has a hollow columnar (cylindrical) structure surrounded by cell partitions 63 that divide the second cell 61, and both axial ends of the columnar structure are open end faces. The second cell 61 has, as open end faces, a first' open end face arranged on a side relatively closer to the polarizer 10 of the polarizer composite 40, and a second' open end face arranged on a side relatively farther away. The second reinforcing member 60 may be arranged so that at least one of the first' open end face and the second' open end face faces the polarizer 10, and it is preferable that both the first' open end face and the second' open end face face the polarizer 10.

The shape of the opening at the open end face of the second cell 61 of the second reinforcing member 60 may be exemplified by the shape of the opening at the open end face of the first cell 51. The shape of the opening at the first' open end face and the shape of the opening at the second' open end face are preferably the same shape and size, but may be different shapes, or may be the same shape but different sizes. Furthermore, the shapes of the openings at the open end faces of the multiple second cells 61 may be the same as each other, or may be different from each other.

The second cells 61 of the second reinforcing member 60 are preferably arranged so that the openings of the second cells 61 are adjacent to each other in a plan view of the opening end surface. The second cells 61 may be arranged so that the second cells 61 are arranged without gaps between each other, for example, when the shape of the opening of the opening end surface of the second cell 61 shown in FIG. 1(c) is a hexagon or the like, in a plan view of the opening end surface. Alternatively, the second cells 61 may be arranged so that parts of the cell partition walls 63 of the second cells 61 are in contact with each other, and there are gaps between the second cells 61, for example, when the shape of the opening of the opening end surface of the second cell 61 is a circle or the like, in a plan view of the opening end surface.

As shown in FIG. 1( c), for example, the second reinforcing material 60 preferably has a honeycomb structure in which the openings at both the first' opening end face and the second' opening end face are hexagonal in shape, and a plurality of second cells 62 are arranged in the planar direction of the polarizer composite 40 so that the openings are adjacent to each other with no gaps.

The size and height of the opening of the second cell 62 can be, for example, the size and height exemplified for the opening of the first cell 51. The translucency, line width, and material of the cell partition 63 that divides the second cell 61 of the second reinforcing material 60 can be, for example, the translucency, line width, and material exemplified for the cell partition 53 that divides the first cell 51.

(Active energy ray curable resin composition (curable resin composition))
As described above, the non-polarizing region 12 and the non-cell region 56 in the polarizer composite 40 are regions in which a cured product of an active energy ray curable resin (curable resin (X)) is provided, and are preferably formed from an active energy ray curable resin composition (hereinafter, sometimes referred to as a "curable resin composition") containing the curable resin (X). The curable resin (X) contained in the curable resin composition is cured by irradiation with active energy rays such as ultraviolet rays, visible light, electron beams, and X-rays. The curable resin (X) is preferably an ultraviolet ray curable resin that is cured by irradiation with ultraviolet rays. The curable resin composition containing the curable resin (X) may be an active energy ray curable adhesive, and in this case, it is more preferably an ultraviolet ray curable adhesive.

The curable resin composition is preferably a solvent-free type. The term "solvent-free type" means that no solvent is actively added. Specifically, a solvent-free curable resin composition means that the content of the solvent is 5% by weight or less relative to 100% by weight of the curable resin (X) contained in the curable resin composition.

The curable resin (X) preferably contains an epoxy compound. An epoxy compound is a compound having one or more, preferably two or more, epoxy groups in the molecule. Examples of the epoxy compound include alicyclic epoxy compounds, aliphatic epoxy compounds, and hydrogenated epoxy compounds (glycidyl ethers of polyols having an alicyclic ring). The epoxy compound contained in the curable resin (X) may be one type or two or more types.

The content of the epoxy compound is preferably 40% by weight or more, more preferably 50% by weight or more, and even more preferably 60% by weight or more, relative to 100% by weight of the curable resin (X). The content of the epoxy compound may be 100% by weight or less, 90% by weight or less, or even 80% by weight or less, or 75% by weight or less, relative to 100% by weight of the curable resin (X).

