Method for manufacturing a shaped body

Abstract

The present application provides a transfer medium laminate having a hard coat layer and a resin layer (A) provided on one surface of the hard coat layer, the hard coat layer having stretchability, and the resin constituting the resin layer having an energy storage modulus of 1000 MPa or less. The resin layer (A) preferably contains an ultraviolet absorber. The hard coat layer is preferably a semi-cured product of a hard coat material, and the resin layer (A) is preferably a layer formed on the surface of the semi-cured product. The present application also provides a polarizing film having the transfer medium laminate, a method for producing the same, and a method for producing a molded article using the polarizing film.

Description

TECHNICAL FIELD

[0001] The present application relates to a transfer medium laminate, a polarizing film, a method for manufacturing a polarizing film, and a method for manufacturing a molded body using a polarizing film. BACKGROUND

[0002] In display devices such as liquid crystal display devices and organic electroluminescent display devices, a film functioning as a linear polarizer is provided for various purposes. The linear polarizer is mostly a thin layer of material with weak mechanical strength, and thus is usually used in a state of a polarizing film having a polarizer and a protective film. For the purpose of improving scratch resistance of the surface of the display device and the like, the polarizing film is sometimes provided with a hard coat layer. The hard coat layer is mostly formed by applying a liquid-like hard coat layer material for forming a hard coat layer to the surface of a molded body that is a formation target and curing it. However, a laminate including a hard coat layer can also be formed on the surface of a member other than the formation target and transferred to the surface of the molded body (for example, Patent Documents 1 and 2).

[0003] PRIOR ART DOCUMENTS

[0004] PATENT DOCUMENTS

[0005] Patent Document 1: Japanese Patent Application Laid-Open (JP A) No. 2014-130298

[0006] Patent Document 2: International Publication No. 2019 / 087806 (corresponding publication: U.S. Patent Application Publication No. 2021 / 109268 specification). SUMMARY

[0007] PROBLEMS TO BE SOLVED BY THE INVENTION

[0008] In the past, the shape of the display surface of a display device was only a flat shape, but in recent years, there are also cases where the display surface is required to be a curved surface in a display device. If a hard coat layer can be transferred to such a curved surface, an improvement in manufacturing efficiency can be expected. In particular, if a polarizing film having a hard coat layer can be attached to simultaneously provide a polarizing film and a hard coat layer, further improvement in manufacturing efficiency can be expected.

[0009] However, if a film having a hard coat layer is to be attached to a curved surface, there is a problem that cracks are generated. Furthermore, a polarizing film having a hard coat layer has a problem that it is easy to generate curling and is not easy to handle in a state before attachment.

[0010] Therefore, an object of the present application is to provide a polarizing film which is high in followability to a curved surface, easy to attach to a curved surface, and in which generation of curling is suppressed, a material constituting the polarizing film, and a method for manufacturing them and a method for manufacturing a molded body using them.

[0011] MEANS FOR SOLVING THE PROBLEMS

[0012] The present inventors have conducted studies in order to solve the above problems, and as a result, have found that the above problems can be solved by forming a transfer medium laminate that is a combination of a hard coat layer having a specific property and a resin layer, thereby completing the present invention. That is, the present invention provides the following solutions.

[0013] [1] A transfer medium laminate having a hard coat layer and a resin layer (A) provided on one surface of the hard coat layer,

[0014] The hard coat layer has stretchability,

[0015] The resin that constitutes the resin layer has a storage modulus of 1000 MPa or less.

[0016] [2] The transfer medium laminate according to [1], wherein the thickness of the resin layer (A) is 0.1 μm or more and 10 μm or less.

[0017] [3] The transfer medium laminate according to [1] or [2], wherein the resin layer (A) contains an ultraviolet absorber.

[0018] [4] The transfer medium laminate according to any one of [1] to [3], wherein the hard coat layer is a semi-cured product of a hard coat layer material, and the resin layer (A) is a layer formed on the surface of the semi-cured product.

[0019] [5] The transfer medium laminate according to any one of [1] to [4], wherein the in-plane direction retardation Re of the resin layer is 0 nm or more and 5 nm or less.

[0020] [6] The transfer medium laminate according to any one of [1] to [5], wherein the transfer medium laminate further comprises a support provided on the surface of the hard coat layer that is opposite to the resin layer (A) side.

[0021] [7] The transfer medium laminate according to [6], wherein the support has a release layer provided on the surface of the hard coat layer side.

[0022] [8] A method for manufacturing a transfer medium laminate, the method for manufacturing a transfer medium laminate according to any one of [1] to [7], the method for manufacturing a transfer medium laminate comprising:

[0023] a step of spreading a hard coat layer material on the surface of a support;

[0024] a step of semi-curing the hard coat layer material to form a hard coat layer having stretchability; and

[0025] A resin is spread on the hard coat layer to form a resin layer (A) having a storage modulus of 1000 MPa or less.

[0026] [9] A polarizing film having: the transfer medium laminate according to any one of [1] to [7];

[0027] a polarizer layer provided on the resin layer (A) side of the transfer medium laminate; and

[0028] a bonding layer interposed between the transfer medium laminate and the polarizer layer.

[0029]

[10] A method for manufacturing a polarizing film, the polarizing film having: the transfer medium laminate according to any one of [1] to [7];

[0030] a polarizer layer provided on the resin layer (A) side of the transfer medium laminate; and

[0031] a bonding layer interposed between the transfer medium laminate and the polarizer layer,

[0032] the resin layer (A) contains an ultraviolet absorber,

[0033] the method for manufacturing a polarizing film includes: a process of adhering the transfer medium laminate and the polarizer layer via an ultraviolet-curable adhesive to produce an adhered article; and

[0034] a process of irradiating the adhered article with ultraviolet rays from the polarizer layer side of the adhered article.

[0035]

[11] A manufacturing method for a molded body with a polarizer layer, the manufacturing method including:

[0036] a process (A) of manufacturing a polarizing film by the manufacturing method according to

[10] ;

[0037] a process (B) of adhering the polarizing film to a base member; and

[0038] a process (C) of main curing a hard coat layer in the polarizing film,

[0039] the base member for the process (B) is a member having a curved surface, or the process (B) is followed by a process (Bx) of bending the base member before the process (C).

[0040] Effects of the Invention

[0041] According to the present application, a polarizing film in which the ease of attachment to a curved surface is improved and in which curling is suppressed, and a transfer medium laminate constituting the polarizing film, can be provided. According to the present application, a method for manufacturing the polarizing film, and a method for easily manufacturing a molded body that can be used as a component of a display device having a curved display surface using the polarizing film, are also provided. DETAILED DESCRIPTION

[0042] Hereinafter, the present application will be described in detail with reference to embodiments and examples. However, the present application is not limited to the embodiments and examples shown below, and can be arbitrarily changed within the scope of the claims of the present application and equivalents thereof.

[0043] In the following description, "solution" and "solvent" include not only a solution in which a solute is dissolved in a solvent and the medium thereof, but also those and the medium thereof which are generally understood to include other substances in a liquid-like medium. For example, "solution" also includes a dispersion liquid in which solid particulate dispersoids are dispersed in a liquid-like dispersion medium, and an emulsion in which liquid particulate discontinuous phases are dispersed in a liquid-like continuous phase.

[0044] In the following description, "a (meth)acrylate", "(meth)acryl", and "(meth)acrylic acid" include a substance involving an acrylic acid group, a substance involving a methacrylic acid group, and a mixture thereof. For example, "(meth)acrylate" is a term including an acrylate, a methacrylate, and a mixture thereof.

[0045] In the following description, a "long strip-like" film refers to a film having a length of 5 times or more the width of the film, preferably a length of 10 times or more, and specifically refers to a film having a length that can be wound into a roll shape for storage or transportation. The upper limit of the ratio of the length of the film to the width is not particularly limited, and can be, for example, 100000 times or less.

[0046] In the following description, unless otherwise specified, an adhesive includes not only an adhesive in the narrow sense, but also an adhesive having a shear storage modulus of less than 1 MPa at 23°C (an adhesive that can be used as a pressure-sensitive adhesive). Here, the adhesive in the narrow sense refers to an adhesive having a shear storage modulus of 1 MPa to 500 MPa at 23°C after energy ray irradiation or after heat treatment.

[0047] In the following description, unless otherwise specified, the in-plane retardation Re of a certain film is a value indicated by Re = (nx - ny) x d. Here, nx indicates the refractive index of the direction in which the largest refractive index is given in the direction perpendicular to the thickness direction (in-plane direction) of the above-mentioned film. ny indicates the refractive index of the direction perpendicular to the direction of nx in the in-plane direction of the above-mentioned film. d indicates the thickness of the above-mentioned film. Unless otherwise specified, the measurement wavelength is 550 nm.

[0048] [1. Outline of transfer medium laminate and method for manufacturing the same]

[0049] In the present application, the transfer medium laminate refers to a laminate including a hard coat layer, and is a laminate for achieving transfer of the hard coat layer by being attached to the surface of a solid shaped body. The transfer medium laminate of the present application has a hard coat layer and a resin layer (A) provided on one surface of the hard coat layer directly or through other layers. The transfer medium laminate of the present application can also include a support provided on the surface of the hard coat layer opposite to the resin layer (A) side as an arbitrary constituent element.

[0050] The transfer medium laminate of the present application can be manufactured by an arbitrary manufacturing method, and as examples of a preferred manufacturing method, a manufacturing method including the following steps can be given. Hereinafter, this method will be described as the manufacturing method of the transfer medium laminate of the present application.

[0051] Step (1): a step of spreading a hard coat layer material on the surface of a support.

[0052] Step (2): a step of semi-curing the hard coat layer material to form a hard coat layer having stretchability.

[0053] Step (3): a step of spreading a resin on the hard coat layer to form a resin layer (A) having a storage modulus of 1000 MPa or less.

[0054] [2. Support]

[0055] As the support, an arbitrary member having a surface suitable for forming a hard coat layer can be used. In the final product (a display device, or a shaped body constituting a polarizer layer-equipped tape of the display device, etc.), the support can remain as a part thereof, and generally in the steps after step (3) until the final product is obtained, the support can be peeled off and removed.

