Laminate, stretched laminate, manufacturing method of stretched laminate, manufacturing method of optical film laminate having polarizing film using the same, and polarizing film

Patent metadata

Field	Value
Publication number	US-2016377772-A1
Application number	US-201615263293-A
Country	US
Kind code	A1
Filing date	Sep 12, 2016
Priority date	Mar 14, 2014
Publication date	Dec 29, 2016
Grant date	—

Abstract

Provided is a laminate comprising a thermoplastic resin substrate and a polyvinyl alcohol based resin layer formed on the thermoplastic resin substrate, being used to form a polarizing film of the polyvinyl alcohol based resin layer treated with a post-process comprising at least a dyeing step of dyeing the polyvinyl alcohol based resin layer with a dichroic material, the post-process being performed after the polyvinyl alcohol based resin layer formed on the thermoplastic resin substrate is stretched together with the thermoplastic resin substrate, wherein the polyvinyl alcohol based resin layer comprises a polyvinyl alcohol based resin and a halide.

First claim

1 . A laminate comprising a thermoplastic resin substrate and a polyvinyl alcohol based resin layer formed on the thermoplastic resin substrate, being used to form a polarizing film of the polyvinyl alcohol based resin layer treated with a post-process comprising at least a dyeing step of dyeing the polyvinyl alcohol based resin layer with a dichroic material, the post-process being performed after the polyvinyl alcohol based resin layer formed on the thermoplastic resin substrate is stretched together with the thermoplastic resin substrate,
wherein the polyvinyl alcohol based resin layer comprises a polyvinyl alcohol based resin and a halide.

2 . The laminate according to claim 1 , wherein the post-process further comprises a final stretching step of stretching the polyvinyl alcohol based resin layer.

3 . The laminate according to claim 1 , wherein the molar ratio of the halide to the polyvinyl alcohol based resin is 1.0 or more and 5.3 or less.

4 . The laminate according to claim 1 , wherein the halide is an iodide.

5 . The laminate according to claim 4 , wherein the iodide is potassium iodide.

6 . The laminate according to claim 1 , wherein the halide is sodium chloride.

7 . The laminate according to claim 1 , wherein the polyvinyl alcohol resin layer formed on the thermoplastic resin substrate prior to stretching is obtained by applying a polyvinyl alcohol based resin coating liquid containing the halide to the thermoplastic resin substrate and then drying at 80° C. or lower.

8 . A stretched laminate comprising a thermoplastic resin substrate and a polyvinyl alcohol based resin layer formed on the thermoplastic resin substrate, being used to form a polarizing film of the polyvinyl alcohol based resin layer treated with a post-process comprising at least a dyeing step of dyeing the polyvinyl alcohol based resin layer with a dichroic material,
wherein the polyvinyl alcohol based resin layer comprises a polyvinyl alcohol based resin and a halide, and the polyvinyl alcohol based resin layer formed on the thermoplastic resin substrate is stretched together with the thermoplastic resin substrate.

9 . The stretched laminate according to claim 8 , wherein the post-process further comprises a final stretching step of stretching the polyvinyl alcohol based resin layer.

10 . The stretched laminate according to claim 8 , wherein the molar ratio of the halide to the polyvinyl alcohol based resin is 1.0 or more and 5.3 or less.

11 . The stretched laminate according to claim 8 , wherein the halide is an iodide.

12 . The stretched laminate according to claim 11 , wherein the iodide is potassium iodide.

13 . The stretched laminate according to claim 8 , wherein the halide is sodium chloride.

14 . The stretched laminate according to claim 8 , wherein the polyvinyl alcohol resin layer formed on the thermoplastic resin substrate prior to stretching is obtained by applying a polyvinyl alcohol based resin coating liquid containing the halide to the thermoplastic resin substrate and then drying at 80° C. or lower.

15 . The stretched laminate according to claim 8 , wherein the polyvinyl alcohol based resin layer formed on the thermoplastic resin substrate is stretched in the air together with the thermoplastic resin substrate.

