TWI864093B - Polarizer composite and optical laminate - Google Patents

Abstract

An object of the present invention is to provide a polarizer composite with a novel polarizer and an optical laminate.

The polarizer composite has 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 has multiple first cells having open end faces, and each open end face is arranged so as to face the surface of the polarizer. The first reinforcing material has a cell region in which the first cells exist and which exists in a region corresponding to the polarizing region, and a non-cell region in which the first cells do not exist and which exists in a region corresponding to the non-polarizing region. The second reinforcing material has multiple second cells having open end faces, and each open end face is arranged so as to face the surface of the polarizer. The second reinforcing material has the multiple second cells, and the second cells are present in a region corresponding to at least the non-polarizing region. The non-polarizing region and the non-cell region contain a cured product of an active energy ray-curable resin, and the cured product contained in the non-polarizing region is provided in a through hole surrounded by the polarizing region in a plan view.

Description

Polarizer composites and optical laminates

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

Polarizers are widely used as polarized light supply elements or polarized light detection elements in display devices such as liquid crystal display devices or organic electroluminescent (EL) display devices. Display devices equipped with polarizers have also expanded to mobile devices such as laptop computers and mobile phones. Due to the requirements for diversified display purposes, clear display partitions, and decoration, polarizers with different transmittance areas are expected. In particular, in small and medium-sized portable terminals such as smartphones or tablet terminals, in order to create a design without boundaries on the entire surface from a decorative point of view, polarizers are sometimes attached to the entire display surface. In this case, the polarizing film is sometimes overlapped on the camera lens area, the area where the icon or logo is printed under the screen, and therefore, there is a problem of poor camera sensitivity and poor design.

For example, Patent Document 1 describes that a dichroic substance low concentration portion with a relatively low content of dichroic substance is partially provided in the polarizer contained in the polarizing plate, and the camera is configured in a manner corresponding to the dichroic substance low concentration portion, thereby not causing adverse effects on the camera performance.

[Prior Art Literature]

[Patent Literature]

Patent document 1: Japanese Patent Publication No. 2015-215609

In Patent Document 1, a resin film containing a dichroic substance is chemically treated by contacting an alkaline solution to partially decolorize the resin film to form a dichroic substance low concentration portion. The alkaline solution used for decolorization requires time and cost because it is treated as waste liquid. In addition, Patent Document 1 states that when iodine is used as a dichroic substance, the iodine content can be reduced by contacting it with an alkaline solution to form a dichroic substance low concentration portion. However, a specific method for forming a dichroic substance low concentration portion when using a dichroic substance other than iodine is not disclosed.

The purpose of the present invention is to provide a polarizer composite and an optical laminate having a novel polarizer, which replaces the polarizer having a region with a low content of dichroic substances formed by chemical treatment such as decolorization.

The present invention provides the following polarizer composite and optical laminate.

[1] A polarizer composite comprising a polarizer, a first reinforcing material disposed on one side of the polarizer, and a second reinforcing material disposed on the other side of the polarizer, wherein:

The polarizer has a polarizing region with a thickness of less than 15 μm and a non-polarizing region surrounded by the polarizing region when viewed from above.

The aforementioned first reinforcing material has a plurality of first cells with open end faces, and each open end face is arranged in a manner opposite to the surface of the aforementioned polarizer;

The first reinforcing material has a cell cavity region and a non-cell cavity region. The cell cavity region is a region where the first cell cavity exists and the cell cavity region exists in a region corresponding to the polarization region. The non-cell cavity region is a region where the first cell cavity does not exist and the non-cell cavity region exists in a region corresponding to the non-polarization region.

The aforementioned second reinforcing material has a plurality of second cells with open end faces, and each open end face is arranged in a manner opposite to the surface of the aforementioned polarizer;

The aforementioned second cell cavity exists at least in the area corresponding to the aforementioned non-polarized area,

The aforementioned non-polarized area and the aforementioned non-cell cavity area contain a hardened material of an active energy ray-hardening resin,

The aforementioned hardened material contained in the aforementioned non-polarizing area is provided in a through hole surrounded by the aforementioned polarizing area when viewed from above.

[2] The polarizer composite as described in [1], wherein the thickness of the cured product is equal to the sum of the thickness of the polarizing region and the thickness of the cell region.

[3] The polarizer composite as described in [1], wherein the thickness of the hardened material is less than the sum of the thickness of the polarizing region and the thickness of the cell region.

[4] The polarizer composite as described in [1], wherein the thickness of the hardened material is greater than the sum of the thickness of the polarizing region and the thickness of the cell region.

[5] A polarizer composite as described in any one of [1] to [4], wherein the non-polarizing region is light-transmissive.

[6] A polarizer composite as described in any one of [1] to [5], wherein the diameter of the non-polarizing region when viewed from above is greater than 0.5 mm and less than 20 mm.

[7] A polarizer composite as described in any one of [1] to [6], wherein the active energy ray-curable resin contains an epoxy compound.

[8] The polarizer composite as described in [7], wherein the epoxy compound comprises an alicyclic epoxy compound.

[9] A polarizer composite as described in any one of [1] to [8], wherein the shapes of the openings of the aforementioned opening end faces of the aforementioned first cell cavity and the aforementioned second cell cavity are independently polygonal, circular, or elliptical.

[10] A polarizer composite as described in any one of [1] to [9], wherein a light-transmitting filling material is provided in the internal space of the first cell cavity.

[11] A polarizer composite as described in any one of [1] to [10], wherein a light-transmitting filling material is provided in the internal space of the second cell cavity.

[12] An optical laminate having a protective layer on one or both sides of the polarizer composite described in any one of [1] to [11].

The present invention can provide a polarizer composite and an optical laminate having a novel polarizer.

10: Polarizer

11: Polarization area

11m: First plane

11n: Second plane

12: Non-polarized area

17,18: Protective layer

20: Raw polarizer

21: Polarizer with opening

22: Perforation

25: First support layer

26: Second support layer

27: The third support layer

28: The fourth support layer

31: First layer of body

32: Perforation

33: Second layer of body

34: The third layer

35: The fourth layer of the body

36: Perforation

40,41: Polarizer composite

45: Optical laminates

50: First reinforcement material

51: First cell cavity

52: Perforation

53,63: cell wall

55:Cellular region

56: Non-luminal region

58: Structures and structures for forming reinforcing materials

59: Structure with openings

60: Second reinforcement material

61: Second cell cavity

FIG. 1(a) is a schematic cross-sectional view schematically showing an example of the polarizer composite of the present invention, FIG. 1(b) is a schematic plan view of the first reinforcing material side of the polarizer composite shown in FIG. 1(a), and FIG. 1(c) is a schematic plan view of the second reinforcing material side of the polarizer composite shown in FIG. 1(a).

Figure 2(a) and Figure 2(b) are schematic cross-sectional views showing another example of the polarizer composite of the present invention.

Figures 3(a) and 3(b) schematically show an example of a cross section of the non-polarizing region and the non-cell region of the polarizer composite, and are explanatory diagrams for explaining a method for determining the thickness of the hardened material disposed in the non-polarizing region and the non-cell region.

Figures 4(a) to 4(d) are schematic cross-sectional views showing an example of a method for manufacturing the polarizer composite of the present invention.

