Optical laminate and manufacturing method of the same

Abstract

To provide an optical laminate that can simplify manufacturing processes and be made thin.SOLUTION: The optical laminate includes a base material layer, an optical absorption anisotropic layer, a horizontal alignment layer and a liquid crystal polarizer which are laminated in this order. The optical absorption anisotropic layer includes polymer of polymerizable liquid crystal compound and dichroic dye, and satisfies formulae (1) to (3). The liquid crystal polarizer includes polymer of polymerizable liquid crystal compound and dichroic dye and has an absorption axis in a horizontal direction. The optical absorption anisotropic layer and the horizontal alignment layer are in direct contact with each other or has only a coating layer therebetween. The horizontal alignment layer and the liquid crystal polarizer are in direct contact with each other. A distance from a surface of the optical absorption anisotropic layer facing the base material layer to a surface of the liquid crystal polarizer away from the horizontal alignment layer is 10 μm or less. Az>(Ax+Ay) / 2 (1), 0.001≤Ax≤0.1 (2) and Ax(z=60°) / Ax≥5 (3).SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to an optical laminate and a method for manufacturing the same.

Background Art

[0002] In an organic EL (electroluminescence) display device, in order to reduce the color difference between the front color phase when viewed from the front during white display and the oblique color phase when viewed obliquely, a laminate having a vertically aligned liquid crystal cured film, which is a cured product of a composition containing a polymerizable liquid crystal compound and a dichroic dye, and a horizontally aligned retardation film is known to be used (for example, Patent Document 1). Patent Document 1 also discloses obtaining an elliptical polarizing plate by laminating this laminate and a polarizing film.

[0003] A circular polarizing plate in which a polarizing plate having a polarizing film in which a dichroic dye and a polymerizable liquid crystal compound are horizontally aligned and a retardation layer are laminated is also known (for example, Patent Document 2).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] There is a demand for further thinning of an elliptical polarizing plate or a circular polarizing plate (hereinafter, both are also collectively referred to as "elliptical polarizing plate") and further simplification of the manufacturing process of the elliptical polarizing plate.

[0006] An object of the present invention is to provide an optical laminate and a method for manufacturing the same that can simplify the manufacturing process and achieve thinning.