[0056] The support can generally be a resin-made film. As examples of the resin constituting the support, a resin containing a general-purpose polymer such as polypropylene (PP), polyethylene terephthalate (PET), etc. as a main component can be given.

[0057] In a case where the support is peeled from the hard coat layer in a step after the step (3), as the support, a film subjected to a surface treatment for making the peeling easy can be preferably used. Specifically, a film subjected to a peeling treatment with a surface organic silicon can be used. Further, a film subjected to biaxial stretching is sometimes suitable for the peeling in terms of surface properties, and such a film is also preferably used as the support.

[0058] The surface of the support is usually a flat surface, but is not limited thereto, and a concavo-convex structure formed by, for example, shape transfer with an embossing roll or the like can be provided on the surface of the support. By providing the surface of the support with the concavo-convex structure, the concavo-convex structure can be transferred to the hard coat layer, whereby the surface of the hard coat layer can be imparted with an anti-glare function and / or a reflection-reducing function.

[0059] The support can have any layer such as an antistatic layer, an antireflection layer, a release layer, or the like on the surface thereof. The any layer can be removed together with the support at the time of peeling the support, or can remain in the product. In particular, the support has a release layer provided on the surface on the side of the hard coat layer in addition to the layer of the above-described resin, whereby the peeling of the support and the hard coat layer can be easily performed.

[0060] The thickness of the support can be appropriately adjusted to a desired range. Specifically, the thickness of the support is preferably 20 μm or more, more preferably 30 μm or more, and on the other hand, is preferably 80 μm or less, more preferably 60 μm or less.

[0061] [3. Hard coat layer]

[0062] The hard coat layer in the transfer medium laminate of the present application has stretchability. In the present application, the stretchability of the hard coat layer means a property that, when the hard coat layer is stretched uniaxially as an independent film, the hard coat layer can be stretched by 1.50 times or more without generation of a crack. More specifically, the hard coat layer as an independent film is made into a rectangle having a length of 150 mm and a width of 20 mm, and is uniaxially stretched in the length direction to a stretch ratio of 1.50 times or more, and observation is made on the presence or absence of a crack, whereby it can be determined whether or not the hard coat layer has stretchability. If a crack is not generated at the time of a stretch ratio of 1.50 times, it can be determined that the hard coat layer has stretchability. By having such stretchability, the followability of the transfer medium laminate and the polarizing film to a curved surface can be improved.

[0063] In the final product, the hardness of the hard coat layer is greater than the hardness of the resin layer (A), and it is possible to have a function of suppressing the occurrence of damage on the surface of the resin layer (A). The hard coat layer in the final product preferably shows a hardness of "HB" or more in the pencil hardness test prescribed in JIS K5600-5-4. Furthermore, the hard coat layer at this time preferably has high scratch resistance. Specifically, it is preferable to have scratch resistance to the extent that when steel wool #0000 is pressed against the hard coat layer with a load of 0.025 MPa, and reciprocated 10 times on the surface of the hard coat layer, no scratch is visually confirmed upon observation. The hard coat layer can have an anti-glare function and / or a reflection-reducing function.

[0064] The hard coat layer in the transfer medium laminate can be a semi-cured product of a hard coat material. In the present application, the hard coat material refers to a material that can form a hard coat layer by curing. Furthermore, the "semi-cured product" of the hard coat material refers to a substance that has been cured compared to the hard coat material before curing, but can be in a state of a material having higher hardness by further processing (such as ultraviolet irradiation, etc.) thereafter. In contrast, a substance that increases the hardness to the properties required for the final product, such as hardness, is referred to as a "main cured product".

[0065] The hard coat material can be a material containing a polymerizable substance (H) as a main component, and any component that can be contained as necessary. As the polymerizable substance (H), various polymerizable substances that can impart the desired hardness to the hard coat layer in the final product can be used.

[0066] As specific examples of the polymerizable substance (H), multifunctional (meth)acrylates can be given.

[0067] The weight average molecular weight of the multifunctional (meth)acrylate is preferably 10,000 or more, and more preferably 100,000 or less. The weight average molecular weight of each (meth)acryl group of the multifunctional (meth)acrylate is preferably 200 or more, and more preferably 400 or less. By having this molecular weight, synthesis becomes easy, good performance of the hard coat layer can be obtained, and handling of the hard coat material becomes easy.

[0068] The multifunctional (meth)acrylate is preferably a substance having a structure obtained by reacting a polymer containing a monomer component of an epoxy group-containing (meth)acrylate-based monomer with an α,β-unsaturated carboxylic acid. By using such a substance as the multifunctional (meth)acrylate, it is possible to easily obtain a hard coat layer having high hardness and excellent scratch resistance.

[0069] The epoxy group-containing (meth)acrylate monomer refers to a compound having one or more epoxy groups and one or more unsaturated double bonds in the molecule. As examples of the epoxy group-containing (meth)acrylate monomer, there can be mentioned glycidyl (meth)acrylate, β-methyl glycidyl (meth)acrylate, 3,4-epoxycyclohexylmethyl (meth)acrylate, vinylcyclohexene monooxide (i.e., 1,2-epoxy-4-vinylcyclohexane), and combinations thereof. Among these, from the viewpoint of ease of availability, glycidyl (meth)acrylate is preferred.

[0070] The monomer component can contain, in addition to the epoxy group-containing (meth)acrylate monomer, any monomer copolymerizable therewith.

[0071] As examples of the arbitrary monomer, there can be mentioned (meth)acrylate, styrene, vinyl acetate, (meth)acrylamide, acrylonitrile, a macromonomer having an unsaturated double bond at either end and not containing an epoxy group and a carboxyl group, and combinations thereof.

[0072] As specific examples of the macromonomer, there can be mentioned: macromonomers AA-6, AB-6, AS-6, and AY-707S (manufactured by Toagosei Co., Ltd.); Silaplaine FM-0711 and FM-0721 (manufactured by Shin-Etsu Chemical Co., Ltd.); Placcel FA10L (manufactured by DKS Co., Ltd.); and Blemmer PME-4000 and PSE-1300 (manufactured by NOF Corporation).

[0073] As examples of the α,β-unsaturated carboxylic acid, there can be mentioned α,β-unsaturated monocarboxylic acids such as (meth)acrylic acid, α,β-unsaturated dicarboxylic acids such as (meth)acrylic acid dimer, and combinations thereof. Among these, from the viewpoint of imparting a desired hardness to the hard coat layer in the final product, (meth)acrylic acid is preferred.

[0074] As an example of any component that can be contained in the hard coat material, a polymerization initiator can be given. As the polymerization initiator, various polymerization initiators that can initiate polymerization of the polymerizable substance (H) by irradiation of active energy rays such as ultraviolet rays can be used. As specific examples of the polymerization initiator, 2,2-dimethoxy-1,2-diphenylethane-1-ketone, 1-cyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenyl-propane-1-ketone, 1-[4-(2-hydroxyethoxy)-phenyl]-2-hydroxy-2-methyl-1-propane-1-ketone, 2-hydroxy-1-{4-[4-(2-hydroxy-2-methyl-propionyl)-benzyl]phenyl}-2-methyl-propane-1-ketone, phenyl glyoxylic acid methyl ester, 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropane-1-ketone, 2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butanone-1,2-(dimethylamino)-2-[(4-methylphenyl)methyl]-1-[4-(4-morpholinyl)phenyl]-1-butanone, bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide, 2,4,6-trimethylbenzoyl-diphenyl-phosphine oxide, 4-methylbenzophenone, 1-[4-(4-benzoylphenylthio)phenyl]-2-methyl-2-(4-methylphenylsulfonyl)propane-1-ketone, 1-[4-(phenylthio)phenyl]-1,2-octanedione-2-(O-benzoyl oxime), ethanone-1-[9-ethyl-6-(2-methylbenzoyl)-9H-carbazol-3-yl]-1-(O-acetyl oxime), and combinations thereof. As an example of a commercially available polymerization initiator, "IRGACURE 184" manufactured by Ciba Specialty Chemicals Inc. can be given.

[0075] The proportion of the polymerization initiator in the hard coat material with respect to 100 parts by weight of the polymerizable substance (H) is preferably 0.1 parts by weight or more, and more preferably 10 parts by weight or less. By making the proportion of the polymerization initiator within the above range, the hard coat in the transfer medium laminate and the polarizing film can be easily imparted with the desired stretchability, and the hard coat in the final product can be imparted with the desired hardness.

[0076] The hard coat material can contain, in addition to the above components, microparticles. The microparticles can adjust various physical properties of the hard coat such as the electrical conductivity and the refractive index. The microparticles preferably have a refractive index of 1.4 or more.

[0077] The fine particles can be organic fine particles composed of an organic substance or inorganic fine particles composed of an inorganic substance. The fine particles are preferably inorganic fine particles, and more preferably inorganic oxide fine particles. As inorganic oxides that can constitute the fine particles, there are, for example, silicon dioxide, titanium dioxide (titania), zirconium dioxide, zinc oxide, tin oxide, cerium oxide, antimony pentoxide, titanium dioxide, indium tin oxide (ITO) doped with tin, antimony-doped tin oxide (ATO), phosphorus-doped tin oxide (PTO), indium zinc oxide (IZO) doped with zinc, aluminum-doped zinc oxide (AZO), and fluorine-doped tin oxide (FTO).

[0078] As the fine particles, silicon dioxide fine particles are preferred because the balance between adhesion to the polymer of the polymerizable substance (H) and transparency is excellent, and the refractive index of the hard coat layer can be easily adjusted.

[0079] The hard coat material can contain one kind of fine particles alone or two or more kinds of fine particles in combination.

[0080] The number average particle diameter of the fine particles is preferably 1 nm or more and 1000 nm or less, more preferably 1 nm or more and 500 nm or less, and further preferably 1 nm or more and 250 nm or less. The smaller the number average particle diameter of the fine particles, the more the haze of the hard coat layer can be reduced, and the adhesion of the fine particles to the polymer of the polymerizable substance (H) can be improved.