Figures 5(a) and 5(b) are schematic cross-sectional views showing the manufacturing method of the polarizer composite shown in Figure 4 in succession.

FIG6 is a schematic cross-sectional view showing an example of the optical laminate of the present invention.

The following is a description of the preferred implementation of the polarizer, polarizer composite, and optical laminate of the present invention with reference to the drawings. In all the following drawings, the scales are appropriately adjusted to facilitate the understanding of each component, and the scales of each component shown in the drawings are not necessarily consistent with the scales of the actual components.

<Polarizer composite>

FIG. 1(a) is a schematic cross-sectional view schematically showing an example of a polarizer composite of the present embodiment, FIG. 1(b) is a schematic plan view of the first reinforcing material side of the polarizer composite shown in FIG. 1(a), and FIG. 1(c) is a schematic plan view of the second reinforcing material side of the polarizer composite shown in FIG. 1(a). FIG. 2(a) and FIG. 2(b) are schematic cross-sectional views showing another example of a polarizer composite of the present embodiment. The polarizer composite 40 shown in FIG. 1 and FIG. 2 has a polarizer 10, a first reinforcing material 50 disposed on one side of the polarizer 10, and a second reinforcing material 60 disposed on the other side of the polarizer 10.

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

The polarizing region 11 and the non-polarizing region 12 in the polarizer 10 can be arranged in such a way that the polarizing region 11 surrounds the non-polarizing region 12, and there is no particular limitation. When the polarizer 10 is viewed from above, the total area occupied by the polarizing region 11 is preferably larger than the total area occupied by the non-polarizing region 12. The polarizer 10 can have one non-polarizing region 12, or it can have two or more non-polarizing regions 12. When there are two or more non-polarizing regions 12, the shapes of the non-polarizing regions 12 can be the same or different from each other.

The first reinforcing material 50 of the polarizer composite 40 is an example as shown in FIG. 1(b), and has a plurality of first cells 51 with open end faces, and each open end face is arranged in a manner opposite to the surface of the polarizer 10. The first reinforcing material 50 has a cell region 55 where the first cell 51 exists, and a non-cell region 56 where the first cell 51 does not exist. The first cell 51 has a hollow columnar (cylindrical) structure surrounded by a cell partition wall 53 that divides the first cell 51, and both ends of the columnar structure in the axial direction are opened to form open end faces. The non-cell region 56 where the first cell 51 does not exist refers to a region where the cell partition wall 53 constituting the first cell 51 and the hollow columnar (cylindrical) space surrounded by the cell partition wall 53 do not exist.

In the first reinforcing material 50, the cell region 55 exists in a region corresponding to the polarizing region 11 in the polarizer 10, and the non-cell region 56 exists in a region corresponding to the non-polarizing region 12 of the polarizer 10. Here, the cell region 55 exists in a region corresponding to the polarizing region 11, which means that the cell region 55 and the polarizing region 11 are substantially the same shape and size in the top view direction. Similarly, the non-cell region 56 exists in a region corresponding to the non-polarizing region 12, which means that the non-cell region 56 and the non-polarizing region 12 are substantially the same shape and size (diameter) at substantially the same position in the top view direction. In other words, when the non-cell region 56 is projected onto the polarizer 10 in the top view direction, the projection area of the non-cell region 56 is roughly consistent with the non-polarizing region 12 in the polarizer 10. By means of the manufacturing method of the polarizer composite described later, a polarizer composite in which the cell region 55 exists in the region corresponding to the polarizing region 11 can be efficiently manufactured. When the polarizer 10 contained in the polarizer composite 40 has two or more non-polarizing regions 12, if the non-cell region 56 exists in at least one region corresponding to the non-polarizing region 12, the cell region 55 may also exist in other regions corresponding to the non-polarizing region 12.

The second reinforcing material 60 of the polarizer composite 40 is an example as shown in FIG. 1( c ), and has a plurality of second cells 61 with open end faces, and each open end face is arranged in a manner opposite to the surface of the polarizer 10. The second reinforcing material 60 has a hollow columnar (tubular) structure surrounded by a cell partition wall 63 that divides the second cell 61, similarly to the first cell 51, and both ends of the columnar structure in the axial direction are opened to form open end faces. The second reinforcing material 60 is different from the first reinforcing material 50 in that the second cell 61 also exists in the area corresponding to the non-polarizing area 12 (the portion indicated by the wavy line in FIG. 1( c )). The second reinforcement material 60 preferably has a second cavity 61 in both the polarizing region 11 and the non-polarizing region 12, and more preferably, the second cavity 61 exists on the entire surface of the polarizer 10.

The non-polarizing area 12 of the polarizer 10 and the non-cell area 56 of the first reinforcement 50 contain a hardened material of an active energy ray hardening resin (hereinafter, also referred to as "hardening resin (X)"). The non-polarizing area 12 is an area where a hardened material of hardening resin (X) is provided in the through hole 22 surrounded by the polarizing area 11 when viewed from above. The non-cell area 56 is an area where a hardened material of hardening resin (X) is provided in the through hole 52, and the through hole 52 is provided in a manner that the entire or a part of the plurality of first cells 51 is missing and is provided in an area corresponding to the through hole 22. The through hole 22 of the polarizer 10 and the through hole 52 of the first reinforcement 50 can be provided to have the same shape when viewed from above. The through hole 22 and the through hole 52 can be arranged to be connected in the thickness direction of the polarization region 11, and a hardened material of the curable resin (X) can be continuously arranged in the above-mentioned connected through holes 22 and 52.

The polarizer 10 of the polarizer composite 40 has a non-polarizing area 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, such as a smart phone or a tablet terminal, the camera lens, a printed part of an icon or a logo, etc., is arranged in a manner corresponding to the non-polarizing area 12, so that the reduction in camera sensitivity and the reduction in design can be suppressed.

In the polarizer composite 40, it is believed that since the polarizer 10 contains the non-polarizing area 12, cracks are easily generated around the non-polarizing area 12 due to the contraction of the polarizer 10, and the contraction of the polarizer 10 is accompanied by temperature changes when applied to a display device. In addition, it is believed that since the thickness of the polarizing area 11 of the polarizer 10 is as thin as 15μm or less, cracks are easily generated when impacted. In the polarizer composite 40, it is believed that since the first reinforcing material 50 and the second reinforcing material 60 are respectively provided on both sides of the polarizer 10 as described above, the generation of cracks due to temperature changes or impacts, or the deterioration of small cracks into large cracks, can be suppressed.

In the polarizer composite 40, by making the non-polarizing region 12 and the non-cell region 56 contain a hardened material of a hardening resin (X), the through hole 22 of the polarizer 10 and the through hole 52 of the first reinforcing material 50 can be made solid. Since the polarizer 10 of the polarizer composite 40 is as thin as 15 μm or less, if the hardened material of a hardening resin (X) is not provided in the non-polarizing region 12 and the through hole 22 is made hollow, there is a risk of cracks and other undesirable conditions around the through hole 22 due to the shrinkage of the polarizer caused by the temperature change when it is used in a display device. In contrast, as in the polarizer 10 of the polarizer composite 40, by providing a hardened material of a hardening resin (X) in the through holes 22 and the through holes 52, the non-polarizing area 12 and the non-cell area 56 can be made solid, thereby suppressing the occurrence of the above-mentioned adverse conditions.