Means for Solving the Problems

[0007] The present invention provides the following optical laminate and a method for manufacturing the optical laminate. 〔1〕 An optical laminate in which a substrate layer, a light absorption anisotropic layer, a horizontal alignment layer, and a liquid crystal polarizer are laminated in this order, wherein the light absorption anisotropic layer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and satisfies the following relationships of formulas (1) to (3), the liquid crystal polarizer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and has an absorption axis in a horizontal direction with respect to the plane of the liquid crystal polarizer, the substrate layer and the light absorption anisotropic layer are in direct contact, or only a vertical alignment layer is provided between the substrate layer and the light absorption anisotropic layer, the light absorption anisotropic layer and the horizontal alignment layer are in direct contact, or only a coating layer is provided between the light absorption anisotropic layer and the horizontal alignment layer, the horizontal alignment layer and the liquid crystal polarizer are in direct contact, and the distance from the surface of the light absorption anisotropic layer on the substrate layer side to the surface of the liquid crystal polarizer on the side opposite to the horizontal alignment layer side is 10 μm or less. Az > (Ax + Ay) / 2 (1) 0.001 ≦ Ax ≦ 0.1 (2) Ax(z = 60°) / Ax ≧ 5 (3) [In formulas (1) to (3), Ax, Ay, and Az are the absorbances at the absorption maximum wavelengths in the wavelength range of 380 nm or more and 780 nm or less of the light absorption anisotropic layer, and represent the absorbances of linearly polarized light vibrating in the x-axis direction, y-axis direction, and z-axis direction, respectively. Ax(z = 60°) is the absorbance at the absorption maximum wavelength, and represents the absorbance of linearly polarized light vibrating in the x-axis direction when the light absorption anisotropic layer is rotated by 60° with the y-axis as the rotation axis. Here, the x-axis is an arbitrary one direction in the plane of the light absorption anisotropic layer, the y-axis is a direction orthogonal to the x-axis in the plane of the light absorption anisotropic layer, and the z-axis is a direction orthogonal to the x-axis and the y-axis. ] 〔2〕 The optical laminate according to 〔1〕, further comprising a protective layer on a side opposite to the horizontal alignment layer side of the liquid crystal polarizer. 〔3〕 The optical laminate according to 〔2〕, wherein the liquid crystal polarizer and the protective layer are in direct contact with each other. 〔4〕 Further comprising a first liquid crystal retardation layer laminated via a first adhesive layer on a side opposite to the liquid crystal polarizer side of the protective layer, The first liquid crystal retardation layer contains a polymer of a polymerizable liquid crystal compound oriented in a horizontal direction with respect to the plane of the first liquid crystal retardation layer. The optical laminate according to 〔2〕 or 〔3〕. 〔5〕 Further comprising a second liquid crystal retardation layer laminated via a second adhesive layer on a side opposite to the liquid crystal polarizer side of the first liquid crystal retardation layer, The second liquid crystal retardation layer contains a polymer of a polymerizable liquid crystal compound oriented in a vertical direction with respect to the plane of the second liquid crystal retardation layer. The optical laminate according to 〔4〕. 〔6〕 The optical laminate according to any one of 〔1〕 to 〔5〕, wherein the base material layer is a resin film. 〔7〕 The base material layer includes a coating resin layer, The resin constituting the coating resin layer is at least one selected from the group consisting of a cellulose ester resin, an olefin resin, and a (meth)acrylic resin. The optical laminate according to any one of 〔1〕 to 〔6〕. 〔8〕 The dichroic dye contained in the liquid crystal polarizer is an azo dye. The optical laminate according to any one of 〔1〕 to 〔7〕. 〔9〕 A method for manufacturing an optical laminate in which a base material layer, a light absorption anisotropic layer, a horizontal alignment layer, and a liquid crystal polarizer are laminated in this order, The light absorption anisotropic layer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and satisfies the following relationships of formulas (1) to (3), The liquid crystal polarizer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and has an absorption axis in a horizontal direction with respect to the plane of the liquid crystal polarizer, A step of forming the light absorption anisotropic layer so as to be in direct contact with the base material layer or so as to be in direct contact with a vertical alignment layer formed on the surface of the base material layer, Forming the horizontal alignment layer directly on the light absorption anisotropic layer or via a coating layer; Directly applying, on the horizontal alignment layer, a composition for forming the liquid crystal polarizer, the composition for forming the liquid crystal polarizer containing a polymerizable liquid crystal compound and a dichroic dye; and the method for manufacturing an optical laminate includes: The step of forming the horizontal alignment layer: [a] directly applying, on the light absorption anisotropic layer, a composition for forming the horizontal alignment layer for forming the horizontal alignment layer, or [b] directly applying, on the light absorption anisotropic layer, a composition for forming the coating layer for forming the coating layer, and directly applying, on the coating layer, a composition for forming the horizontal alignment layer for forming the horizontal alignment layer. Az>(Ax + Ay) / 2 (1) 0.001 ≦ Ax ≦ 0.1 (2) Ax(z = 60°) / Ax ≧ 5 (3) [In formulas (1) to (3), Ax, Ay, and Az are absorbances at the absorption maximum wavelengths in the wavelength range of 380 nm or more and 780 nm or less of the light absorption anisotropic layer, and represent absorbances of linearly polarized light vibrating in the x-axis direction, y-axis direction, and z-axis direction, respectively. Ax(z = 60°) is the absorbance at the absorption maximum wavelength, and represents the absorbance of linearly polarized light vibrating in the x-axis direction when the light absorption anisotropic layer is rotated by 60° with the y-axis as the rotation axis. Here, the x-axis is an arbitrary direction in the plane of the light absorption anisotropic layer, The y-axis is a direction orthogonal to the x-axis in the plane of the light absorption anisotropic layer, The z-axis is a direction orthogonal to the x-axis and the y-axis. ] 〔10〕 In the optical laminate, the distance from the surface on the base material layer side of the light absorption anisotropic layer to the surface on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer is 10 μm or less. The method for manufacturing an optical laminate according to 〔9〕. The step of forming the light absorption anisotropic layer includes directly applying a composition for forming a light absorption anisotropic layer containing a polymerizable liquid crystal compound and a dichroic dye on the base material layer or on the vertical alignment layer, the method for manufacturing an optical laminate according to [9] or

[10] . 〔12〕 The optical laminate further has a protective layer on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer, The method for manufacturing an optical laminate according to any one of [9] to

[11] , further including directly applying a composition for forming a protective layer on the surface on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer.

Advantages of the Invention

[0008] According to the present invention, the manufacturing process of the optical laminate can be simplified, and the optical laminate can be made thinner.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Embodiments for Carrying Out the Invention

[0010] Hereinafter, with reference to the drawings, preferred embodiments of an optical laminate and a method for manufacturing the same will be described.