The epoxy equivalent of the epoxy compound is usually within the range of 40 to 3000 g/equivalent, preferably 50 to 1500 g/equivalent. If the epoxy equivalent exceeds 3000 g/equivalent, the compatibility with other components contained in the curable resin (X) may decrease.

The epoxy compound contained in the curable resin (X) preferably contains an alicyclic epoxy compound. An alicyclic epoxy compound is an epoxy compound having one or more epoxy groups bonded to an alicyclic ring in the molecule. An "epoxy group bonded to an alicyclic ring" refers to a bridging oxygen atom --O-- in the structure shown in the following formula. In the following formula, m is an integer of 2 to 5.

A compound in which a group in which one or more hydrogen atoms in (CH ₂ ) _m in the above formula are removed is bonded to another chemical structure can be an alicyclic epoxy compound. One or more hydrogen atoms in (CH ₂ ) _m may be appropriately substituted with a linear alkyl group such as a methyl group or an ethyl group. Among alicyclic epoxy compounds, epoxy compounds having an oxabicyclohexane ring (m=3 in the above formula) or an oxabicycloheptane ring (m=4 in the above formula) are preferably used because they provide excellent adhesion between the polarizing region 11 of the polarizer 10 and the cell region 55 of the first reinforcing member 50 and the cured product of the curable resin (X) that forms the non-polarizing region 12 and the non-cell region 56. Specific examples of alicyclic epoxy compounds that are preferably used are shown below, but are not limited to these compounds.

［式（ＩＶ）中、Ｒ^８及びＲ^９は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表す。］ [a] Epoxycyclohexylmethyl epoxycyclohexanecarboxylates represented by the following formula (IV):

[In formula (IV), R ⁸ and R ⁹ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.]

［式（Ｖ）中、Ｒ^１０及びＲ^１１は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表し、ｎは２～２０の整数を表す。］ [b] Epoxycyclohexane carboxylates of alkanediols represented by the following formula (V):

[In formula (V), R ¹⁰ and R ¹¹ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and n represents an integer of 2 to 20.]

［式（ＶＩ）中、Ｒ^１２及びＲ^１３は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表し、ｐは２～２０の整数を表す。］ [c] Epoxycyclohexylmethyl esters of dicarboxylic acids represented by the following formula (VI):

[In formula (VI), R ¹² and R ¹³ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and p represents an integer of 2 to 20.]

［式（ＶＩＩ）中、Ｒ^１４及びＲ^１５は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表し、ｑは２～１０の整数を表す。］ [d] Epoxycyclohexylmethyl ethers of polyethylene glycol represented by the following formula (VII):

[In formula (VII), R ¹⁴ and R ¹⁵ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and q represents an integer of 2 to 10.]

［式（ＶＩＩＩ）中、Ｒ^１６及びＲ^１７は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表し、ｒは２～２０の整数を表す。］ [e] Epoxycyclohexylmethyl ethers of alkanediols represented by the following formula (VIII):

[In formula (VIII), R ¹⁶ and R ¹⁷ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and r represents an integer of 2 to 20.]

［式（ＩＸ）中、Ｒ^１８及びＲ^１９は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表す。］ [f] A diepoxy trispiro compound represented by the following formula (IX):

[In formula (IX), R ¹⁸ and R ¹⁹ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.]

［式（Ｘ）中、Ｒ^２０及びＲ^２１は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表す。］ [g] A diepoxy monospiro compound represented by the following formula (X):

[In formula (X), R ²⁰ and R ²¹ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.]

［式（ＸＩ）中、Ｒ^２２は、水素原子又は炭素数１～５の直鎖状アルキル基を表す。］ [h] Vinylcyclohexene diepoxides represented by the following formula (XI):

[In formula (XI), R ²² represents a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.]