The thickness of the hardened material of the hardening resin (X) disposed in the polarizer composite 40 may be the same as the total thickness of the thickness of the polarizing region 11 and the thickness of the cell region 55 (FIG. 1(a)), may be less than the total thickness (FIG. 2(a)), or may be greater than the total thickness (FIG. 2(b)). The hardened material of the hardening resin (X) disposed in the polarizer composite 40 may be disposed to fill at least a portion of the through hole 22 of the polarizer 10 and at least a portion of the through hole 52 of the first reinforcing material 50. The cured product of the curable resin (X) is preferably configured to fill the entire through hole 22 of the polarizer 10, and more preferably configured to fill the entire through hole 22 of the polarizer 10 and the entire through hole 52 of the first reinforcing material 50.

The thickness of the hardened material disposed 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 on the opposite side of the first reinforcing material 50 side) and a second plane including the opening end surface of the cell region 55 of the first reinforcing material 50 (the opening end surface on the opposite side of the polarizer 10 side) are assumed. Next, in the non-polarizing region 12, a first position and a second position are determined, the first position being the position where the shortest distance between the hardened material surface on the polarizer 10 side and the first plane is the largest, and the second position being the position where the shortest distance between the hardened material surface on the first reinforcing material 50 side and the second plane is the largest. Then, the shortest distance at the first position (dm), the shortest distance at the second position (dn), and the total value (dm+dn+D) of the distance between the first plane and the second plane (D) is taken as the thickness of the hardened material set on the polarizer composite 40.

The method for determining the thickness of the hardened material disposed in the non-polarizing area 12 and the non-cell area 56 is specifically described with reference to FIG3 when the thickness is different from the total thickness of the polarizing area 11 and the cell area 55. FIG3(a) and FIG3(b) are diagrams schematically showing an example of a cross section of the non-polarizing area and the non-cell area periphery of the polarizer composite, and are explanatory diagrams for explaining the method for determining the thickness of the hardened material disposed in the non-polarizing area and the non-cell area.

When a hardened material is provided in the non-polarizing area 12 and the non-cell area 56 as shown in FIG3(a), a straight line from the surface of the first reinforcing material 50 opposite to the polarizer 10 to the non-cell area 56 is assumed to be a first plane 11m. Among the straight lines connecting "an arbitrary point on the first plane 11m" and "an arbitrary point on the surface of the hardened material provided in the non-cell area 56" with the shortest distance, the position where the length of the straight line ("dm" in FIG3(a)) becomes the maximum is taken as the first position. Next, as shown in FIG3(a), a straight line indicated by a dotted line from the surface of the polarizer 10 opposite to the first reinforcing material 50 to the non-polarizing area 12 is assumed to be a second plane 11n. Among the straight lines connecting "any point on the second plane 11n" and "any point on the surface of the hardened material disposed in the non-polarizing area 12" with the shortest distance, the position where the length of the straight line ("dn" in FIG. 3(a)) becomes the maximum is set as the second position. Here, as shown in FIG. 3(a), in the thickness direction of the polarizer composite 40, when the surface of the hardened material disposed in the non-polarizing area 12 and the non-cell area 56 exists closer to the inner side (polarizer 10 and first reinforcing material 50 side) than the first plane 11m and the second plane 11n, dm and dn are negative values. In addition, the distance between the first plane 11m and the second plane 11n is set as D. In this way, the thickness of the hardened material disposed in the non-polarizing area 12 and the non-cell area 56 shown in FIG3(a) can be determined as D+dm+dn (dm and dn are negative values).

When a hardened material is provided in the non-polarizing region 12 and the non-cell region 56 as shown in FIG3(b), the thickness of the hardened material provided in the non-polarizing 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 connecting "an arbitrary point on the first plane 11m" and "an arbitrary point on the surface of the hardened material provided on the first reinforcing material 50" with the shortest distance, the position where the length of the straight line ("dm" in FIG3(b)) becomes the maximum is set as the first position. Next, among the straight lines connecting "any point on the second plane 11n" and "any point on the surface of the hardened material disposed in the non-polarizing region 12" with the shortest distance, the position where the length of the straight line ("dn" in FIG. 3(b)) becomes the maximum is set as the second position. Here, as shown in FIG. 3(b), in the thickness direction of the polarizer composite 40, when the surface of the hardened material disposed in the non-polarizing region 12 and the non-cell region 56 exists on the outer side (the opposite side of the polarizer 10 and the first reinforcing material 50) than the first plane 11m and the second plane 11n, dm and dn are positive values. In this way, the thickness of the hardened material disposed in the non-polarizing area 12 and the non-cell area 56 shown in FIG3(b) can be determined as D+dm+dn (dm and dn are positive values).

For the polarizer composite 40 shown in FIG. 2(a), the second reinforcing material 60 can enter the through hole 22 of the polarizer 10 and be arranged on the cured product of the curable resin (X) in the through hole 22. For the polarizer composite 40 shown in FIG. 2(b), the second reinforcing material 60 can be arranged on the surface of the cured product of the curable resin (X) that is arranged to protrude from the through hole 22 of the polarizer 10.

As for the first reinforcing material 50 and the second reinforcing material 60 of the polarizer composite 40, the first cell 51 and the second cell 61 of the first reinforcing material 50 and the second reinforcing material 60 can be of the same shape and size, or at least one of the shape and size can be different from each other. The opening of the first cell 51 of the first reinforcing material 50 and the opening of the second cell 61 of the second reinforcing material 60 provided in the polarizer 10 can be arranged to overlap each other when viewed from above, but preferably arranged to be staggered.

The polarizer composite 40 is applied to a display device or the like in a state of having 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, there is a possibility that the visibility of the display device is reduced due to the difference in refractive index between the cell partition wall 53 and the internal space of the first cell 51, and the difference in refractive index between the cell partition wall 63 and the internal space of the second cell 61. Therefore, it is preferred to provide a light-transmitting filler in the internal space of the first cell 51 of the first reinforcing material 50 and the internal space of the second cell 61 of the second reinforcing material 60 in the polarizer composite 40. As for the first reinforcing material 50 and the second reinforcing material 60 of the polarizer composite 40, when a gap is provided between a plurality of first cells 51 or a plurality of second cells 61 as described later, it is preferred that a light-transmitting filler is also provided in the gap.

In this manual, light transmittance refers to the property (transmittance) of transmitting more than 80% of visible light in the wavelength range of 400nm to 700nm, preferably more than 85%, more preferably more than 90%, and more preferably more than 92%. The following definition of "light transmittance" and the preferred range of visible light transmittance are the same as above.

The polarizer composite 40 may be a sheet-shaped body, or a long body having a length that can be rolled into a roll during storage or transportation. The plane shape and size of the polarizer composite 40 are not particularly limited.

(Polarized area)

The polarizing region 11 of the polarizer 10 preferably exhibits absorption dichroism at wavelengths ranging from 380 nm to 780 nm. The polarizer 10 has the property of absorbing linear polarization with a vibration plane parallel to its absorption axis and transmitting linear polarization with a vibration plane orthogonal to the absorption axis (parallel to the transmission axis), and this property can be mainly obtained by the polarizing region 11.