[0081] The haze (%) can be measured according to JIS K-7136 using, for example, a commercially available haze meter (for example, "NDH 2000" manufactured by Nippon Denshoku Industries Co., Ltd.).

[0082] In the composition for forming a hard coat layer, the content of the fine particles is preferably 10 to 80 parts by weight, more preferably 10 to 50 parts by weight, and further preferably 20 to 40 parts by weight, relative to 100 parts by weight of the polymerizable substance (H). When the content of the fine particles is in the above range, the optical properties such as the haze value and the total light transmittance are excellent.

[0083] The total light transmittance (%) can be measured according to JIS K-7361 using, for example, a commercially available haze meter ("NDH 2000" manufactured by Nippon Denshoku Industries Co., Ltd.).

[0084] The hard coat material can contain, in addition to the above components, any component. As examples thereof, there are, for example, a polymerization inhibitor, an antioxidant, an antistatic agent, a light stabilizer, a solvent, an antifoaming agent, and a leveling agent.

[0085] In the manufacturing method of the transfer medium laminate of the present application, the hard coat layer is formed by a process including the above process (1) and process (2).

[0086] The spreading of the hard coat material in the process (1) can be performed by applying the hard coat material, or a solution containing the hard coat material, to the surface of the support to form a coating film thereof. In the case of preparing a solution containing the hard coat material, as a solvent therefor, any liquid capable of dissolving or dispersing the hard coat material therein can be used. As examples of the solvent, various organic solvents can be given. As specific examples thereof, alcohols such as methanol, ethanol, isopropanol, n-butanol, isobutanol, and the like; glycols such as ethylene glycol, ethylene glycol monobutyl ether, ethylene glycol monoethyl ether acetate, diethylene glycol, diethylene glycol monobutyl ether, diacetone glycol, and the like; aromatic hydrocarbons such as toluene, xylene, and the like; aliphatic hydrocarbons such as n-hexane, n-heptane, and the like; esters such as ethyl acetate, butyl acetate, and the like; ketones such as methyl ethyl ketone, methyl isobutyl ketone, and the like; oximes such as methyl ethyl ketone oxime, and the like; and combinations of two or more of them, and the like can be given. In the case where the formation of the hard coat layer is performed using a hard coat material solution, as a result of the operation such as drying in the process of formation, the solvent is volatilized, and the solid component remains in the hard coat layer. The proportion of the solid component in the hard coat material solution (i.e., the component remaining in the hard coat layer after the formation of the hard coat layer) can be appropriately adjusted to perform the desired operation, and can be, for example, 5% by weight or more and 40% by weight or less.

[0087] The semi-curing of the hard coat material in the process (2) can be performed by drying the coating film of the hard coat material, irradiating the coating film of the hard coat material with active energy rays, or a combination thereof. As the active energy rays, active energy rays suitable for the polymerization initiator contained in the hard coat material can be selected. From the viewpoint of easiness in the process such as adjustment of the degree of polymerization, it is preferable to use an ultraviolet polymerization initiator as the polymerization initiator, and to use ultraviolet rays as the active energy rays. By appropriately adjusting the conditions at the time of semi-curing of the hard coat material, a hard coat layer having stretchability can be formed.

[0088] The hard coat layer in the semi-cured state formed by the process (2) is preferably in a so-called tack-free state on the surface thereof. The surface being tack-free means having a degree of hardness such that the material constituting the hard coat layer does not adhere to a finger when the surface is contacted with the finger. By making the surface tack-free, the laminate in a state where the hard coat layer is exposed on the surface can be stored in a state such as a film roll, and thus the degree of freedom in the implementation of the manufacturing method can be improved.

[0089] The thickness of the hard coat layer can be appropriately adjusted to the desired range. Specifically, the thickness of the hard coat layer is preferably 0.5 μm or more and 20 μm or less, more preferably 0.5 μm or more and 10 μm or less, and further preferably 0.5 μm or more and 8 μm or less.

[0090] [4. Resin layer (A)]

[0091] The resin layer (A) is a layer made of a resin having a storage modulus of 1000 MPa or less. The storage modulus is preferably 960 MPa or less, more preferably 920 MPa or less. The lower limit of the storage modulus is not particularly limited and can be, for example, 200 MPa or more. By having the storage modulus within this range, significant curling of the transfer medium laminate and the polarizing film can be suppressed, and the followability to a curved surface can be improved.

[0092] The storage modulus of the resin constituting the resin layer (A) can be determined by molding the resin into a 1-mm-thick film for measurement, measuring the storage modulus of the above film for measurement at 23°C using a dynamic viscoelasticity measuring device (for example, "ARES" manufactured by TA Instruments Japan Inc.), and thereby calculated.

[0093] The resin constituting the resin layer (A) preferably has a low water vapor permeability at 40°C and 90% RH as measured as a 100-μm-thick film. The water vapor permeability is preferably less than 5 g / (m 2 ·day), more preferably 4 g / (m 2 ·day) or less. The lower limit of the water vapor permeability is desirably 0 g / (m 2 ·day) and can be 0.1 g / (m 2 ·day). By having the water vapor permeability be the upper limit value or less, the low moisture permeability of the resin layer (A) can be sufficiently excellent, and the water vapor can be suppressed from reaching the polarizer layer, and the reliability of the polarizing film can be excellent. The water vapor permeability can be measured using a commercially available water vapor permeability measuring device, and specifically, can be measured according to the method described in the evaluation item column in the examples.

[0094] The resin constituting the resin layer (A) generally contains a polymer as a main component. As examples of the polymer, a polyester, an acrylic polymer, and a polymer having an alicyclic structure can be given.

[0095] The resin forming the resin layer (A) preferably contains a polymer having an alicyclic structure.

[0096] The polymer having an alicyclic structure is a polymer having a structural unit having an alicyclic structure. The polymer having an alicyclic structure generally has a low water vapor permeability. Therefore, by forming the resin layer (A) with a resin containing a polymer having an alicyclic structure, the water vapor can be suppressed from reaching the polarizer layer, and the moisture resistance of the polarizing film can be improved.

[0097] The resin forming the resin layer (A) can contain one kind of polymer having an alicyclic structure alone, or two or more kinds in combination.

[0098] The polymer having an alicyclic structure can have an alicyclic structure in the main chain, can have an alicyclic structure in the side chain, or can have an alicyclic structure in both the main chain and the side chain. Among them, from the viewpoint of mechanical strength and heat resistance, a polymer having an alicyclic structure in at least the main chain is preferable.

[0099] As the alicyclic structure, for example, a saturated alicyclic hydrocarbon (naphthene) structure, an unsaturated alicyclic hydrocarbon (cycloalkene, cycloalkyne) structure, and the like. Among them, from the viewpoint of mechanical strength and heat resistance, a naphthene structure and a cycloalkene structure are preferable, and a naphthene structure is particularly preferable.

[0100] The number of carbon atoms constituting the alicyclic structure is preferably 4 or more, more preferably 5 or more, and is preferably 30 or less, more preferably 20 or less, and particularly preferably 15 or less in each alicyclic structure. By making the number of carbon atoms constituting the alicyclic structure in this range, the mechanical strength, heat resistance, and moldability of the resin containing the polymer having an alicyclic structure are highly balanced.

[0101] In the polymer having an alicyclic structure, the proportion of the structural unit having an alicyclic structure can be appropriately selected depending on the purpose of use. The proportion of the structural unit having an alicyclic structure in the polymer having an alicyclic structure is preferably 55% by mass or more, more preferably 70% by mass or more, and particularly preferably 90% by mass or more, and can be 100% by mass or less. When the proportion of the structural unit having an alicyclic structure in the polymer having an alicyclic structure is in this range, the transparency and heat resistance of the resin containing the polymer having an alicyclic structure become good.

[0102] As the polymer having an alicyclic structure, for example, a norbornene-based polymer, a monocyclic cyclic olefin-based polymer, a cyclic conjugated diene-based polymer, a vinyl alicyclic hydrocarbon polymer, and a hydrogenated product thereof, and a hydrogenated product of a vinyl aromatic hydrocarbon polymer can be given. Among them, since the transparency and moldability are good, one or more selected from a norbornene-based polymer and a hydrogenated product of a vinyl aromatic hydrocarbon polymer is more preferable.

[0103] As examples of the norbornene-based polymers, there are mentioned ring-opening polymers of monomers having a norbornene structure and hydrogenates thereof, and addition polymers of monomers having a norbornene structure and hydrogenates thereof. Further, as examples of the ring-opening polymers of monomers having a norbornene structure, there are mentioned ring-opening homopolymers of one kind of monomers having a norbornene structure, ring-opening copolymers of two or more kinds of monomers having a norbornene structure, and ring-opening copolymers of monomers having a norbornene structure and any monomers copolymerizable therewith. Furthermore, as examples of the addition polymers of monomers having a norbornene structure, there are mentioned addition homopolymers of one kind of monomers having a norbornene structure, addition copolymers of two or more kinds of monomers having a norbornene structure, and addition copolymers of monomers having a norbornene structure and any monomers copolymerizable therewith. Among these, hydrogenates of the ring-opening polymers of monomers having a norbornene structure, addition copolymers of monomers having a norbornene structure and α-olefins, and hydrogenates of the addition copolymers of monomers having a norbornene structure and α-olefins are preferred, and hydrogenates of the ring-opening copolymers of two or more kinds of monomers having a norbornene structure, addition copolymers of monomers having a norbornene structure and α-olefins, and hydrogenates of the addition copolymers of monomers having a norbornene structure and α-olefins are more preferred.

[0104] As the monomers having a norbornene structure, there are mentioned, for example, bicyclo[2.2.1]hept-2-ene (common name: norbornene), tricyclo[4.3.0.1 2,5 ]dec-3,7-diene (common name: dicyclopentadiene), 7,8-benzotricyclo[4.3.0.1 2,5 ]dec-3-ene (common name: methano-tetrahydrofluorene), tetracyclo[4.4.0.1 2,5 .1 7,10 ]dodec-3-ene (common name: tetracyclododecene), and derivatives of these compounds (for example, derivatives having a substituent on the ring), and the like. Here, as the substituent, there are mentioned, for example, an alkyl group, an alkylene group, a polar group, and the like. These substituents can be the same or different, and a plurality of substituents can be bonded to form a ring. The monomers having a norbornene structure can be used singly or in combination of two or more kinds at an arbitrary ratio.