［式（ＸＩＩ）中、Ｒ^２３及びＲ^２４は、互いに独立して、水素原子又は炭素数１～５の直鎖状アルキル基を表す。］ [i] Epoxy cyclopentyl ethers represented by the following formula (XII):

[In formula (XII), R ²³ and R ²⁴ each independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.]

［式（ＸＩＩＩ）中、Ｒ^２５は、水素原子又は炭素数１～５の直鎖状アルキル基を表す。］ [j] Diepoxytricyclodecanes represented by the following formula (XIII):

[In formula (XIII), R ²⁵ represents a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms.]

Examples of aliphatic epoxy compounds include polyglycidyl ethers of aliphatic polyhydric alcohols or their alkylene oxide adducts. More specifically, they include diglycidyl ether of 1,4-butanediol; diglycidyl ether of 1,6-hexanediol; triglycidyl ether of glycerin; triglycidyl ether of trimethylolpropane; diglycidyl ether of polyethylene glycol; diglycidyl ether of propylene glycol; and polyglycidyl ethers of polyether polyols obtained by adding one or more alkylene oxides (ethylene oxide or propylene oxide) to aliphatic polyhydric alcohols such as ethylene glycol, propylene glycol, or glycerin.

Hydrogenated epoxy compounds are obtained by reacting epichlorohydrin with an alicyclic polyol obtained by hydrogenating the aromatic rings of an aromatic polyol. Examples of aromatic polyols include bisphenol-type compounds such as bisphenol A, bisphenol F, and bisphenol S; novolac-type resins such as phenol novolac resin, cresol novolac resin, and hydroxybenzaldehyde phenol novolac resin; and polyfunctional compounds such as tetrahydroxydiphenylmethane, tetrahydroxybenzophenone, and polyvinylphenol. Among the hydrogenated epoxy compounds, hydrogenated diglycidyl ether of bisphenol A is preferred.

The curable resin (X) may contain a (meth)acrylic compound or the like together with an active energy ray curable compound such as an epoxy compound. By using a (meth)acrylic compound in combination, it is expected that the adhesion between the polarizing region 11 of the polarizer 10 and the cell region 55 of the first reinforcing member 50 and the cured product of the curable resin (X) forming the non-polarizing region 12 and the non-cell region 56, and the hardness and mechanical strength of the cured product of the curable resin (X) can be improved, and further, it becomes easier to adjust the viscosity, curing speed, etc. of the curable resin (X). "(Meth)acrylic" means at least one selected from the group consisting of acrylic and methacrylic.

The curable resin composition containing the curable resin (X) preferably contains a polymerization initiator. Examples of the polymerization initiator include cationic polymerization agents such as photocationic polymerization agents and radical polymerization initiators. The photocationic polymerization initiator generates cationic species or Lewis acids by irradiation with active energy rays such as visible light, ultraviolet light, X-rays, and electron beams, and initiates the polymerization reaction of the epoxy group. As described above, the curable resin (X) is preferably an ultraviolet-curable resin that cures by irradiation with ultraviolet light, and since the curable resin (X) preferably contains an alicyclic epoxy compound, the polymerization initiator in this case is preferably one that generates cationic species or Lewis acids by irradiation with ultraviolet light.

The curable resin composition may further contain additives such as photosensitizers, polymerization accelerators, ion trapping agents, antioxidants, chain transfer agents, tackifiers, thermoplastic resins, fillers, flow control agents, plasticizers, defoamers, antistatic agents, and leveling agents.

(Filling material)
The filler that may be provided in the first reinforcing material 50 and the second reinforcing material 60 is not particularly limited as long as it has translucency and can fill the internal spaces of the first cells 51 of the first reinforcing material 50 and the internal spaces of the second cells 61 of the second reinforcing material 60. The filler is preferably a material different from the material constituting the cell partition walls 53 of the first reinforcing material 50 and the cell partition walls 63 of the second reinforcing material 60, and preferably contains a resin material. Examples of the resin material include one or more types selected from the group consisting of thermoplastic resins, thermosetting resins, active energy ray curable resins, and other curable resins, and may be a pressure sensitive adhesive or adhesive.