The polarizing region 11 may be formed by, for example: adsorption/alignment of dichroic substances such as iodine or dichroic dyes on hydrophilic polymer films such as polyvinyl alcohol films, partially formalized polyvinyl alcohol films, and partially saponified films of ethylene/vinyl acetate copolymers; adsorption/alignment of dichroic substances on dehydrated polyvinyl alcohol or dehydrogenated polyvinyl chloride, polyolefin alignment films, or aligned liquid crystal compounds. Among them, the one obtained by dyeing the polyvinyl alcohol film with iodine and uniaxially stretching is preferred in terms of excellent optical properties.

First, the manufacturing method of the polyvinyl alcohol film obtained by dyeing it with iodine and uniaxially stretching it, which will become the preferred polarization region 11, is briefly described.

Dyeing with iodine can be performed, for example, by immersing the polyvinyl alcohol film in an iodine aqueous solution. The stretching ratio of the uniaxial stretching is preferably 3 to 7 times. The stretching can be performed after the dyeing treatment, or while dyeing. In addition, the dyeing can also be performed after stretching.

The polyvinyl alcohol film can be subjected to swelling treatment, crosslinking treatment, cleaning treatment, drying treatment, etc. as needed. For example, by immersing the polyvinyl alcohol film in water and washing it before dyeing, not only can the dirt or anti-caking agent on the surface of the polyvinyl alcohol film be washed away, but the polyvinyl alcohol film can also be swollen to prevent uneven dyeing.

The stretching treatment, dyeing treatment, crosslinking treatment (boric acid treatment), water washing treatment, and drying treatment of the polyvinyl alcohol resin film can be performed, for example, according to the method described in Japanese Patent Publication No. 2012-159778. In the method described in the document, a polyvinyl alcohol resin layer that will become the polarizing area 11 is formed by applying a polyvinyl alcohol resin to a substrate film. At this time, the substrate film used can also be used as the first support layer 25 described later.

Next, the polarization region 11 formed by adsorption/alignment of dichroic dyes on the aligned liquid crystal compound is briefly described. In this case, the polarization region 11 may be, for example, a dichroic dye aligned in a cured film formed by polymerization of a liquid crystal compound as described in Japanese Patent Publication No. 2013-37353, Japanese Patent Publication No. 2013-33249, Japanese Patent Publication No. 2016-170368, Japanese Patent Publication No. 2017-83843, etc. The dichroic dye may be one that has absorption in the wavelength range of 380 to 800 nm, preferably an organic dye. Examples of dichroic dyes include azo compounds. The liquid crystal compound is a liquid crystal compound that can be polymerized in an aligned state and may have a polymerizable group in the molecule. The cured film formed by the polymerization of the liquid crystal compound can be formed on the substrate film. In this case, the substrate film can also be used as the first supporting layer 25 described later.

After the polarizing film used in the polarizing area 11 is made as described above, it is preferred to form the non-polarizing area 12 by perforation to form the polarizer 10. In this specification, the polarizing film formed only by the polarizing area 11 is sometimes referred to as the raw polarizer 20.

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

The single body transmittance (Ts) is measured according to the 2-degree field of view (C light source) of JIS Z8701 and the Y value obtained by performing sensitivity correction. The sensitivity-corrected polarization degree (Py) can be measured, for example, using an ultraviolet-visible spectrophotometer (manufactured by JASCO Corporation, product name: V7100). It can be obtained by the following formula based on the parallel transmittance Tp and orthogonal transmittance Tc after sensitivity correction.

Py[%]={(Tp-Tc)/(Tp+Tc)} ^1/2 ×100

The thickness of the polarizing region 11 is less than 15 μm, less than 13 μm, less than 10 μm, less than 8 μm, less than 5 μm, and usually more than 1 μm. If the thickness of the polarizing region 11 exceeds the above range, the workability of the hardened material of the active energy ray hardening resin (X) containing the hardening resin (X) described later, which is used to set the non-polarizing region 12, is easily reduced. In addition, when the polarizing region 11 does not reach the above range, it will be difficult to obtain the desired optical properties. The thickness of the polarizing region 11 can be measured using, for example, a contact film thickness measuring device (MS-5C, manufactured by Nikon Co., Ltd.).

(Non-polarized area)

Generally speaking, "non-polarized light" refers to light with irregularities that can be observed in the electric field component. In other words, non-polarized light is irregular light in which a specific polarization state that is dominant cannot be observed. In addition, "partially polarized light" refers to light in an intermediate state between polarized light and non-polarized light, and refers to light mixed with non-polarized light and at least one of linear polarized light, circular polarized light, and elliptical polarized light. The non-polarized area 12 of the polarizer 10 means that the light (transmitted light) that transmits the non-polarized area 12 becomes non-polarized light or partially polarized light. It is particularly preferred that the transmitted light is a non-polarized area.

The non-polarizing area 12 of the polarizer 10 is an area surrounded by the polarizing area 11 when viewed from above. The non-polarizing area 12 contains a cured product of a curable resin (X). The non-polarizing area 12 is preferably a cured product of an active energy ray-curable resin composition containing a curable resin (X) described later, which is provided in a through hole provided in a polarizer (raw material polarizer 20) formed only by the polarizing area 11. The non-polarizing area 12 is light-transmissive.

By making the non-polarizing area 12 of the polarizer 10 light-transmissive, the optical transparency in the non-polarizing area 12 can be ensured. Thus, when the polarizer composite 40 is applied to a display device, a camera lens, a printed part of an icon or logo, etc. can be arranged corresponding to the non-polarizing area 12, thereby suppressing the reduction of the camera sensitivity or the reduction of the design.

The planar shape of the non-polarizing area 12 is not particularly limited, but can be set to a circle; an ellipse; an oval; a polygon such as a triangle or a quadrangle; a rounded polygon in which at least one corner of the polygon is rounded (having an R shape), etc.

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

The thickness of the hardened material of the hardening resin (X) disposed in the non-polarizing area 12 may be the same as the thickness of the polarizing area 11, may be less than the thickness of the polarizing area 11, or may be greater than the thickness of the polarizing area 11. As described above, the hardened material of the hardening resin (X) disposed in the non-polarizing area 12 is preferably disposed to fill the entire through hole 22.

The thickness of the hardened material disposed in the non-polarizing area 12 can be measured according to the above-described method for measuring the thickness of the hardened material disposed in the polarizer composite 40. Specifically, in the above-described measuring method, the first plane is set as the surface of the polarizing area 11 of the polarizer 10 (the surface on the first reinforcing material 50 side), and the thickness of the hardened material of the curable resin (X) is determined.

(Cellular area of the first reinforcement material)

The cell region 55 is a region of the first reinforcement material 50 where the first cell 51 exists. The first cell 51 has a hollow columnar (tube-shaped) structure surrounded by a cell partition wall 53 that divides the first cell 51 as shown in FIG1(b), and both ends of the columnar structure in the axial direction are open to form open end faces. The first cell 51 has a first open end face arranged on the near side relative to the distance of the polarizer 10 of the polarizer composite 40, and a second open end face arranged on the far side relative to the distance as open end faces. The cell region 55 can be arranged in a manner that at least one of the first open end face and the second open end face is arranged in a manner that is opposite to the polarizer 10, and preferably, both the first open end face and the second open end face are arranged in a manner that is opposite to the polarizer 10.