[0105] As the kind of the polar group, there are mentioned, for example, a hetero atom, or a group having a hetero atom, and the like. As the hetero atom, there are mentioned, for example, an oxygen atom, a nitrogen atom, a sulfur atom, a silicon atom, a halogen atom, and the like. As specific examples of the polar group, there are mentioned a carboxyl group, a carbonyloxy group, a carbonyl group, a hydroxyl group, an oxyl group, an ester group, a silanol group, a silyl group, an amino group, a nitrile group, a sulfonic acid group, and the like.

[0106] As monomers capable of ring-opening copolymerization with monomers having norbornene structure, there are, for example, monocyclic olefins such as cyclohexene, cycloheptene, cyclooctene and the like and derivatives thereof; cyclic conjugated dienes such as cyclohexadiene, cycloheptadiene and the like and derivatives thereof, and the like. The monomers capable of ring-opening copolymerization with monomers having norbornene structure can be used singly or in combination of two or more kinds in any ratio.

[0107] Ring-opening polymers of monomers having norbornene structure can be produced by, for example, polymerizing or copolymerizing the monomers in the presence of a ring-opening polymerization catalyst.

[0108] In the addition copolymers of monomers having norbornene structure and α-olefins, as α-olefins, there are, for example, α-olefins having 2 to 20 carbon atoms such as ethylene, propylene, 1-butene and the like and derivatives thereof. Among them, ethylene is preferred. The α-olefins can be used singly or in combination of two or more kinds in any ratio.

[0109] Addition polymers of monomers having norbornene structure can be produced by, for example, polymerizing or copolymerizing the monomers in the presence of an addition polymerization catalyst.

[0110] Hydrogenated products of the above-mentioned ring-opening polymers and addition polymers can be produced by, for example, hydrogenating preferably 90% or more of carbon-carbon unsaturated bonds in a solution of the ring-opening polymers and the addition polymers in the presence of a hydrogenation catalyst containing a transition metal such as nickel, palladium and the like.

[0111] The hydrogenated product of the vinyl aromatic hydrocarbon polymer refers to a hydrogenated product of a polymer containing repeating units [I] derived from an aromatic vinyl compound. The repeating units derived from an aromatic vinyl compound refer to repeating units having a structure obtained by polymerizing an aromatic vinyl compound. However, the hydrogenated product and the structural units thereof are not limited by the method of production thereof.

[0112] As the aromatic vinyl compound corresponding to the repeating unit [I], there are, for example, styrene; α-methylstyrene, 2-methylstyrene, 3-methylstyrene, 4-methylstyrene, 2,4-dimethylstyrene, 2,4-diisopropylstyrene, 4-tert-butylstyrene, 5-tert-butyl-2-methylstyrene, and the like styrenes having an alkyl group having 1 to 6 carbon atoms as a substituent; 4-chlorostyrene, dichlorostyrene, 4-monofluorostyrene, and the like styrenes having a halogen atom as a substituent; 4-methoxystyrene and the like styrenes having an alkoxy group having 1 to 6 carbon atoms as a substituent; 4-phenylstyrene and the like styrenes having an aryl group as a substituent; 1-vinylnaphthalene, 2-vinylnaphthalene, and the like vinyl naphthalenes, and the like. One of these can be used alone, or two or more of these can be used in combination at an arbitrary ratio. Among these, from the viewpoint of being able to reduce hygroscopicity, aromatic vinyl compounds not containing a polar group such as styrene, styrenes having an alkyl group having 1 to 6 carbon atoms as a substituent, and the like are preferred, and from the viewpoint of being easily obtained industrially, styrene is particularly preferred.

[0113] The hydrogenate of the polymer containing the repeating unit [I] from the aromatic vinyl compound is preferably a specific block copolymer hydrogenate [E]. The block copolymer hydrogenate [E] is a hydrogenate of a block copolymer [D]. The block copolymer [D] is a polymer block formed of a polymer block [A] and a polymer block [B], or a polymer block [A] and a polymer block [C]. The polymer block [A] is a polymer block in which the repeating unit [I] from the aromatic vinyl compound is a main component. The polymer block [B] is a polymer block in which the repeating unit [I] from the aromatic vinyl compound and the repeating unit [II] from the chain-type conjugated diene compound are main components. The polymer block [C] is a polymer block in which the repeating unit [II] from the chain-type conjugated diene compound is a main component. Here, the "main component" means a component of 50% by weight or more in the polymer block. The repeating unit from the chain-type conjugated diene compound means a repeating unit having a structure obtained by polymerizing the chain-type conjugated diene compound.

[0114] As the chain-type conjugated diene compound corresponding to the repeating unit [II], there are, for example, 1,3-butadiene, isoprene, 2,3-dimethyl-1,3-butadiene, 1,3-pentadiene, and the like. One of these can be used alone, or two or more of these can be used in combination at an arbitrary ratio. The chain-type conjugated diene compound can be linear, or branched.

[0115] The hydrogenate of the vinyl aromatic hydrocarbon polymer is a substance obtained by hydrogenating the unsaturated bond possessed by the vinyl aromatic hydrocarbon polymer. Here, the unsaturated bond of the vinyl aromatic hydrocarbon polymer to be hydrogenated includes any one of a carbon-carbon unsaturated bond of a main chain and a side chain of the polymer, and a carbon-carbon unsaturated bond of an aromatic ring.

[0116] The hydrogenate can be produced by, for example, hydrogenating the unsaturated bond of the vinyl aromatic hydrocarbon polymer by 90% or more in the presence of a hydrogenation catalyst containing a transition metal such as nickel or palladium in a solution of the vinyl aromatic hydrocarbon polymer.

[0117] The weight average molecular weight Mw of the polymer contained in the resin forming the resin layer (A) is preferably 10,000 or more, more preferably 15,000 or more, particularly preferably 20,000 or more, and is preferably 100,000 or less, more preferably 80,000 or less, particularly preferably 50,000 or less. When the weight average molecular weight is in such a range, the mechanical strength and moldability of the resin layer (A) are highly balanced.

[0118] The molecular weight distribution (Mw / Mn) of the polymer contained in the resin forming the resin layer (A) is preferably 1.2 or more, more preferably 1.5 or more, particularly preferably 1.8 or more, and is preferably 3.5 or less, more preferably 3.0 or less, particularly preferably 2.7 or less. Here, Mn represents the number average molecular weight. By making the molecular weight distribution be the lower limit value or more of the above range, the productivity of the polymer can be improved, and the manufacturing cost can be suppressed. Further, by making the molecular weight distribution be the upper limit value or less, the amount of low molecular components becomes small. As a result, the relaxation of the resin layer (A) at the time of high temperature exposure can be suppressed, and the stability of the resin layer (A) can be improved.

[0119] The above-mentioned weight average molecular weight (Mw) and number average molecular weight (Mn) can be measured using gel permeation chromatography (GPC). As a solvent used for GPC, cyclohexane, toluene, tetrahydrofuran can be mentioned. In the case of using GPC, the weight average molecular weight is measured in the form of a relative molecular weight converted to, for example, polyisoprene or polystyrene.

[0120] The resin forming the resin layer (A) preferably contains, in addition to the polymer, preferably a plasticizer and / or a softening agent (a plasticizer or a softening agent, or both). By further containing a plasticizer and / or a softening agent in the resin forming the resin layer (A), the moldability (for example, stretchability) of the resin forming the resin layer (A) can be made good.

[0121] As the plasticizer and / or softening agent, a compound having an ester structure and an aliphatic hydrocarbon polymer can be mentioned. The resin forming the resin layer (A) preferably contains one or more selected from a compound having an ester structure and an aliphatic hydrocarbon polymer as a plasticizer and / or softening agent, and more preferably contains an aliphatic hydrocarbon polymer.

[0122] As the compound having an ester structure, for example, phosphate ester compounds such as triphenyl phosphate, tricresyl phosphate, and phenyldiphenyl phosphate; aliphatic carboxylic acid esters such as oxalic acid ester, malonic acid ester, succinic acid ester, glutaric acid ester, adipic acid ester, pimelic acid ester, suberic acid ester, azelaic acid ester, sebacic acid ester, and stearic acid ester; and aromatic carboxylic acid ester compounds such as benzoic acid ester, phthalic acid ester, isophthalic acid ester, terephthalic acid ester, trimellitic acid ester, and pyromellitic acid ester can be given.

[0123] As the aliphatic hydrocarbon polymer, for example, polyisobutylene, hydrogenated polyisobutylene, hydrogenated polyisoprene, hydrogenated 1,3-pentadiene-based petroleum resin, hydrogenated cyclopentadiene-based petroleum resin, and hydrogenated styrene / indene-based petroleum resin can be given.

[0124] The total of the plasticizer and the softening agent is preferably 5 parts by weight or more, more preferably 10 parts by weight or more, and further preferably 20 parts by weight or more, and is preferably 100 parts by weight or less, more preferably 70 parts by weight or less, and further preferably 50 parts by weight or less, with respect to 100 parts by weight of the polymer included in the resin forming the resin layer (A). By making the ratio of the total of the plasticizer and the softening agent in the resin within the above range, the moldability of the resin can be made more favorable.

[0125] The resin forming the resin layer (A) preferably includes a UV absorber. By making the resin include a UV absorber, a resin layer (A) including a UV absorber can be formed. By making the resin layer (A) include a UV absorber, the following effects can be obtained: in the process of manufacturing the polarizing film, the process of laminating the transfer medium layer to the polarizer layer via a UV-curable adhesive is easily performed while the stretchability of the hard coat layer is maintained. In addition, the effect of reducing the deterioration of the final product due to the irradiation of UV included in external light can also be obtained.

[0126] As specific examples of the UV absorber, benzotriazole-based UV absorbers and triazine-based UV absorbers can be given. As examples of commercially available UV absorbers, "Tinuvin 326", "Tinuvin 329", and "Tinuvin 234" (all of which are benzotriazole-based UV absorbers manufactured by BASF), and "ATASTAB LA-70" (a triazine-based UV absorber manufactured by ADEKA) can be given.