Examples of thermoplastic resins include polyolefin resins such as linear polyolefin resins (polypropylene resins, etc.) and cyclic polyolefin resins (norbornene resins, etc.); cellulose ester resins such as triacetyl cellulose and diacetyl cellulose; polyester resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate; polycarbonate resins; (meth)acrylic resins; polystyrene resins; polyether resins; polyurethane resins; polyamide resins; polyimide resins; and fluorine resins.

The curable resin may be, for example, the curable resin (X) described above.

An adhesive exhibits adhesive properties by attaching itself to an adherend, and is known as a pressure-sensitive adhesive. Examples of adhesives include those that contain a polymer, such as a (meth)acrylic polymer, a silicone polymer, a polyester polymer, a polyurethane polymer, a polyether polymer, or a rubber polymer, as the main component. In this specification, the main component refers to a component that contains 50% by mass or more of the total solid content of the adhesive. The adhesive may be of the active energy ray curing type or the heat curing type, and the degree of crosslinking or adhesive strength may be adjusted by irradiation with active energy rays or heating.

The adhesive contains a curable resin component and is an adhesive other than a pressure-sensitive adhesive (adhesive). Examples of adhesives include water-based adhesives in which a curable resin component is dissolved or dispersed in water, active energy ray-curable adhesives containing active energy ray-curable compounds, and thermosetting adhesives.

As the adhesive, a water-based adhesive that is widely used in the technical field of polarizing plates can be used. Examples of resin components contained in the water-based adhesive include polyvinyl alcohol-based resins and urethane-based resins. Examples of active energy ray-curable adhesives include compositions that are cured by irradiation with active energy rays such as ultraviolet light, visible light, electron beams, and X-rays. Examples of active energy ray-curable adhesives include curable resin compositions containing the above-mentioned curable resin (X). Examples of thermosetting adhesives include those containing epoxy-based resins, silicone-based resins, phenol-based resins, melamine-based resins, etc. as the main component.

(Method of Manufacturing Polarizer Composite)
4 and 5 are schematic cross-sectional views showing an example of a method for producing a polarizer composite 40 (FIG. 1(a)). Although FIG. 4 and FIG. 5 show a case where the polarizer composite 40 shown in FIG. 1(a) is obtained, the polarizer composite 40 shown in FIG. 2(a) and (b) can also be produced by the method described below. The polarizer composite 40 can be produced, for example, by using a reinforcing material forming structure 58 (hereinafter sometimes referred to as "structure 58") formed on one side of a raw polarizer 20 having the same overall luminous sensitivity corrected polarization degree (Py) and not having a non-polarizing region 12, which is made of only a cell region 55 and does not have a non-cell region 56. Since the raw polarizer 20 is formed only of the polarizing region 11 of the polarizer 10 described above, the thickness of the raw polarizer 20 is preferably 15 μm or less, which is the same thickness as the polarizing region 11 of the polarizer 10. Since the structure 58 becomes the cell region 55 of the first reinforcing material 50 described above, it is preferable that the structure 58 has the same thickness as the cell region 55 of the first reinforcing material 50.

The polarizer composite 40 can be manufactured, for example, by the following process. First, as shown in FIG. 4(a), a first support layer 25 is provided on one side of the raw polarizer 20 so as to be peelable from the raw polarizer 20, and then a structure 58 is formed on the other side of the raw polarizer 20 to prepare the first laminate 31. The structure 58 can be obtained, for example, by using a resin material or an inorganic oxide to form cell partitions 53 that divide the first cells 51 on the surface of the raw polarizer 20.