The opening shape of the first cell cavity 51 of the cell cavity region 55 is not particularly limited, but preferably a polygon, a circle, or an ellipse. The opening shape of the first opening end face and the opening shape of the second opening end face are preferably the same shape with the same size, but may be different shapes, or the same shape with different sizes. In addition, the opening shapes of the plurality of first cell cavities 51 of the cell cavity region 55 may be the same or different from each other.

The plurality of first cells 51 of the cell region 55 are preferably arranged in a manner that the openings of the first cells 51 are adjacent to each other when viewed from above the opening end surface. When viewed from above the opening end surface, the plurality of first cells 51 can be arranged in a manner that the first cells 51 are arranged without gaps, such as when the opening shape of the first cell 51 is hexagonal, etc. as shown in FIG. 1(b). Alternatively, when viewed from above the opening end surface, the plurality of first cells 51 can be arranged in a manner that a portion of the cell partition walls 53 of the plurality of first cells 51 are connected and there are gaps between the plurality of first cells 51, such as when the opening shape of the first cell 51 is circular, etc.

Preferably, the cell region 55 of the first reinforcing material 50 is, for example, as shown in FIG1(b), the opening shape at either the first opening end face or the second opening end face is a hexagon, and in the plane direction of the polarizer composite 40, it has a honeycomb structure in which a plurality of first cells 51 are arranged in a manner such that the openings are adjacent to each other without gaps.

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

The height of the first cell cavity 51 (the length in the direction perpendicular to the opening end surface of the first cell cavity 51) is usually greater than 0.1μm, can be greater than 0.5μm, can be greater than 1μm, can also be greater than 3μm, and is usually less than 15μm, can be less than 13μm, and can also be less than 10μm.

The cell wall 53 of the cell region 55 that divides the first cell 51 is preferably light-transmissive.

The line width of the cell wall 53 of the cell region 55 is, for example, greater than 0.05 mm, greater than 0.1 mm, greater than 0.5 mm, or greater than 1 mm, and is usually less than 5 mm, or less than 3 mm.

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

(Non-cell area of the first reinforcement)

The non-cell region 56 is a region of the first reinforcing material 50 where the first cell 51 does not exist. As described above, it is a region where the cell partition wall 53 constituting the first cell 51 and the hollow columnar (tube-shaped) space surrounded by the cell partition wall 53 do not exist. The non-cell region 56 has a through hole 52, which is provided in a manner that the entirety or a portion of the plurality of first cells 51 is missing and is provided in a region corresponding to the through hole 22 of the polarizer 10. The non-cell region 56 may contain a hardened material of a hardening resin (X) in the through hole 52.

The planar shape and diameter of the non-cell region 56 are not particularly limited, and the shape and diameter exemplified as the planar shape of the non-polarizing region 12 can be used. The planar shape and diameter of the non-cell region 56 are preferably the same as the planar shape and diameter of the non-polarizing region 12.

(Second reinforcement material)

The second cell 61 of the second reinforcement 60 is as shown in FIG1(c), and has a hollow columnar (tubular) structure surrounded by a cell partition wall 63 that divides the second cell 61, and the two axial ends of the columnar structure are opened to form open end faces. The second cell 61 has a 1' open end face arranged on the near side of the polarizer 10 of the polarizer composite 40, and a 2' open end face arranged on the far side as the open end faces. The second reinforcement 60 can be arranged in a manner that at least one of the 1' open end face and the 2' open end face is arranged in a manner that is opposite to the polarizer 10, and preferably, both the 1' open end face and the 2' open end face are arranged in a manner that is opposite to the polarizer 10.

The opening shape of the second cell 61 of the second reinforcement 60 can be cited as an example of the opening shape of the first cell 51. The opening shape of the 1st opening end face and the opening shape of the 2nd opening end face are preferably the same shape with the same size, but they can also be different shapes, or the same shape with different sizes. In addition, the opening shapes of the plurality of second cells 61 can be the same or different from each other.

The plurality of second cells 61 of the second reinforcement material 60 are preferably arranged in a manner that the openings of the second cells 61 are adjacent to each other when viewed from above the opening end surface. When viewed from above the opening end surface, the plurality of second cells 61 may be arranged in a manner that the second cells 61 are arranged without gaps, such as when the opening shape of the second cell 61 is hexagonal, etc. as shown in FIG. 1(c). Alternatively, when viewed from above the opening end surface, the plurality of second cells 61 may be arranged in a manner that a portion of the cell partition walls 63 of the plurality of second cells 61 are connected and there are gaps between the plurality of second cells 61, such as when the opening shape of the second cell 61 is circular, etc.

The second reinforcing material 60 is preferably, for example, as shown in FIG1(c), the opening shape of either the 1st opening end face or the 2nd opening end face is a hexagon, and in the surface direction of the polarizer composite 40, it has a honeycomb structure in which a plurality of second cells 61 are arranged in a manner such that the openings are adjacent to each other without gaps.

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

(Active energy ray-hardening resin composition (hardening resin composition))

As described above, the non-polarizing area 12 and the non-cell area 56 in the polarizer composite 40 are areas where a hardened material of an active energy ray-hardening resin (hardening resin (X)) is provided, and are preferably formed by an active energy ray-hardening resin composition (hereinafter, also referred to as a "hardening resin composition") containing the hardening resin (X). The hardening resin (X) contained in the hardening resin composition is hardened by irradiation with active energy rays such as ultraviolet rays, visible light, electron rays, and X-rays. The hardening resin (X) is preferably an ultraviolet-hardening resin that is hardened 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 preferably an ultraviolet ray curable adhesive.

The curable resin composition is preferably a solvent-free type. The so-called solvent-free type means that no solvent is actively added. Specifically, the so-called solvent-free curable resin composition means that the solvent content is less than 5% by weight 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. The so-called epoxy compound refers to a compound having one or more (preferably two or more) epoxy groups in the molecule. Examples of epoxy compounds include alicyclic epoxy compounds, aliphatic epoxy compounds, and hydrogenated epoxy compounds (glycidyl ethers of polyols having alicyclic rings). The epoxy compound contained in the curable resin (X) may be one or more.

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 relative to 100% by weight of the curable resin (X), 90% by weight or less, 80% by weight or less, or 75% by weight or less.

The epoxy equivalent of the epoxy compound is usually 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 be reduced.

The epoxy compound contained in the curable resin (X) is preferably 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. The so-called "epoxy group bonded to an alicyclic ring" means the bridging oxygen atom -O- in the structure shown in the following formula. In the following formula, m is an integer from 2 to 5.

In the above formula, a compound in which one or more hydrogen atoms in (CH ₂ ) _m are removed and bonded to other chemical structures can become an alicyclic epoxy compound. One or more hydrogen atoms in (CH ₂ ) _m can also be appropriately substituted by a linear alkyl group such as a methyl group or an ethyl group. Among the alicyclic epoxy compounds, an epoxy compound having an oxy-doped biscyclohexane ring (where m=3 in the above formula) or an oxy-doped biscycloheptane ring (where m=4 in the above formula) is preferably used because it can provide excellent adhesion between the polarizing region 11 of the polarizer 10 and the cell region 55 of the first reinforcement 50, and the cured product of the curable resin (X) forming the non-polarizing region 12 and the non-cell region 56. Specific examples of alicyclic epoxy compounds that can be preferably used are shown below, but the invention is not limited to these compounds.