[0011] (Optical Laminate) Figs. 1 to 4 are cross-sectional views schematically showing an optical laminate according to an embodiment of the present invention. In the optical laminates 1 to 4, a substrate layer 11, a light absorption anisotropic layer 13, a horizontal alignment layer 15, and a liquid crystal polarizer 16 are laminated in this order. The light absorption anisotropic layer 13 contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and satisfies the relationships of formulas (1) to (3) described later. The liquid crystal polarizer 16 contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and has an absorption axis in the horizontal direction with respect to the plane of the liquid crystal polarizer 16.

[0012] The optical laminates 1 to 4 may further have a protective layer 17 on the side opposite to the horizontal alignment layer 15 side of the liquid crystal polarizer 16.

[0013] The optical laminates 3 and 4 may further have a retardation element. The retardation element may be a retardation layer that is a stretched film, or may be a liquid crystal retardation layer containing a polymer of a polymerizable liquid crystal compound. For example, as shown in Figs. 3 and 4, the optical laminates 3 and 4 may have a first liquid crystal retardation layer 22 on the side opposite to the liquid crystal polarizer 16 side of the protective layer 17, and may have a second liquid crystal retardation layer 24 on the side opposite to the liquid crystal polarizer 16 side of the first liquid crystal retardation layer 22. The optical laminates 3 and 4 may be an elliptical polarizing plate or a circular polarizing plate (hereinafter, both are collectively referred to as an "elliptical polarizing plate"), or may be an elliptical polarizing plate that functions as an antireflection film.

[0014] When the optical laminates 3 and 4 do not have the protective layer 17, the first liquid crystal retardation layer 22 may be laminated on the side opposite to the horizontal alignment layer 15 side of the liquid crystal polarizer 16. The first liquid crystal retardation layer 22 may be laminated on the liquid crystal polarizer 16 or the protective layer 17 via a first adhesive layer 21. In this case, it is preferable that the first adhesive layer 21 is in direct contact with the first liquid crystal retardation layer 22 and the liquid crystal polarizer 16 or the protective layer 17. The second liquid crystal retardation layer 24 may be laminated on the first liquid crystal retardation layer 22 via a second adhesive layer 23. In this case, it is preferable that the second adhesive layer 23 is in direct contact with the second liquid crystal retardation layer 24 and the first liquid crystal retardation layer 22 or a first alignment layer described later.

[0015] The optical laminate 3, 4 may have a first alignment layer (not shown) that is in direct contact with the first liquid crystal retardation layer 22. The first alignment layer can be disposed between the liquid crystal polarizer 16 or the protective layer 17 and the first liquid crystal retardation layer 22. When the optical laminate 3, 4 has the first adhesive layer 21, the first alignment layer can be disposed between the first liquid crystal retardation layer 22 and the first adhesive layer 21. Alternatively, the first alignment layer may be disposed on the side opposite to the liquid crystal polarizer 16 side of the first liquid crystal retardation layer 22. The optical laminate 3, 4 may have a second alignment layer (not shown) that is in direct contact with the second liquid crystal retardation layer 24. The second alignment layer is preferably disposed on the side opposite to the first liquid crystal retardation layer 22 side of the second liquid crystal retardation layer 24, but may also be disposed on the first liquid crystal retardation layer 22 side of the second liquid crystal retardation layer 24.

[0016] When the optical laminate 3, 4 is an elliptical polarizing plate, in order to highly achieve the antireflection function, it is preferable that the first liquid crystal retardation layer 22, or the combination of the first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24, has a λ / 4 plate function (i.e., a phase difference function of π / 2) over the entire visible light range. The first liquid crystal retardation layer 22 or the second liquid crystal retardation layer 24 may be a λ / 4 liquid crystal retardation layer having a λ / 4 plate function, or may be a λ / 4 liquid crystal retardation layer with reverse wavelength dispersion. The first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24 may be a combination of a λ / 2 liquid crystal retardation layer having a positive wavelength dispersion λ / 2 plate function and a positive wavelength dispersion λ / 4 liquid crystal retardation layer. For example, the first liquid crystal retardation layer 22 may be a positive wavelength dispersion λ / 2 liquid crystal retardation layer, and the second liquid crystal retardation layer 24 may be a positive wavelength dispersion λ / 4 liquid crystal retardation layer.

[0017] In the optical laminate 3, 4 as an elliptical polarizing plate, from the viewpoint of compensating the antireflection function in the oblique direction, it may include a positive C-plate having anisotropy in the thickness direction. In the optical laminate 3, 4, for example, the first liquid crystal retardation layer 22 may be a λ / 4 liquid crystal retardation layer with reverse wavelength dispersion, and the second liquid crystal retardation layer 24 may be a positive C-plate. The optical laminate 3, 4 may have a positive C-plate in addition to the first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24.