The method for forming the cell partitions 53 using a resin material is not particularly limited, but examples thereof include printing methods such as inkjet printing, screen printing, and gravure printing; photolithography; and coating methods using nozzles, dies, etc. In the above methods, a resin composition in which the resin material is mixed with a solvent, additives, etc. may be used. Examples of additives include leveling agents, antioxidants, plasticizers, tackifiers, organic or inorganic fillers, pigments, antioxidants, ultraviolet absorbers, and antioxidants. The cell partitions 53 may be formed by subjecting the printed or coated resin composition to a treatment for solidification or hardening as necessary.

There are no particular limitations on the method for forming the cell partition 53 using an inorganic oxide, but it can be formed, for example, by vapor deposition of the inorganic oxide.

The prepared first laminate 31 is punched, cut out, cut, or laser cut to form a through hole 32 penetrating in the lamination direction (FIG. 4(b)). As a result, a perforated polarizer 21 in which a through hole 22 is formed in the raw polarizer 20 and a perforated structure 59 in which a through hole 52 is formed in the structure 58 are formed on the first support layer 25 in which a through hole is formed. Next, a second support layer 26 is peelably provided on the perforated structure 59 side of the first laminate 31 in which the through hole 32 is formed (FIG. 4(c)), and then the first support layer 25 is peeled off (FIG. 4(d)). As a result, a second laminate 33 in which the second support layer 26, the perforated structure 59, and the perforated polarizer 21 are laminated in this order is obtained (FIG. 4(d)). The second support layer 26 is provided so as to block one side of the perforated structure 52.

Next, the through holes 22 of the perforated polarizer 21 of the second laminate 33 and the through holes 52 of the perforated structure 59 are filled with a curable resin composition containing a curable resin (X), and the curable resin (X) in the through holes 22, 52 is cured by irradiating with active energy rays. As a result, a cured product of the curable resin (X) is formed in the through holes 22 of the perforated polarizer 21 and the through holes 52 of the perforated structure 59, and a first reinforcing material 50 and a polarizer 10 are formed on the second support layer 26 (FIG. 5(a)). In the polarizer 10 shown in FIG. 5(a), the area other than the through holes 22 of the perforated polarizer 21 becomes a polarizing area 11, and the area of the through holes 22 where the cured product is provided becomes a non-polarizing area 12. The first reinforcing material 50 shown in FIG. 5(a) is provided on one side of the polarizer 10, with the area other than the through-hole 52 of the perforated structure 59 being the cell area 55, and the area of the through-hole 52 where the cured material is provided being the non-cell area 56.

Next, a second reinforcing material 60 is formed on the side of the polarizer 10 opposite to the first reinforcing material 50, and a polarizer composite 40 is formed on the second support layer 26 (FIG. 5(b)). The second reinforcing material 60 may form cell partitions 63 by, for example, the method described above for forming the cell partitions 53 of the structure 58. After the second reinforcing material 60 is formed, the second support layer 26 may be peeled off.

The method of filling the through holes 22 of the perforated polarizer 21 and the through holes 52 of the perforated structure 59 with the curable resin composition is not particularly limited. For example, the curable resin composition may be injected into the through holes 22, 52 of the second laminate 33 using a dispenser or a dispenser, or the through holes 22, 52 may be filled with the curable resin composition while coating the surface of the perforated polarizer 21 of the second laminate 33 with the curable resin composition. The cured layer of the curable resin composition coated on the surface of the perforated polarizer 21 can be used as a protective layer described later. When coating the curable resin composition, a substrate film may be provided so as to cover the surface of the coating layer formed by the coating. The substrate film may be peeled off after the curable resin (X) is cured.

The first support layer 25 may be a support layer used in the manufacture of the raw polarizer 20 described below, or may be the above-mentioned base film used in coating the curable resin composition. Alternatively, it may be a peelable support layer attached to the raw polarizer 20 with a volatile liquid such as water, or may be an adhesive sheet peelable from the raw polarizer 20. The second support layer 26 may be a peelable support layer attached to the perforated polarizer 21 with a volatile liquid such as water, or may be an adhesive sheet peelable from the perforated polarizer 21.