[a] Epoxycyclohexanecarboxylic acid epoxycyclohexylmethyl esters represented by the following formula (IV):

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

[b] Epoxycyclohexane carboxylic acid esters of alkanediol represented by the following formula (V):

[In formula (V), R ¹⁰ and R ¹¹ 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].

[c] Epoxycyclohexylmethyl esters of dicarboxylic acids represented by the following formula (VI):

[In formula (VI), R ¹² and R ¹³ 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].

[d] Epoxycyclohexyl methyl ethers of polyethylene glycol represented by the following formula (VII):

[In formula (VII), R ¹⁴ and R ¹⁵ 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].

[e] Epoxycyclohexyl methyl ethers of alkanediols represented by the following formula (VIII):

[In formula (VIII), R ¹⁶ and R ¹⁷ 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].

[f] A diepoxy trispiro compound represented by the following formula (IX):

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

[g] A diepoxy monospiro compound represented by the following formula (X):

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

[h] Vinylcyclohexene diene oxides 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].

[i] Epoxycyclopentyl ethers represented by the following formula (XII):

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

[j] Bicyclic oxytricyclic decanes 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].

Aliphatic epoxy compounds include polyglycidyl ethers of aliphatic polyols or their alkylene oxide adducts. More specifically, examples include: diglycidyl ether of 1,4-butanediol; diglycidyl ether of 1,6-hexanediol; triglycidyl ether of glycerol; triglycidyl ether of trihydroxymethylpropane; diglycidyl ether of polyethylene glycol; diglycidyl ether of propylene glycol; polyglycidyl ether of polyether polyols obtained by adding one or more alkylene oxides (ethylene oxide or propylene oxide) to aliphatic polyols such as ethylene glycol, propylene glycol or glycerol, etc.

Hydrogenated epoxy compounds are obtained by reacting alicyclic polyols obtained by hydrogenating aromatic rings of aromatic polyols with epichlorohydrin. Examples of aromatic polyols include bisphenol-type compounds such as bisphenol A, bisphenol F, and bisphenol S; phenolic novolac resins such as phenol novolac resins, cresol novolac resins, and hydroxybenzaldehyde phenol novolac resins; and polyfunctional compounds such as tetrahydroxydiphenylmethane, tetrahydroxydiphenyl ketone, and polyvinylphenol. Preferred examples of hydrogenated epoxy compounds include diglycidyl ether of hydrogenated bisphenol A.

The curable resin (X) may also contain (meth) acrylic compounds and the like while containing active energy ray curable compounds such as epoxy compounds. By using (meth) acrylic compounds together, it is expected that the adhesion between the polarizing region 11 of the polarizer 10 and the cell region 55 of the first reinforcement 50 and the cured product of the curable resin (X) forming the non-polarizing region 12 and the non-cell region 56, the hardness and mechanical strength of the cured product of the curable resin (X) can be improved, and the viscosity and curing speed of the curable resin (X) can be adjusted more easily. "(Meth) acrylic acid" means at least one selected from the group consisting of acrylic acid and methacrylic acid.

The curable resin composition containing the curable resin (X) preferably contains a polymerization initiator. The polymerization initiator may be, for example, a cationic polymerization initiator such as a photo-cationic polymerization initiator or a free radical polymerization initiator. The photo-cationic polymerization initiator is a polymer that generates cationic species or Lewis acid by irradiation with active energy rays such as visible light, ultraviolet rays, X-rays, electron rays, etc., and initiates the polymerization reaction of the epoxy group. As described above, the curable resin (X) is preferably a UV-curable resin that is cured by irradiation with ultraviolet rays. Since the curable resin (X) preferably contains an alicyclic epoxy compound, the polymerization initiator in this case is preferably a resin that generates cationic species or Lewis acid by irradiation with ultraviolet rays.

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

(Filling material)

The filler material that can be provided in the first reinforcement material 50 and the second reinforcement material 60 is not particularly limited as long as it is light-transmissive and can fill the internal space of the first cell cavity 51 of the first reinforcement material 50 and the internal space of the second cell cavity 61 of the second reinforcement material 60. The filler material is preferably a material different from the material constituting the cell cavity partition wall 53 of the first reinforcement material 50 and the cell cavity partition wall 63 of the second reinforcement material 60, and more preferably contains a resin material. The resin material can be, for example, one or more selected from the group consisting of a thermoplastic resin, a thermosetting resin, or an active energy ray-curing resin, and can also be an adhesive (pressure-sensitive adhesive) or a bonding agent.

Examples of thermoplastic resins include: polyolefin resins such as chain polyolefin resins (such as polypropylene resins) and cyclic polyolefin resins (such as norbornene resins); cellulose ester resins such as cellulose triacetate and cellulose diacetate; 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; fluorine resins, etc.

The hardening resin may be, for example, the hardening resin (X) mentioned above.

Adhesives are those that exhibit adhesion by attaching themselves to the adherend, that is, so-called pressure-sensitive adhesives. Adhesives may contain, for example, (meth)acrylic polymers, polysilicone polymers, polyester polymers, polyurethane polymers, polyether polymers, or rubber polymers as main components. In this specification, the so-called main component refers to a component that contains 50% by mass or more of the total solid content of the adhesive. Adhesives can be active energy ray-curing type or heat-curing type, and the degree of crosslinking or adhesion can be adjusted by active energy ray irradiation or heating.

Adhesives are adhesives other than pressure-sensitive adhesives (adhesives) that contain a curable resin component. Examples of adhesives include water-based adhesives made by dissolving or dispersing a curable resin component in water, active energy ray-curable adhesives containing active energy ray-curable compounds, and thermosetting adhesives.

Adhesives may also use water-based adhesives commonly used in the technical field of polarizing plates. Examples of resin components contained in water-based adhesives include polyvinyl alcohol resins and amine resins. Examples of active energy ray-curable adhesives include compositions that are cured by irradiation with active energy rays such as ultraviolet rays, visible light, electron rays, and X-rays. Active energy ray-curable adhesives may also use the above-mentioned curable resin composition containing the curable resin (X). Examples of thermosetting adhesives include those containing epoxy resins, silicone resins, phenolic resins, melamine resins, etc. as main components.

(Manufacturing method of polarizer composite)

FIG. 4 and FIG. 5 are schematic cross-sectional views schematically showing an example of a method for manufacturing a polarizer composite 40 (FIG. 1(a)). Although FIG. 4 and FIG. 5 show the situation in which the polarizer composite 40 shown in FIG. 1(a) is manufactured, the polarizer composite 40 shown in FIG. 2(a) and FIG. 2(b) can also be manufactured by the method described below. The polarizer composite 40 can be manufactured, for example, using "a structure 58 for forming a reinforcing material (hereinafter, sometimes referred to as "structure 58") formed on one side of a raw material polarizer 20 having the same visual sensitivity correction polarization (Py) as a whole and having no non-polarizing area 12, which is composed of only a cell region 55 and does not have a non-cell region 56." Since the raw polarizer 20 is formed only by the polarization region 11 of the polarizer 10, the thickness of the raw polarizer 20 is preferably the same thickness as the polarization region 11 of the polarizer 10, that is, less than 15μm. Since the structure 58 will become the cell region 55 of the first reinforcing material 50, it is preferably 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 steps. First, as shown in FIG4(a), a first support layer 25 is provided on one side of the raw polarizer 20 in a manner that is removable 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 manufactured, for example, by using a resin material or an inorganic oxide to form a cell wall 53 that divides the first cell 51 on the surface of the raw polarizer 20.