[0127] The resin forming the resin layer (A) can include various additives in addition to the above components. As the additives, for example, antioxidants and light stabilizers can be given.

[0128] The thickness of the resin layer (A) is preferably 0.5 μm or more, more preferably 0.8 μm or more, and is preferably 9 μm or less, more preferably 8 μm or less. By making the thickness of the resin layer (A) 0.5 μm or more, the reliability of the polarizing film under a high-temperature high-humidity environment can be further improved, and the polarizer layer included in the polarizing film can be more favorably protected. By making the thickness of the resin layer (A) 9 μm or less, the thickness of the polarizing film can be made thinner, and the effect of suppressing curling can be improved.

[0129] The resin layer (A) is preferably optically substantially isotropic. Here, "optically substantially isotropic" means that the in-plane retardation Re is preferably 0 nm or more and 5 nm or less, and more preferably 0 nm or more and 2 nm or less.

[0130] In the manufacturing method of the transfer medium laminate of the present application, the resin layer (A) is formed by a process including the above-mentioned process (3).

[0131] The spreading of the resin in process (3) can be performed by applying the resin or a solution containing the resin to the surface of the hard coat layer to form a coating film thereof. In the case of preparing a solution containing the resin, as a solvent therefor, any liquid capable of dissolving or dispersing the resin therein can be used. As examples of the solvent, various organic solvents can be given. As specific examples thereof, the same examples as those of the solvent capable of being used in process (1) can be given.

[0132] After process (3), the spread resin or the solution thereof can be subjected to drying or the like as necessary, the coating film is cured, and the resin layer (A) is formed.

[0133] After the resin layer (A) is formed, the surface of the resin layer (A) can be subjected to a treatment such as corona treatment. By this treatment, the resin layer (A) can exert a function such as improving the adhesion to the adhesive layer.

[0134] By performing the process including the formation of the resin layer (A) of process (3), a transfer medium laminate having a layer structure of (support) / (hard coat layer) / (resin layer (A)) can be obtained. Here, by performing process (3) at the time when the hard coat layer is in the state of a semi-cured product, a transfer medium laminate having a structure in which the resin layer (A) is formed on the surface of the semi-cured product can be obtained. By having this structure, various advantages can be obtained. That is, at this time, the state of protecting the hard coat layer having a low hardness with the resin layer (A) and the support is achieved, and thus the mechanical damage of the hard coat layer due to the subsequent operations can be reduced. Further, by making the hard coat layer in the state of a semi-cured product, the state of maintaining the followability of the hard coat layer to the curved surface is achieved.

[0135] [5. Summary of Polarizing Film]

[0136] The polarizing film of the present application has the above-mentioned transfer medium laminate, a polarizer layer, and an adhesive layer interposed between the transfer medium laminate and the polarizer layer. The polarizer layer is provided on the resin layer (A) side of the transfer medium laminate (i.e., the side opposite to the hard coat layer side; in the case of having a support, the side opposite to the support).

[0137] The polarizing film has a transfer medium laminate, and as described above, the transfer medium laminate has a layer having stretchability as the hard coat layer, and thus the hard coat layer in the polarizing film is also a layer having stretchability. Generally, a polarizing film having a polarizer layer and a hard coat layer is brittle due to the hard coat layer, and thus has low followability to a curved surface when attached to the curved surface. In this regard, the polarizing film of the present application, by having the above-mentioned structure, can be produced as a film having high followability to a curved surface. Further, the transfer medium laminate has low tendency to generate curling, and thus the polarizing film also has low tendency to generate curling. Thus, the operation of attaching the polarizing film to a base member having a curved surface or the like shape becomes easy.

[0138] [6. Polarizer layer]

[0139] As the polarizer layer, a film capable of transmitting one of two linearly polarized lights intersecting at right angles and absorbing or reflecting the other linearly polarized light can be used. When a specific example of the polarizer layer is given, a polarizer layer obtained by applying a dyeing treatment using a dichroic substance such as iodine, a stretching treatment, a cross-linking treatment, or the like to a film of a polyvinyl alcohol resin containing a polyvinyl alcohol such as polyvinyl alcohol, partially formacetalized polyvinyl alcohol, or the like, in an appropriate order and manner can be given. The polarizer layer preferably contains a polyvinyl alcohol resin.

[0140] The thickness of the polarizer layer is preferably 1 μm or more, more preferably 2 μm or more, and further preferably 4 μm or more, and is preferably 25 μm or less, and more preferably 23 μm or less.

[0141] [7. Adhesive layer]

[0142] The adhesive layer is generally a layer that adheres the polarizer layer to the resin layer (A). As an example of an adhesive used to form the adhesive layer, an acrylic adhesive; an epoxy adhesive; a polyurethane adhesive; a polyester adhesive; a polyvinyl alcohol adhesive; a polyolefin adhesive; a modified polyolefin adhesive; a polyvinyl alkyl ether adhesive; a rubber adhesive, a vinyl chloride-vinyl acetate adhesive; an SEBS (styrene-ethylene-butylene-styrene copolymer) adhesive, an ethylene-based adhesive such as an ethylene-styrene copolymer; an acrylic ester-based adhesive such as an ethylene-(meth)acrylate copolymer, an ethylene-(meth)acrylate copolymer, or the like can be given.

[0143] The adhesive is preferably an ultraviolet-curable adhesive. By using an ultraviolet-curable adhesive, the manufacturing method of the polarizing film described later can be easily performed. As a specific example of the ultraviolet-curable adhesive, "ARKLS KRX-7007" (trade name, manufactured by ADEKA) can be given.

[0144] The thickness of the adhesive layer is usually more than 0 μm, preferably 0.1 μm or more, more preferably 1 μm or more, and preferably 5 μm or less, more preferably 3 μm or less. By making the thickness of the adhesive layer within the above range, the adhesive layer can more strongly adhere the polarizer layer and the resin layer (A), the bending recovery of the polarizing film can be improved, and the thickness of the polarizing film can be made thinner.

[0145] [8. Arbitrary Layer]

[0146] The polarizing film can have an arbitrary layer in addition to the above-described layers. As an example of the arbitrary layer, a bonding layer provided on the side opposite to the resin layer (A) side of the polarizer layer can be given. The thickness of the bonding layer is preferably 2 μm or more, more preferably 5 μm or more, and preferably 25 μm or less, more preferably 20 μm or less.

[0147] [9. Manufacturing Method of Polarizing Film]

[0148] The polarizing film of the present application can be manufactured by an arbitrary manufacturing method, and as an example of a preferred manufacturing method, a manufacturing method in which a resin layer containing an ultraviolet absorber is used as the resin layer (A), an ultraviolet-curable adhesive is used as the adhesive for forming the adhesive layer, and the following processes are included can be given. Hereinafter, this method will be described as the manufacturing method of the polarizing film of the present application.

[0149] Process (4): A process of adhering the transfer medium laminate to the polarizer layer via the ultraviolet-curable adhesive, to produce an adhered product.

[0150] Process (5): A process of irradiating the adhered product with ultraviolet rays from the polarizer layer side of the adhered product.

[0151] [9.1. Process (4)]

[0152] In process (4), the transfer medium laminate is adhered to the polarizer layer via the ultraviolet-curable adhesive. At the time when the adhering is completed, the adhesive is in a state where the curing treatment has not been performed. Therefore, for example, in the case where a laminate having a layer structure of (support body) / (hard coat layer) / (resin layer (A)) is used as the transfer medium laminate, the adhered product obtained by process (4) has a layer structure of (support body) / (hard coat layer) / (resin layer (A)) / (layer of the adhesive (uncured)) / (polarizer layer).

[0153] [9.2. Process (5)]

[0154] In process (5), the laminate is irradiated with ultraviolet rays from the side of the polarizer layer of the laminate. Therefore, the ultraviolet rays of the irradiation reach the layer of the adhesive (unhardened) through the polarizer layer, whereby the hardening of the adhesive is achieved, and the adhesive layer is formed. As a result, a polarizing film of the present application having, for example, a layer structure of (support) / (hard coat layer) / (resin layer (A)) / (adhesive layer (layer formed by hardening of the layer of the adhesive)) / (polarizer layer) can be obtained.

[0155] A part of the ultraviolet rays irradiated in process (5) can reach the resin layer (A) through the layer of the adhesive or the adhesive layer. If the resin layer (A) is a layer having a high ultraviolet ray transmittance, the ultraviolet rays can further reach the hard coat layer through the resin layer (A). However, in the production method of the polarizing film of the present application, since the resin layer (A) containing the ultraviolet ray absorber is used, the amount of the ultraviolet rays reaching the hard coat layer can be reduced. Therefore, even in the case where a material having ultraviolet ray curability is used as the hard coat layer, the production of the polarizing film can be completed in a state where the properties such as the stretchability and the semi-hardened state of the hard coat layer are maintained. The material having ultraviolet ray curability can be easily adjusted in the degree of hardening by adjusting the amount of irradiation. Therefore, in the production method of the present application, all these advantages can be easily enjoyed.

[0156] [9.3. Optional process]

[0157] The production method of the polarizing film of the present application can include an optional process in addition to the above processes. For example, a process of forming an arbitrary layer that the polarizing film can have can be included. Specifically, a process of providing an adhesive layer as an arbitrary layer on the surface of the polarizer layer on the opposite side from the adhesive layer can be included. The formation of the adhesive layer is preferably performed by coating an adhesive composition on a suitable release film to form a layer of the adhesive composition and laminating it to the surface of the polarizer layer. The process of providing the adhesive layer can be performed at any stage from before process (4) to after process (5), and is preferably performed after process (5) from the viewpoint of the easiness of the operation. As a result of performing this optional process, a polarizing film with an adhesive layer and a release film having, for example, a layer structure of (support) / (hard coat layer) / (resin layer (A)) / (adhesive layer (layer formed by hardening of the layer of the adhesive)) / (polarizer layer) / (adhesive layer) / (release film) can be obtained. Furthermore, in the case where a laminate containing the support is used as the transfer medium laminate, the support can be peeled off at any stage of the production method of the polarizing film, or can be left without being peeled off.