As described above, in the polarizer composite 40, the thickness of the raw polarizer 20 is 15 μm or less, so that the depth of the through-hole 22 provided in the holey polarizer 21 can also be 15 μm or less. Since the height of the first cell 51 of the holey structure 59 is also usually 15 μm or less, the depth of the through-hole 52 provided in the holey structure 59 can also be 15 μm or less. This allows the through-hole 22 of the holey polarizer 21 and the through-hole 52 of the holey structure 59 to be filled with the curable resin composition, and the curable resin (X) contained in the curable resin composition filled in the through-holes 22 and 52 to be cured in a short time, thereby suppressing a decrease in workability.

In the manufacturing method of the polarizer composite 40, a through hole 32 is formed in a first laminate 31 having a structure 58, a raw polarizer 20, and a first support layer 25 in this order. The raw polarizer 20 forms the region that will become the non-polarized region 12 of the polarizer 10, and since the raw polarizer 20 is thin, having a thickness of 15 μm or less, there is a risk of problems such as cracks occurring around the through hole 22 when forming the through hole 22 in the raw polarizer 20. In the manufacturing method of the polarizer composite 40, the structure 58 is provided on the raw polarizer 20, and the through hole 22 is formed in a state in which the raw polarizer 20 is reinforced by the structure 58, so that the occurrence of cracks in the holey polarizer 21 is suppressed, and a polarizer 10 in which the occurrence of cracks is suppressed can be obtained.

(Raw material polarizer)
It is preferable that raw polarizer 20 is not likely to be significantly altered by active energy rays irradiated to cure the curable resin (X) in the curable resin composition filled in through hole 22. Such raw polarizer 20 is, for example, a film in which a dichroic dye is adsorbed and aligned on a polyvinyl alcohol-based resin film, or a film in which a dichroic dye is aligned in a cured layer of a polymerizable liquid crystal compound, and the manufacturing methods for these are as described in the polarizing region 11 above.

(Structure for forming reinforcement material (structure))
The structure 58 is a structure that is made up of only the cell region 55 and does not have the non-cell region 56. As described above, the structure 58 is made by forming the first cells 51 using a resin material or an inorganic oxide. The cell partition wall 53 can be formed by dividing the cell. The materials that can be used as the resin material and the inorganic oxide and the method for forming the cell partition wall 53 using them are the materials and methods exemplified above. Examples include:

<Optical laminate>
FIG. 6 is a schematic cross-sectional view showing an example of the optical laminate of the present embodiment. The optical laminate 45 shown in FIG. 6 has protective layers 17 and 18 on both sides of the polarizer composite 40 shown in FIG. 1(a). The optical laminate 45 may have the protective layer 17 (or 18) only on one side of the polarizer composite 40. The polarizer composite 40 included in the optical laminate 45 may be the polarizer composite 40 shown in FIG. 2(a) or (b). The protective layers 17 and 18 can be provided on the polarizer composite 40 via a bonding layer such as a pressure-sensitive adhesive layer or an adhesive layer. In this case, for example, a film-like protective layer may be laminated on the polarizer composite 40 via a bonding layer. The protective layers 17 and 18 may be provided so as to be in direct contact with the polarizer composite 40 without a bonding layer. In this case, for example, the protective layers 17 and 18 can be formed by applying a composition containing a resin material constituting the protective layers 17 and 18 onto the polarizer composite 40 and solidifying or curing the applied layer.

When the optical laminate 45 is formed by providing protective layers 18, 17 on the first reinforcing member 50 and the second reinforcing member 60 of the polarizer composite 40 via a bonding layer, it is preferable to form the protective layers 18, 17 by providing a bonding layer so as to fill the internal space of the first cell 51 of the first reinforcing member 50, the gaps between the multiple first cells 51, the internal space of the second cell 61 of the second reinforcing member 60, and the gaps between the multiple second cells 61, etc.