The method of using the resin material to form the cell cavity wall 53 is not particularly limited, and examples thereof include: printing methods such as inkjet printing, screen printing, and gravure printing; photoetching methods; coating methods using a nozzle or a mold, etc. In the above methods, a resin composition formed by mixing the resin material with a solvent, an additive, etc. can also be used. Additives can include: leveling agents, antioxidants, plasticizers, thickeners, organic or inorganic fillers, pigments, anti-aging agents, ultraviolet absorbers, antioxidants, etc. The cell cavity wall 53 can also be formed by curing or hardening the printed or coated resin composition as needed.

The method of using inorganic oxide to form the cell wall 53 is not particularly limited, and it can be formed by evaporating inorganic oxide, for example.

The prepared first laminate 31 is formed with a through hole 32 penetrating in the lamination direction by punching, cutting, cutting, or laser cutting (Fig. 4(b)). Thus, on the first support layer 25 formed with the through hole, a "polarizer 21 with an opening formed with a through hole 22 formed on the raw polarizer 20" and a "structure 59 with an opening formed with a through hole 52 formed on the structure 58" are formed. Next, after the second support layer 26 is disposed in a removable manner on the side of the structure 59 with an opening of the first laminate 31 with the through hole 32 formed (Fig. 4(c)), the first support layer 25 is peeled off (Fig. 4(d)). Thus, a second laminate 33 is obtained, which is sequentially laminated with a second support layer 26, a structure 59 with openings, and a polarizer 21 with openings (Fig. 4(d)). The second support layer 26 is provided in a manner to seal one side of the through hole 52 of the structure 59 with openings.

Next, a hardening resin composition containing a hardening resin (X) is filled in the through hole 22 of the polarizer 21 with an opening and the through hole 52 of the structure 59 with an opening of the second laminate 33, and the hardening resin (X) in the through hole 22, 52 is hardened by irradiating the active energy line. Thus, a hardened material of the hardening resin (X) is formed in the through hole 22 of the polarizer 21 with an opening and the through hole 52 of the structure 59 with an opening, and the first reinforcing material 50 and the polarizer 10 are formed on the second support layer 26 (FIG. 5(a)). The polarizer 10 shown in FIG5(a) is a polarizer 21 with an opening, and the area other than the through hole 22 becomes the polarization area 11, and the area with the through hole 22 provided with a hardened material becomes the non-polarization area 12. The first reinforcing material 50 shown in FIG5(a) is provided on one side of the polarizer 10, and the area other than the through hole 52 of the structure 59 with an opening becomes the cell area 55, and the area with the through hole 52 provided with a hardened material becomes the non-cell area 56.

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

The method of filling the through hole 22 of the polarizer 21 with openings and the through hole 52 of the structure 59 with openings with the curable resin composition is not particularly limited. For example, the curable resin composition may be injected into the through holes 22 and 52 of the second laminate 33 using a dispenser or a distributor, or the curable resin composition may be applied to the surface of the polarizer 21 with openings of the second laminate 33 while filling the through holes 22 and 52 with the curable resin composition. The cured layer of the curable resin composition applied to the surface of the polarizer 21 with openings may serve as a protective layer described later. When applying the curable resin composition, a base film can also be provided in a manner to cover the surface of the coating layer formed by the application. The base film can also be peeled off after the curable resin (X) is cured.

The first support layer 25 can be a support layer used in the manufacture of the raw polarizer 20 described later, or the above-mentioned base film used when applying the curable resin composition. Alternatively, it can be a removable support layer attached to the raw polarizer 20 by a volatile liquid such as water, or a removable adhesive sheet for the raw polarizer 20. The second support layer 26 can be a removable support layer attached to the polarizer 21 with an opening by a volatile liquid such as water, or a removable adhesive sheet for the polarizer 21 with an opening.

As described above, in the polarizer composite 40, by making the thickness of the raw polarizer 20 less than 15 μm, the depth of the through hole 22 provided in the polarizer 21 with an opening can also be made less than 15 μm. Since the height of the first cell 51 of the structure 59 with an opening is also usually less than 15 μm, the depth of the through hole 52 provided in the structure 59 with an opening can also be made less than 15 μm. In this way, the filling of the through hole 22 of the polarizer 21 with an opening and the through hole 52 of the structure 59 with an opening with the curable resin composition, and the curing treatment of the curable resin (X) contained in the curable resin composition filled in the through hole 22, 52 can be performed in a short time, so the reduction of workability can be suppressed.

In the manufacturing method of the polarizer composite 40, a through hole 32 is formed in the first laminate 31 having the structure 58, the raw polarizer 20, and the first support layer 25 in sequence. The raw polarizer 20 is formed to form a region that will become the non-polarizing region 12 of the polarizer 10, and its thickness is as thin as 15μm or less. Therefore, when the through hole 22 is formed in the raw polarizer 20, there is a risk of causing cracks around the through hole 22. In the manufacturing method of the polarizer composite 40, since the structure 58 is provided in the raw polarizer 20, the through hole 22 is formed in a state where the raw polarizer 20 is reinforced by the structure 58, so that the cracks in the polarizer 21 with the opening can be suppressed, and the polarizer 10 with suppressed cracks can be obtained.

(Raw polarizer)

The raw polarizer 20 is preferably one that is not easily deteriorated significantly by the active energy rays irradiated to cure the curable resin (X) in the curable resin composition filled in the through hole 22. Such a raw polarizer 20 is, for example, a film formed by adsorbing and aligning a dichroic pigment on a polyvinyl alcohol resin film, or a film formed by aligning a dichroic pigment in a curing layer of a polymerizable liquid crystal compound. The manufacturing method of these is as described in the above-mentioned polarization region 11.

(Structural body for forming reinforcement material (structural body))

The structure 58 is a structure composed only of the cell cavity region 55 and does not have the non-cell cavity region 56. The structure 58 can be obtained by using a resin material or an inorganic oxide to form a cell cavity wall 53 that divides the first cell cavity 51 as described above. The materials that can be used as the resin material and the inorganic oxide, and the method of forming the cell cavity wall 53 using the same, can be exemplified by the materials and methods exemplified above.

<Optical layered structure>

FIG6 is a schematic cross-sectional view schematically showing an example of an optical laminate of the present embodiment. The optical laminate 45 shown in FIG6 has protective layers 17 and 18 on both sides of the polarizer composite 40 shown in FIG1(a). The optical laminate 45 may also be one having 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 also be the polarizer composite 40 shown in FIG2(a) or (b). The protective layers 17 and 18 may be disposed on the polarizer composite 40 via a bonding layer such as an adhesive layer or a bonding agent layer. In this case, for example, a thin film-like protective layer can be laminated on the polarizer composite 40 via a laminating layer. The protective layers 17 and 18 can also be provided on the polarizer composite 40 in a directly connected manner without passing through a laminating 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 on the polarizer composite 40 and curing or hardening the coating layer.