16 . The stretched laminate according to claim 15 , wherein the stretch ratio in the stretching in the air is 1.5 or more and 3.5 or less.

17 . The stretched laminate according to claim 16 , wherein the stretching temperature in the stretching in the air is 100° C. or higher and 150° C. or lower.

18 . The stretched laminate according to claim 8 , wherein the post-process comprises at least
a dyeing step of dyeing the polyvinyl alcohol based resin layer with a dichroic material to form a colored laminate, and an in-boric acid water stretching step of stretching the colored laminate in a boric acid aqueous solution.

19 . The stretched laminate according to claim 8 , wherein the polarizing film has a thickness of 10 μm or less.

20 . The stretched laminate according to claim 8 , wherein the polarizing film has a thickness of 7 μm or less.

21 . The stretched laminate according to claim 8 , wherein the polarizing film has a thickness of 5 μm or less.

22 . A roll of stretched laminate formed by winding the stretched laminate according to claim 8 , in a roll form.

23 . A manufacturing method of a stretched laminate including a thermoplastic resin substrate and a polyvinyl alcohol based resin layer formed on a thermoplastic resin substrate, being used to form a polarizing film of the polyvinyl alcohol based resin layer treated with a post-process including at least a dyeing step of dyeing the polyvinyl alcohol based resin layer with a dichroic material, comprising the steps of;
applying a polyvinyl alcohol based resin coating liquid containing a halide to the thermoplastic resin substrate so as to form a laminate including the thermoplastic resin substrate and a polyvinyl alcohol based resin layer containing a polyvinyl alcohol based resin and a halide, formed on the thermoplastic resin substrate; and stretching the laminate to form a stretched laminate.

24 . The manufacturing method of a stretched laminate according to claim 23 , wherein the post-process further comprises a final stretching step of stretching the polyvinyl alcohol based resin layer.

25 . The manufacturing method of a stretched laminate according to claim 23 , wherein the molar ratio of the halide to the polyvinyl alcohol based resin contained in the polyvinyl alcohol based resin layer included in the laminate is 1.0 or more and 5.3 or less.

26 . The manufacturing method of a stretched laminate according to claim 23 , wherein the halide is an iodide.

27 . The manufacturing method of a stretched laminate according to claim 26 , wherein the iodide is potassium iodide.

28 . The manufacturing method of a stretched laminate according to claim 23 , wherein the halide is sodium chloride.

29 . The manufacturing method of a stretched laminate according to claim 23 , wherein the step of forming the laminate further comprises a step of drying at 80° C. or lower, after application of the polyvinyl alcohol based resin coating liquid containing a halide.

30 . The manufacturing method of a stretched laminate according to claim 23 , wherein the laminate is stretched in the air.

31 . The manufacturing method of a stretched laminate according to claim 30 , wherein the stretch ratio in the stretching in the air is 1.5 or more and 3.5 or less.

32 . The manufacturing method of a stretched laminate according to claim 31 , wherein the stretching temperature in the stretching in the air is 100° C. or higher and 150° C. or lower.

33 . A manufacturing method of a roll of stretched laminate comprising winding, in a roll form, a stretched laminate manufactured by the manufacturing method of a stretched laminate according to claim 23 so as to form a roll of stretched laminate.

34 . A manufacturing method of an optical film laminate comprising:
a step of stretching a laminate including a thermoplastic resin substrate and a polyvinyl alcohol based resin layer containing a polyvinyl alcohol based resin and a halide, formed on the thermoplastic resin substrat

Assignees

• Nitto Denko Corp

Inventors

• Goto Shusaku
• Miyatake Minoru
• Kamijo Takashi
• Kunikata Satoru

Classifications

• G02B5/305 Primary

  including organic materials, e.g. polymeric layers · CPC title

• B29C55/02

  of plates or sheets · CPC title

• G02B5/3033 Primary

  in the form of a thin sheet or foil, e.g. Polaroid · CPC title

• G02B5/3025

  Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state (G02B5/3008, G02B5/3016 take precedence) · CPC title

• G02B5/30

  Polarising elements (light-modulating devices with active elements G02F1/00) · CPC title