When the optical laminate 45 has protective layers 18, 17 provided so as to be in direct contact with the first reinforcing member 50 and the second reinforcing member 60 of the polarizer composite 40, it is preferable to form the protective layers 18, 17 by providing a composition containing the resin material that constitutes the protective layers 18, 17 so as to fill the internal space of the first cell 51 of the first reinforcing member 50, the gaps between the multiple first cells 51, the internal space of the second cell 61 of the second reinforcing member 60, and the gaps between the multiple second cells 61, etc.

In the optical laminate 45, the protective layers 18 and 17 may be cured layers of a curable resin (X) provided directly on the first reinforcing material 50 and the second reinforcing material 60, respectively. The curable resin (X) constituting the cured layer protective layers 18 and 17 is not particularly limited as long as it is a resin that is cured by irradiation with active energy rays such as ultraviolet light, visible light, electron beams, and X-rays, and examples thereof include the curable resin (X) described above. The protective layers 18 and 17 may be cured layers of a curable resin composition containing the same curable resin (X) as the curable resin (X) constituting the cured product contained in the non-polarizing region 12 and the non-cell region 56 of the polarizer 10.

To manufacture the optical laminate 45, for example, a curable resin composition is coated on the first reinforcing member 50 and the second reinforcing member 60 side of the polarizer composite 40, and the curable resin (X) is cured by irradiating with active energy rays. In this way, protective layers 18 and 17, which are cured layers of the curable resin (X), may be formed on the first reinforcing member 50 and the second reinforcing member 60, respectively, to obtain the optical laminate 45.

In the optical laminate 45 shown in FIG. 6, one of the protective layers 17 and 18 may be a protective layer provided via a bonding layer, and the other may be a protective layer provided without a bonding layer. The protective layers 17 and 18 included in the optical laminate 45 may be the same as each other or different from each other.

When the curable resin composition is coated, a substrate film may be provided so as to cover the surface of the coating layer formed by the coating. In this case, the substrate film may be used as the protective layers 17, 18, and the cured layer of the curable resin (X) may be used as an attachment layer for attaching the protective layers 17, 18. The substrate film may be peeled off after the curable resin (X) is cured.

(Protective Layer)
The protective layers 17 and 18 are preferably resin layers capable of transmitting light, and may be resin films or coating layers formed by applying a composition containing a resin material. The resin used for the resin layer is preferably a thermoplastic resin having excellent transparency, mechanical strength, thermal stability, moisture blocking properties, isotropy, stretchability, etc. Examples of the thermoplastic resin include the thermoplastic resin constituting the base film that may be used in the manufacture of the raw polarizer 20 described above. When the optical laminate 45 has the protective layers 17 and 18 on both sides, the resin compositions of the protective layers 17 and 18 may be the same as each other or different from each other.

From the viewpoint of thinning, the thickness of the protective layers 17 and 18 is usually 200 μm or less, preferably 150 μm or less, more preferably 100 μm or less, and may be 80 μm or less, or may be 60 μm or less. The thickness of the protective layers 17 and 18 is usually 5 μm or more, may be 10 μm or more, or may be 20 μm or more. The protective layers 17 and 18 may or may not have a phase difference. When the optical laminate 45 has the protective layers 17 and 18 on both sides, the thicknesses of the protective layers 17 and 18 may be the same as each other or may be different from each other.

(Laminating layer)
The attachment layer is a pressure-sensitive adhesive layer or an adhesive layer. Examples of the pressure-sensitive adhesive for forming the pressure-sensitive adhesive layer and the adhesive for forming the adhesive layer include the pressure-sensitive adhesive and adhesive used to form the filler described above.