When the optical laminate 45 is a structure in which the protective layers 18 and 17 are respectively disposed on the first reinforcing material 50 and the second reinforcing material 60 of the polarizer composite 40 via a bonding layer, it is preferred to form the protective layers 18 and 17 by disposing the bonding layer in a manner such that the internal space of the first cell 51 of the first reinforcing material 50, the gaps between the plurality of first cells 51, the internal space of the second cell 61 of the second reinforcing material 60, and the gaps between the plurality of second cells 61 are filled.

When the optical laminate 45 is a structure in which the protective layers 18 and 17 are respectively disposed on the first reinforcing material 50 and the second reinforcing material 60 of the polarizer composite 40 in a directly connected manner, it is preferred to form the protective layers 18 and 17 by disposing a composition containing a resin material constituting the protective layers 18 and 17 in a manner that fills the inner space of the first cell 51 of the first reinforcing material 50, the gaps between the plurality of first cells 51, the inner space of the second cell 61 of the second reinforcing material 60, and the gaps between the plurality of second cells 61.

In the optical laminate 45, the protective layers 18 and 17 may also be hardened layers of hardening resin (X) directly disposed on the first reinforcing material 50 and the second reinforcing material 60, respectively. The hardening resin (X) constituting the protective layers 18 and 17 belonging to the hardening layer may be a resin that can be hardened by irradiation with active energy rays such as ultraviolet rays, visible light, electron rays, and X-rays, and is not particularly limited, and may be, for example, the hardening resin (X) described above. The protective layers 18 and 17 may be hardening layers of a hardening resin composition containing the same hardening resin (X) as the hardening material contained in the non-polarizing region 12 and the non-cell region 56 constituting the polarizer 10.

In order to manufacture the optical laminate 45, for example, a curable resin composition is applied to the first reinforcing material 50 and the second reinforcing material 60 of the polarizer composite 40, and the curable resin (X) is cured by irradiating the active energy line. In this way, protective layers 18 and 17 belonging to the cured material layer of the curable resin (X) can be formed on the first reinforcing material 50 and the second reinforcing material 60, respectively, to obtain the optical laminate 45.

In the optical laminate 45 shown in FIG6 , one of the protective layers 17 and 18 can be set as a protective layer provided via a bonding layer, and the other can be set as a protective layer provided without a bonding layer. The protective layers 17 and 18 included in the optical laminate 45 can be the same as each other or different from each other.

When applying the curable resin composition, a base film can be provided to cover the surface of the coating layer formed by the application. In this case, the base film can also be used as the protective layer 17, 18, and the cured layer of the curable resin (X) can be used as a bonding layer for bonding the protective layers 17, 18. The base film can also be peeled off after the curable resin (X) is cured.

(Protective layer)

The protective layers 17 and 18 are preferably light-transmissive resin layers, resin films, or coating layers formed by coating a composition containing a resin material. The resin used in the resin layer is preferably a thermoplastic resin with excellent transparency, mechanical strength, thermal stability, moisture barrier, isotropy, and elongation. Thermoplastic resins can be, for example, thermoplastic resins that can be used to form a substrate film in the manufacture of the above-mentioned raw polarizer 20. When the optical laminate 45 has protective layers 17 and 18 on both sides, the resin compositions of the protective layers 17 and 18 can be the same or different from each other.

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

(bonding layer)

The bonding layer is an adhesive layer or a bonding agent layer. The adhesive used to form the adhesive layer and the bonding agent used to form the bonding agent layer can be, for example, the adhesive and bonding agent used to form the above-mentioned filler.

<Laminated body with bonding layer for optical display element>

The polarizer complex 40 shown in FIG. 1 and FIG. 2 and the optical laminate 45 shown in FIG. 6 may further have a bonding layer for an optical display element, and the bonding layer for an optical display element is used to bond 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 the bonding layer for optical display element is set on the surface of the first reinforcing material 50 or the second reinforcing material 60, the material constituting the bonding layer for optical display element can be used as the filler set on the first reinforcing material 50 or the second reinforcing material 60, and the filling material is filled in 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, and the bonding layer for optical display element is formed at the same time.

10: Polarizer

11: Polarization area

12: Non-polarized area

22: Perforation

40: Polarizer composite

50: First reinforcement material

51: First cell cavity

52: Perforation

53,63: cell wall

55:Cellular region

56: Non-luminal region

60: Second reinforcement material

61: Second cell cavity

Claims (13)

A polarizer composite comprises a polarizer, a first reinforcing material arranged on one side of the polarizer, and a second reinforcing material arranged on the other side of the polarizer, wherein the polarizer has a polarizing region with a thickness of less than 15 μm and a non-polarizing region surrounded by the polarizing region when viewed from above, the first reinforcing material has a plurality of first cells with open end faces, and each open end face is arranged in a manner opposite to the surface of the polarizer, the first reinforcing material has a cell region and a non-cell region, the cell region has the first cell and the cell region exists on the cell region opposite to the first cell. The area corresponding to the aforementioned polarizing area, the non-cell cavity area is the area where the aforementioned first cell cavity does not exist and the non-cell cavity area exists in the area corresponding to the aforementioned non-polarizing area, the aforementioned second reinforcing material has a plurality of second cells with open end faces, and each open end face is arranged in a manner opposite to the surface of the aforementioned polarizer, the aforementioned second cell cavity exists at least in the area corresponding to the aforementioned non-polarizing area, the aforementioned non-polarizing area and the aforementioned non-cell cavity area contain a hardened material of an active energy ray hardening resin, and the aforementioned hardened material contained in the aforementioned non-polarizing area is provided in a through hole surrounded by the aforementioned polarizing area when viewed from above. The polarizer composite as described in claim 1, wherein the thickness of the hardened material is the same as the sum of the thickness of the polarizing region and the thickness of the cell region. The polarizer composite as described in claim 1, wherein the thickness of the hardened material is less than the sum of the thickness of the polarizing region and the thickness of the cell region. The polarizer composite as described in claim 1, wherein the thickness of the hardened material is greater than the combined thickness of the thickness of the polarizing region and the thickness of the cell region. A polarizer composite as described in any one of claims 1 to 4, wherein the non-polarizing area is light-transmissive. A polarizer composite as described in any one of claims 1 to 4, wherein the diameter of the non-polarizing area when viewed from above is greater than 0.5 mm and less than 20 mm. A polarizer composite as described in any one of claims 1 to 4, wherein the active energy ray-curable resin contains an epoxy compound. The polarizer composite as described in claim 7, wherein the epoxy compound comprises an alicyclic epoxy compound. A polarizer composite as described in any one of claims 1 to 4, wherein the shapes of the openings of the aforementioned opening end faces of the aforementioned first cell cavity and the aforementioned second cell cavity are independently polygonal, circular, or elliptical. The polarizer composite as described in any one of claims 1 to 4 further has a light-transmitting filling material disposed in the internal space of the aforementioned first cell cavity. The polarizer composite as described in any one of claims 1 to 4 further has a light-transmitting filling material disposed in the inner space of the aforementioned second cell cavity. A polarizer composite as described in any one of claims 1 to 4, wherein the planar shape of the non-polarizing region is circular, elliptical, oval, polygonal, or rounded polygonal. An optical laminate having a protective layer on one or both sides of the polarizer composite described in any one of claims 1 to 12.

Images