[0158] [10. Production method of a molded body with a polarizer layer]

[0159] The manufacturing method of the molded body with a polarizer layer of the present application includes the following steps.

[0160] Step (A): a step of manufacturing a polarizing film by the manufacturing method of the polarizing film of the present application.

[0161] Step (B): a step of adhering the polarizing film to a base member.

[0162] Step (C): a step of main-curing a hard coat layer in the polarizing film.

[0163] The molded body manufactured by the manufacturing method of the molded body with a polarizer layer of the present application can have: a base member having a curved surface; a polarizer layer formed on the curved surface; a resin layer (A) formed on the polarizer layer and capable of functioning as a protective film for protecting the polarizer; and a hard coat layer formed on the resin layer (A). The hard coat layer in such a molded body has sufficient hardness and scratch resistance and the like as a hard coat layer for protecting the outermost surface of the molded body, and a layer that well follows the shape of the curved surface can be formed.

[0164] The base member used in Step (B) can be a constituent element of a display device such as a liquid crystal display device and an organic electroluminescent display device.

[0165] As one example, the base member can be a liquid crystal panel of a liquid crystal display device. Here, the liquid crystal panel refers to a member having a pair of substrates and a plurality of display cells in which a liquid-crystalline material is enclosed between the pair of substrates. A liquid crystal display device generally has a liquid crystal panel and a pair of polarizer layers provided on the viewing side and the back side thereof. The manufacturing method of the molded body with a polarizer layer of the present application can be preferably applied to manufacturing a liquid crystal display device having a display surface in a curved shape, or manufacturing a structural member thereof, the liquid crystal display device having a liquid crystal panel as a base member, a polarizer layer on the viewing side thereof, and a hard coat layer for protecting the outermost surface on the viewing side of the display device.

[0166] As another example, the base member can be a display element of an organic electroluminescent display device. Here, the display element refers to a member including a substrate, a first electrode in a layer shape formed on the substrate, a light-emitting layer formed on the first electrode, a second electrode formed on the light-emitting layer, and a sealing layer that seals the electrode and the light-emitting layer. In an organic electroluminescent display device, a member containing a polarizer layer is sometimes provided on the viewing side more than the display element for the purpose of preventing reflection glare of external light, improving display quality when the display surface is observed through polarized sunglasses, and the like. The manufacturing method of the molded body with a polarizer layer of the present application can be preferably applied to manufacturing an organic electroluminescent display device having a display surface in a curved shape, or manufacturing a structural member thereof, the organic electroluminescent display device having a display element as a base member, a polarizer layer on the viewing side thereof, and a hard coat layer for protecting the outermost surface on the viewing side of the display device.

[0167] The bonding in the process (B) can be performed by bonding the polarizing film to the base member using a suitable adhesive. As the adhesive, the adhesive layer as any of the above-described components can be used. For example, in the case of using a polarizing film with an adhesive layer and a release film having a layer structure of (support) / (hard coat layer) / (resin layer (A)) / (adhesive layer) / (polarizer layer) / (adhesive layer) / (release film), the release film can be peeled off to expose the adhesive layer, and the bonding to the base member can be performed via the adhesive layer.

[0168] In one embodiment of the method for producing the molded body with a polarizer layer of the present application, the base member supplied to the process (B) is a member having a curved surface. In another embodiment of the method for producing the molded body with a polarizer layer of the present application, a process (Bx) of bending the base member is further included after the process (B) and before the process (C). Hereinafter, the former production method will be referred to as "production method 1", and the latter production method will be referred to as "production method 2".

[0169] In the production method 1, in the process (B), the polarizing film is bonded to the base member having a curved surface. Specifically, the polarizing film is bonded to the curved surface. Since the polarizing film is generally produced as a flat film, in the case of performing such bonding, the polarizing film needs to follow the curved surface. In the method for producing the molded body with a polarizer layer of the present application, as the polarizing film, a polarizing film with high followability to a curved surface produced by the above-described production method of the polarizing film of the present application is used, and thus this process can be easily performed. Further, since the polarizing film has low tendency to curl, the bonding can be easily performed.

[0170] In the production method 2, as the process (Bx), the base member is bent after the process (B). The surface of the base member before the bending can also be a flat surface. Alternatively, the already bent surface can be further deformed in the process (Bx) to change the degree of bending. Thus, even in the case where the base member is bent after the bonding, the polarizing film needs to follow the curved surface after the process (Bx). In the method for producing the molded body with a polarizer layer of the present application, as the polarizing film, a polarizing film with high followability to a curved surface produced by the above-described production method of the polarizing film of the present application is used, and thus this process can also be easily performed. Further, since the polarizing film has low tendency to curl, the bonding in the process (B) can be easily performed.

[0171] In the process (C), the hard coat layer in the polarizing film is subjected to main curing. By this process of main curing, the hard coat layer becomes a main cured product, loses stretchability, and on the other hand, has the hardness and other properties required for the hard coat layer in the final product. This process is performed while maintaining the state in which the polarizing film follows the curved surface. Therefore, by this process, the molded body with a polarizer layer as a product is a molded body having a curved surface shape, the molded body having: a polarizer layer; a resin layer (A) that protects the polarizer layer; a hard coat layer that has sufficient hardness and scratch resistance and the like as a hard coat layer that protects the resin layer (A) and protects the outer surface of the product, and that well follows the shape of the curved surface.

[0172] Example

[0173] Hereinafter, the present application will be specifically described with examples. However, the present application is not limited to the examples shown below, and the examples can be arbitrarily changed within the scope of the claims of the present application and the equivalent thereof.

[0174] In the following description, "%" and "parts" representing amounts are weight basis, unless otherwise specified. Further, unless otherwise specified, the operations described below are performed under the conditions of ordinary temperature and ordinary pressure.

[0175] [evaluation method]

[0176] (storage modulus)

[0177] A resin to be measured was hot-melted and molded using a hot melt press under the conditions of a gap of 1 mm, 250°C, and 30 MPa, thereby obtaining a measurement film having a thickness of 1 mm.

[0178] The storage modulus at 23°C was measured for the measurement film by a dynamic viscoelasticity measuring device (ARES manufactured by TA Instruments Japan Inc.).

[0179] (water vapor permeability)

[0180] A resin to be measured was hot-melted and molded using a hot melt press under the conditions of a gap of 100 μm, 250°C, and 30 MPa, thereby obtaining a measurement film having a thickness of 100 μm.

[0181] The water vapor permeability was measured for the measurement film using a water vapor permeability measuring device (PERMATRAN-W manufactured by MOCON Corporation) in accordance with the JIS K 7129 B method under the conditions of a temperature of 40°C and a humidity of 90% RH.

[0182] (curling property)

[0183] Cut the membrane of the test object into 10cm × 10cm square sections. Place the sections at 23°C and 55%RH for 24 hours to moisten them. Then, place the sections on the surface of a horizontal platform with the hard coating facing up. Measure the height of each of the four vertices of the section (the vertical distance from the platform surface to the vertices of the section), calculate their maximum value h1, and evaluate the curlability according to the following criteria.

[0184] AA (Very low curl, excellent panel mounting): h1≤10mm

[0185] A (Minimal curling, good panel mounting): 10mm < h1 ≤ 25mm

[0186] B (Large curling, poor panel installation, reduced panel yield): 25mm < h1 ≤ 40mm

[0187] C (Extremely large curl, difficult to install onto the panel): 40mm < h1

[0188] (Bending test)

[0189] The bending test laminates containing aluminum plates and other layers obtained in the examples and comparative examples were bent 90° with the aluminum plate as the inside. The bending test was performed from the hard coating side at a force of 750 mJ / cm. 2 The laminate was irradiated with ultraviolet light under the following conditions. Then, the laminate was placed at 85°C and 85% humidity for 120 hours, and the condition of the bent portion was observed and evaluated according to the following criteria. The bent portion, as the object of observation, was a 20mm wide strip centered on the line where the plate was bent.

[0190] A: It did not change color.

[0191] B: Discoloration was observed in less than 40% of the curved section.

[0192] C: Discoloration was observed in more than 40% of the curved portion.

[0193] [Example 1]

[0194] (1-1. Hard coating material solution)

[0195] To a solution (trade name "LUXYDIR V-6850", manufactured by DIC Corporation, solid content ratio 50% by weight) of a polymerizable substance (H) for a hard coat material was added ethyl acetate as a diluent to obtain a solution (i) having a solid content ratio of 20% by weight. A photopolymerization initiator (trade name "IRGACURE 184", manufactured by Ciba Specialty Chemicals Inc.) was further added at a ratio of 3 parts with respect to 100 parts of the solid content of the solution (i), and stirred for 10 minutes. By this operation, a hard coat material solution (ii) was obtained.

[0196] (1-2. Hard coat layer)

[0197] A support (trade name "TORAYFAN BO40-2500", manufactured by Toray) of a biaxially stretched polypropylene film was prepared. The hard coat material solution (ii) obtained in (1-1) was applied to one surface of the support by a gravure printing method, and dried (90°C x 2 minutes). By this operation, a hard coat layer having a film thickness of 7 μm was formed, and a laminate (i) having a layer structure of (support) / (hard coat layer) was obtained.

[0198] (1-3. Resin A1)

[0199] Referring to the production example described in Japanese Patent Application Publication No. 2002-105151, 25 parts of a styrene monomer was polymerized in a first stage, 30 parts of a styrene monomer and 25 parts of an isoprene monomer were polymerized in a second stage, and then 20 parts of a styrene monomer was polymerized in a third stage, to obtain a block copolymer [D1], and further the block copolymer [D1] was hydrogenated to synthesize a block copolymer hydrogenate [E1]. The block copolymer hydrogenate [E1] had a Mw of 84500, a Mw / Mn of 1.20, and a hydrogenation rate of the main chain and aromatic ring of almost 100%.