<Laminate having an adhesive layer for optical display element>
The polarizer composite 40 shown in Figures 1 and 2 and the optical laminate 45 shown in Figure 6 may further have an attachment layer for an optical display element for attachment to an optical display element (liquid crystal panel, organic EL element) of a display device such as a liquid crystal display device or an organic EL display device.

In the polarizer composite 40 and the optical laminate 45, when an adhesive layer for optical display elements is provided on the surface of the first reinforcing material 50 or the second reinforcing material 60, a material constituting the adhesive layer for optical display elements may be used as the filler provided in the first reinforcing material 50 or the second reinforcing material 60, and the filling of the filler into the internal space of the first cell 51 of the first reinforcing material 50 or the internal space of the second cell 61 of the second reinforcing material 60, etc., and the formation of the adhesive layer for optical display elements may be performed simultaneously.

REFERENCE SIGNS LIST 10 polarizer, 11 polarizing region, 11m first plane, 11n second plane, 12 non-polarizing region, 17, 18 protective layer, 20 raw polarizer, 21 holed polarizer, 22 through hole, 25 first support layer, 26 second support layer, 27 third support layer, 28 fourth support layer, 31 first laminate, 32 through hole, 33 second laminate, 34 third laminate, 35 fourth laminate, 36
Through hole, 40, 41 polarizer composite, 45 optical laminate, 50 first reinforcing material, 51 first cell, 52 through hole, 53 cell partition wall, 55 cell region, 56 non-cell region, 58 reinforcing material forming structure, 59 holed structure, 60 second reinforcing material, 61 second cell, 63 cell partition wall.

Claims (12)

A polarizer composite including a polarizer, a first reinforcing material provided on one surface side of the polarizer, and a second reinforcing material provided on the other surface side of the polarizer,
the polarizer has a polarizing region having a thickness of 15 μm or less and a non-polarizing region surrounded by the polarizing region in a plan view,
The first reinforcing material is
a plurality of first cells each having an open end face, the first cells being arranged so that each open end face faces a surface of the polarizer;
a cell region in which the first cell is present and which is located in a region corresponding to the polarizing region, and a non-cell region in which the first cell is not present and which is located in a region corresponding to the non-polarizing region,
The second reinforcing material is
a plurality of second cells each having an open end face, the second cells being arranged so that each open end face faces a surface of the polarizer;
the second cell is present at least in an area corresponding to the non-polarizing area,
the non-polarizing region and the non-cell region contain a cured product of an active energy ray-curable resin,
A polarizer composite, wherein the cured material contained in the non-polarizing region is provided in a through hole surrounded by the polarizing region in a plan view. The polarizer composite according to claim 1, wherein the thickness of the cured product is equal to the total thickness of the polarizing region and the cell region. The polarizer composite according to claim 1, wherein the thickness of the cured product is smaller than the total thickness of the polarizing region and the cell region. The polarizer composite according to claim 1, wherein the thickness of the cured product is greater than the total thickness of the polarizing region and the cell region. The polarizer composite according to any one of claims 1 to 4, wherein the non-polarizing region has light-transmitting properties. The polarizer composite according to any one of claims 1 to 5, wherein the diameter of the non-polarizing region in a plan view is 0.5 mm or more and 20 mm or less. The polarizer composite according to any one of claims 1 to 6, wherein the active energy ray-curable resin contains an epoxy compound. The polarizer composite of claim 7, wherein the epoxy compound includes an alicyclic epoxy compound. 9. The polarizer composite according to claim 1, wherein the shapes of the openings of the open end faces of the first cell and the second cell are each independently polygonal, circular, or elliptical. The polarizer composite according to any one of claims 1 to 9, further comprising a light-transmitting filler in the internal space of the first cell. The polarizer composite according to any one of claims 1 to 10, further comprising a light-transmitting filler in the internal space of the second cell. An optical laminate having a protective layer on one or both sides of the polarizer composite according to any one of claims 1 to 11.

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