[0200] After 0.1 parts of pentaerythritol tetrakis [3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate] (manufactured by Songwon Industrial Co., Ltd., product name "Songnox 1010") as an antioxidant was melt-kneaded and incorporated in 100 parts of the block copolymer hydrogenate [E1], it was pelletized to obtain a resin A1 for molding. The resin A1 was measured for storage modulus, and the result was 720 MPa. The resin A1 was measured for water vapor permeability, and the result was 4.0 g / (m 2 • day).

[0201] (1-4. Transfer medium laminate)

[0202] The resin Al obtained in (1-3) was dissolved in cyclohexane, and 7 parts by weight of a UV absorber (trade name "ADEKASTAB LA-70", manufactured by ADEKA Corporation) was added with respect to 100 parts by weight of the resin Al to obtain a solution (iii) having a solid content of 15% by weight.

[0203] The surface of the hard coat layer side of the laminate (i) obtained in (1-2) was coated with the solution (iii) using a gravure coater, and dried (90°C x 2 minutes). By this operation, a resin layer (A) having a film thickness of 5 μm was formed, and a transfer medium laminate having a layer structure of (support) / (hard coat layer) / (resin layer (A)) was obtained.

[0204] A part of the transfer medium laminate obtained was used after the following procedure (1-6). The other part was used to measure the in-plane retardation Re. That is, the resin layer (A) was peeled from the transfer medium laminate, and Re was measured.

[0205] (1-5. Polarizer)

[0206] As a raw film, a non-stretched polyvinyl alcohol film (vinylon film, average polymerization degree about 2400, saponification degree 99.9 mol%) having a thickness of 20 μm was prepared. While continuously transporting the film along the length direction via guide rollers, the film was subjected to a swelling treatment, and then a dyeing treatment to adsorb iodine. In the swelling treatment, the film was immersed in pure water at 30°C for 1 minute. In the dyeing treatment, the film was immersed in a dyeing solution (a dyeing agent solution containing iodine and potassium iodide at a molar ratio of 1:23, dyeing agent concentration 1.2 mmol / L) at 32°C for 2 minutes. Then, the film was washed with a 3% boric acid aqueous solution at 35°C for 30 seconds, and then stretched 6 times in an aqueous solution containing 3% boric acid and 5% potassium iodide at 57°C. Then, the film was subjected to a complementary color treatment in an aqueous solution containing 5% potassium iodide and 1.0% boric acid at 35°C, and then dried at 60°C for 2 minutes, by which a polarizer Pa1 having a thickness of 23 μm was obtained. The thickness of the polarizer Pa1 was 7 μm. The moisture content of the polarizer Pa1 was measured using an on-line moisture content measuring device manufactured by Kurashiki Textile Co., Ltd., and the result was 7.5%.

[0207] (1-6. Polarizing film)

[0208] An on-line corona treatment was performed on the surface of the resin layer (A) side of the transfer medium laminate obtained in (1-4), and a layer of a UV-curable adhesive (trade name "ARKLS KRX-7007", manufactured by ADEKA Corporation) was formed using a gravure coater. The resin layer (A) was pressed and bonded to the polarizer Pa1 obtained in (1-5) via the layer of the adhesive using pinch rollers. Immediately thereafter, the bonded product was subjected to UV irradiation of 750 mJ / cm2from the polarizer Pa1 side using a UV irradiation device.2 The layer of the adhesive was cured by ultraviolet irradiation of the UV irradiation device "UV-3000" manufactured by Fusion UV Systems, Inc. to form an adhesive layer having a thickness of 2 μm. By this operation, a polarizing film Pb1 having a layer structure of (support body) / (hard coat layer) / (resin layer (A)) / (adhesive layer) / (polarizer layer Pa1) with a support body was obtained.

[0209] A part of the obtained polarizing film Pb1 was used after the following process (1-8). The other part was used for evaluation of curling property and stretchability. That is, the support body was peeled off from the polarizing film Pb1 with a support body to obtain a polarizing film Pc1 having a layer structure of (hard coat layer) / (resin layer (A)) / (adhesive layer) / (polarizer layer Pa1). This was used as a measurement object to evaluate the curling property. Further, the hard coat layer was peeled off from the polarizing film Pc1, and the hard coat layer was made into a rectangle having a length of 150 mm and a width of 20 mm, and free uniaxial stretching was performed in the length direction, and it was confirmed that the hard coat layer could be stretched to 2.00 times without generation of cracks.

[0210] Further, at this time, the hard coat layer exposed on the surface of the polarizing film Pc1 was touched with a finger to evaluate the tackiness. As a result, even if the hard coat layer was touched with a finger, the material constituting the hard coat layer did not adhere to the finger, and thus it was evaluated as having no tackiness.

[0211] (1-7. Adhesive composition)

[0212] Into a reaction vessel, 69 parts by weight of n-butyl acrylate (n-BA), 30 parts by weight of phenoxy diethylene glycol acrylate, 1 part by weight of 4-hydroxybutyl acrylate (4HBA), 120 parts by weight of ethyl acetate, and 0.1 part by weight of azobisisobutyronitrile (AIBN) were added, the inside of the reaction vessel was replaced with nitrogen after which the reaction solution was warmed to 66°C under stirring in a nitrogen atmosphere, and the reaction was performed for 10 hours. After the completion of the reaction, dilution was performed with ethyl acetate to obtain an acrylic copolymer solution having a solid content of 20% by weight. The acrylic copolymer obtained had a weight average molecular weight (Mw) of 1.1 million as measured by GPC.

[0213] To the obtained copolymer solution of 500 parts by weight (solid content 100 parts by weight), 0.1 part by weight of an isocyanate-based crosslinking agent (trade name "CORONATE L", manufactured by Japan Polyurethane Co., Ltd.) and 0.1 part by weight of a silane coupling agent (trade name "KBM-402", manufactured by Shin-Etsu Polymer Co., Ltd.) were added, and mixed sufficiently to obtain an adhesive composition Al.

[0214] (1-8. Polarizing film composite with adhesive layer and release film)

[0215] As a release film, a PET film (trade name "MRV38", manufactured by Mitsubishi Chemical) subjected to a release treatment with silicone was prepared. The adhesive composition A1 obtained in (1-7) was applied to the surface of the release film using a die coater, and the solvent component was volatilized by drying at 90°C for 3 minutes to form an adhesive layer of 20 μm, thereby obtaining a laminate (iv) having a layer structure of (adhesive layer) / (release film).

[0216] The surface of the adhesive layer side of the laminate (iv) was attached to the surface of the polarizer layer Pa1 of the polarizing film Pb1 with a support obtained in (1-6), thereby obtaining a polarizing film composite Pd1 with an adhesive layer and a release film having a layer structure of (support) / (hard coat layer) / (resin layer (A)) / (adhesive layer) / (polarizer layer Pa1) / (adhesive layer) / (release film).

[0217] (1-9. Bending test)

[0218] The obtained polarizing film composite Pd1 was left to stand for 5 days under conditions of a temperature of 23°C and a humidity of 55%, thereby allowing it to cure. Then, the release film was peeled from the polarizing film composite Pd1, and the adhesive layer was exposed. The adhesive layer was attached to an aluminum plate having a thickness of 0.5 mm, and the support was peeled. Thus, a bending test laminate having a layer structure of (hard coat layer) / (resin layer (A)) / (adhesive layer) / (polarizer layer Pa1) / (adhesive layer) / (aluminum plate) was obtained. The bending test was performed on the bending test laminate.

[0219] [Example 2]

[0220] In the production of the transfer medium laminate of (1-4), the coating thickness of the solution (iii) was changed, and the thickness of the resin layer (A) formed was changed to 1 μm. Otherwise, the transfer medium laminate, the polarizing film, and the bending test laminate were obtained and evaluated by the same procedures as in Example 1.

[0221] [Example 3]

[0222] (3-1. Resin A2)

[0223] Resin A2 was obtained by mixing 100 parts by weight of a norbornene-based polymer resin (trade name "ZEONOR 1430", manufactured by Japan Zeon Corporation) and 50 parts by weight of polyisobutylene (trade name "Nisseki Polybutene HV-300", manufactured by JX Nippon Oil & Energy Corporation, number average molecular weight 1400) as a plasticizer. The water vapor permeability of Resin A2 was measured, and the result was 1 g / (m 2 ·day).

[0224] (3-2. Transfer medium laminate, etc.)

[0225] In manufacturing the transfer medium laminate of (1-4), resin A2 obtained in (3-1) of Example 3 was used instead of resin Al, and otherwise, by the same operations as (1-1) to (1-2) and (1-4) to (1-9) of Example 1, a transfer medium laminate, a polarizing film, and a bending test laminate were obtained and evaluated.

[0226] [Example 4]

[0227] The following points were changed, and otherwise, by the same operations as (1-1) to (1-2) and (1-4) to (1-9) of Example 1, a transfer medium laminate, a polarizing film, and a bending test laminate were obtained and evaluated.

[0228] • In manufacturing the transfer medium laminate of (1-4), resin A2 obtained in (3-1) of Example 3 was used instead of resin Al.

[0229] • In manufacturing the transfer medium laminate of (1-4), the coating thickness of solution (iii) was changed, and the thickness of the resin layer (A) formed was changed to 1 μm.

[0230] [Example 5]

[0231] The following points were changed, and otherwise, by the same operations as Example 1, a transfer medium laminate, a polarizing film, and a bending test laminate were obtained and evaluated.

[0232] • In forming the hard coat layer of (1-2), the same film as the release-treated PET film used in (1-8) was used instead of the biaxially-stretched polypropylene film as the support.

[0233] • In manufacturing the transfer medium laminate of (1-4), the coating thickness of solution (iii) was changed, and the thickness of the resin layer (A) formed was changed to 1 μm.

[0234] [Example 6]

[0235] (6-1. Polarizer)

[0236] As the raw film, a thicker film than the film used in (1-5) was used, and otherwise, by the same operations as (1-5) of Example 1, a polarizer Pa2 was prepared. The thickness of the polarizer Pa2 was 5 μm.

[0237] (6-2. Transfer medium laminate, etc.)

[0238] In the production of the polarizing film (1-6), the polarizer Pa2 obtained in (6-1) was used in place of the polarizer Pal, and otherwise, by the same operations as (1-1) to (1-4) and (1-6) to (1-9) of Example 1, a transfer medium laminate, a polarizing film and a bending test laminate were obtained and evaluated.

[0239] [Comparative Example 1]

[0240] (C1-1. Resin Layer (CA))

[0241] As the film constituting the resin layer (CA), a triacetyl cellulose (TAC) film ("FUJITAC T25" manufactured by FUJIFILM, thickness 25 μm) was prepared. The storage modulus and the water vapor permeability of the triacetyl cellulose constituting the film were measured.

[0242] (C1-2. Hard Coat Layer)

[0243] On one surface of the resin layer (CA), the hard coat layer material solution (ii) obtained in (1-1) of Example 1 was applied by a gravure coater, and dried (90°C x 2 minutes). By this operation, a hard coat layer having a film thickness of 7 μm was formed, and a laminate (C-i) having a layer structure of (hard coat layer) / (resin layer (CA)) was obtained.

[0244] (C1-3. Polarizing Film)

[0245] The surface of the resin layer (CA) side of the laminate (C-i) obtained in (C1-2) was subjected to an in-line corona treatment, and an ultraviolet-curable adhesive (the same as the adhesive used in Example 1) was applied by a gravure coater to form a layer of the adhesive. The resin layer (CA) and the polarizer Pal obtained in (1-5) of Example 1 were pressed and bonded to each other via the layer of the adhesive using pinch rollers. Subsequently, the bonded product was subjected to ultraviolet irradiation of 750 mJ / cm2from the polarizer Pal side using an ultraviolet irradiation device, and the layer of the adhesive was cured to form an adhesive layer having a thickness of 2 μm. By this operation, a polarizing film PC having a layer structure of (hard coat layer) / (resin layer (CA)) / (adhesive layer) / (polarizer layer Pal) was obtained. 2

[0246] A part of the polarizing film PC obtained was used after the following procedure (C1-4). The other part was used for evaluation of the curling property and the stretchability. As the evaluation of the stretchability, the hard coat layer was peeled from the polarizing film PC, and the hard coat layer was made into a rectangle having a length of 150 mm and a width of 20 mm, and a free uniaxial stretching was performed in the length direction. As a result, a crack was generated before the stretching ratio reached 1.50 times, and the subsequent stretching could not be performed.

[0247] (C1-4. Bending Test) ​

[0248] In the production of the polarizing film composite with the adhesive layer and the release film of (1-8), the polarizing film PC obtained in (C1-3) was used instead of the polarizing film Pb1, and, other than that, the same operations as (1-7) to (1-9) of Example 1 were performed to obtain the bending test laminate and perform the evaluation. However, since the polarizing film PC did not have a support, the peeling of the support in (1-9) was not performed.

[0249] [Comparative Example 2]

[0250] (C2-1. Resin layer (CA))

[0251] An acrylic resin ("Sumipex HT55X" manufactured by Sumitomo Chemical Co., Ltd.) was supplied to a hot melt extrusion film molding machine having a T die. The acrylic resin was extruded from the T die and wound on a roll at a take-up speed of 4 m / minute, whereby the acrylic resin was molded into a film shape. Thus, a long film (thickness: 40 μm) formed of the acrylic resin was obtained. This film was used as the film constituting the resin layer (CA). The storage modulus and the water vapor permeability of the acrylic resin constituting the film were measured.

[0252] (C2-2. Polarizer)

[0253] As the raw film, a film thicker than the film used in (1-5) was used, and, other than that, the same operations as (1-5) of Example 1 were performed to prepare the polarizer Pa3. The thickness of the polarizer Pa3 was 23 μm.

[0254] (C2-3. Laminate, etc.)

[0255] The following points were changed, and, other than that, the same operations as (C1-2) to (C1-4) of Comparative Example 1 were performed to obtain the laminate (C-i), the polarizing film, and the bending test laminate and perform the evaluation.

[0256] • As the resin layer (CA), the resin layer of (C2-1) was used instead of the resin layer of (C1-1).

[0257] • As the polarizer, the polarizer Pa3 obtained in (C2-2) was used instead of the polarizer Pa1 obtained in Example 1.

[0258] In the evaluation of the stretchability of the hard coat layer, a crack was generated before the stretch ratio reached 1.50 times, and the subsequent stretching could not be performed.

[0259] [Comparative Example 3]

[0260] (C3-1. Resin layer (CA))

[0261] A norbornene-based polymer resin (the same as used in Example 3) was supplied to a hot melt extrusion film molding machine having a T die. The resin was extruded from the T die to be wound on a roll at a take-up speed of 4 m / min, whereby the resin was molded into a film shape. Thus, a long film (thickness 23 μm) formed of a norbornene-based resin was obtained. This film was used as the film constituting the resin layer (CA). The storage modulus and the water vapor permeability of the resin constituting the film were measured.

[0262] (C3-2. Laminate, etc.)

[0263] As the resin layer (CA), the resin layer of (C3-1) was used instead of the resin layer of (C1-1), and otherwise, by the same operations as (C1-2) to (C1-4) of Comparative Example 1, a laminate (C-i), a polarizing film, and a bending test laminate were obtained and evaluated.

[0264] In the evaluation of the stretchability of the hard coat layer, a crack was generated before the stretch ratio reached 1.50 times, and the following stretching could not be performed.

[0265] The outline of the examples and comparative examples and the evaluation results are shown in Tables 1 to 2.

[0266] [Table 1]

[0267]

[0268] [Table 2]

[0269]

[0270] The meanings of the abbreviations in the table are shown below.

[0271] Resin material: The material of the resin used as the resin layer (A) or the resin layer (CA). A1: Resin A1 prepared in Example 1. A2: Resin A2 prepared in Example 3. TAC: Triacetyl cellulose. PMMA: Acrylic resin. 1430: Norbornene-based polymer resin.

[0272] Elastic modulus: The storage modulus of the resin material. Unit: MPa.

[0273] Water vapor permeability: The water vapor permeability of the resin material. Unit: g / (m 2 day). The measured value in a film for measurement having a thickness of 100 μm.

[0274] Resin layer thickness: The thickness of the resin layer (A) or the resin layer (CA). Unit: μm.

[0275] Resin layer Re: The in-plane retardation Re of the resin layer (A) or the resin layer (CA). Unit: nm.

[0276] Thickness of polarizer: unit: pm.

[0277] Support type: type of support used. OPP: biaxially stretched polypropylene film. Si-PET: PET film subjected to release treatment with silicone.

[0278] Total thickness: total thickness of (hard coat layer) / (resin layer (A)) / (adhesion layer) / (polarizer layer) / (adhesion layer), or total thickness of (hard coat layer) / (resin layer (CA)) / (adhesion layer) / (polarizer layer) / (adhesion layer). Unit: pm.

[0279] Stretchability: evaluation result of stretchability of hard coat layer at the time of forming the polarizing film. Yes: free uniaxial stretching of hard coat layer to 1.50 times can be performed without generation of cracks. No: free uniaxial stretching of hard coat layer to 1.50 times cannot be performed without generation of cracks.

[0280] Stickiness: evaluation result of stickiness of hard coat layer at the time of forming the polarizing film. No: even if the hard coat layer is contacted with a finger, the material constituting the hard coat layer does not adhere to the finger. Yes: when the hard coat layer is touched with a finger, the material constituting the hard coat layer adheres to the finger.

[0281] Curl: value of numerical value h1 in curl evaluation. Unit: mm. Cannot be measured: curl is too strong, and h1 cannot be measured.

[0282] Curl: evaluation result of curl.

[0283] Bending: evaluation result of bending test.

[0284] From the results of Tables 1 to 2, it was found that the polarizing film of the present application obtained using the transfer medium laminate of the present application has a small tendency to generate curl, and is good at following the curved surface shape when attached to an aluminum plate having a curved surface. Therefore, the polarizing film of the present application can be preferably used for manufacturing a molded body having a polarizer layer with a curved surface.

Claims

1. A method for manufacturing a molded article, specifically a method for manufacturing a molded article with a polarizer layer. The manufacturing method includes the following steps: Process A in the manufacture of polarizing films; Step B, which involves attaching the polarizing film to the substrate component; and Step C, which involves the primary curing of the hard coating in the polarizing film. The base component supplied for step B is a component with a curved surface, or the manufacturing method further includes a step Bx that bends the base component after step B and before step C. Step A is a method for manufacturing a polarizing film comprising a transfer medium laminate, a polarizer layer, and an adhesive layer. The transfer medium laminate has a hard coating and a resin layer A disposed on one surface of the hard coating. The polarizer layer is disposed on the resin layer A side of the transfer medium laminate. The adhesive layer is located between the transfer medium laminate and the polarizer layer. The resin layer A contains an ultraviolet absorber. Process A includes the following processes: The process of bonding the transfer medium laminate to the polarizer layer using a UV-curable adhesive to form a laminate; and The process of irradiating the laminate with ultraviolet light from the polarizer layer side of the laminate. The hard coating is tensile. The hard coating is a semi-cured product of the hard coating material. The tensile property refers to the property that, when the hard coating, as an independent film, is made into a rectangle with a length of 150 mm and a width of 20 mm and is stretched freely uniaxially along its length, it can withstand a stretch of more than 1.50 times without cracking. The storage modulus of the resin constituting the resin layer is below 1000 MPa. The hard coating material contains an ultraviolet polymerization initiator as a polymerization initiator. In the transfer medium laminate, the resin layer A is a layer formed on the surface of the semi-cured material.

2. The method for manufacturing a molded article according to claim 1, wherein, In the transfer medium laminate, the thickness of the resin layer A is 0.1 μm or more and 10 μm or less.

3. The method for manufacturing the molded article according to claim 1 or 2, wherein, In the transfer medium laminate, the in-plane retardation Re of the resin layer is greater than 0 nm and less than 5 nm.

4. The method for manufacturing a molded article according to claim 1 or 2, wherein, The transfer medium laminate further includes a support disposed on the surface of the hard coating layer opposite to the resin layer A side.

5. The method for manufacturing a molded article according to claim 4, wherein, The support has a release layer disposed on the surface of the hard coating side.

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