[0018] In the optical laminates 1 to 4, the base material layer 11 and the light absorption anisotropic layer 13 are in direct contact (FIGS. 1 and 3), or only the vertical alignment layer 12 is provided between the base material layer 11 and the light absorption anisotropic layer 13 (FIGS. 2 and 4). When the optical laminates 1 to 4 include the vertical alignment layer 12, the vertical alignment layer 12 is in direct contact with the base material layer 11 and the light absorption anisotropic layer 13. Thereby, the optical laminates 1 to 4 can be made thinner, and as will be described later, the manufacturing process of the optical laminates 1 to 4 can also be simplified.

[0019] In the optical laminates 1 to 4, the light absorption anisotropic layer 13 and the horizontal alignment layer 15 are in direct contact (FIGS. 1 and 3), or only the coating layer 14 is provided between the light absorption anisotropic layer 13 and the horizontal alignment layer 15 (FIGS. 2 and 4). The coating layer 14 is usually a resin layer other than the adhesive layer. When the optical laminates 1 to 4 include the coating layer 14, the coating layer 14 is in direct contact with the light absorption anisotropic layer 13 and the horizontal alignment layer 15. Thereby, the optical laminates 1 to 4 can be made thinner. Also, as will be described later, the manufacturing process of the optical laminates 1 to 4 can be simplified.

[0020] In the optical laminates 1 to 4, the horizontal alignment layer 15 and the liquid crystal polarizer 16 are in direct contact. Therefore, in the optical laminates 1 to 4, the liquid crystal polarizer 16 is in direct contact with the horizontal alignment layer 15 provided in direct contact with the light absorption anisotropic layer 13 or the coating layer 14. Thereby, the optical laminates 1 to 4 can be made thinner, and as will be described later, the manufacturing process of the optical laminates 1 to 4 can also be simplified.

[0021] When the optical laminates 1 to 4 have the protective layer 17, the liquid crystal polarizer 16 and the protective layer 17 may be in direct contact. Thereby, the optical laminates 1 to 4 can be made thinner.

[0022] In the optical laminates 1 to 4, the distance D from the surface on the base material layer 11 side of the light absorption anisotropic layer 13 to the surface opposite to the horizontal alignment layer 15 side of the liquid crystal polarizer 16 is 10 μm or less. The distance D may be 9 μm or less, may be 8 μm or less, may be 7 μm or less, is usually 1 μm or more, and may be 2 μm or more. By the distance D being within the above range, the optical laminates 1 to 4 can be made thinner.

[0023] As described above, the light absorption anisotropic layer 13 contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and satisfies the following relationships of formulas (1) to (3). Az > (Ax + Ay) / 2 (1) 0.001 ≤ Ax ≤ 0.1 (2) Ax(z = 60°) / Ax ≥ 5 (3) [In formulas (1) to (3), Ax, Ay, and Az are the absorbances of the absorption maximum wavelengths in the range of 380 nm or more and 780 nm or less of the light absorption anisotropic layer 13, and represent the absorbances of linearly polarized light vibrating in the x-axis direction, y-axis direction, and z-axis direction, respectively. Ax(z = 60°) is the absorbance at the above absorption maximum wavelength, and represents the absorbance of linearly polarized light vibrating in the x-axis direction when the light absorption anisotropic layer 13 is rotated by 60° with the y-axis as the rotation axis. Here, the x-axis is an arbitrary one direction in the plane of the light absorption anisotropic layer 13, the y-axis is a direction orthogonal to the x-axis in the plane of the light absorption anisotropic layer 13, and the z-axis is a direction orthogonal to the x-axis and the y-axis. ]

[0024] Since the light absorption anisotropic layer 13 satisfies the relationships of formulas (1) to (3), it is considered that the absorption axis of the dichroic dye is oriented in the direction perpendicular to the plane of the light absorption anisotropic layer 13. Therefore, the light absorption anisotropic layer 13 can effectively transmit light from the front direction and effectively absorb light from an oblique direction.

[0025] Since the absorbance Az in the z direction in the above formula (1) is measured by making light incident on the side surface of the light absorption anisotropic layer 13, it is difficult to measure. Therefore, when the angle formed by the vibration plane of the linearly polarized light that is the measurement light and the x-y plane of the light absorption anisotropic layer 13 is 90°, with respect to this vibration plane, the x-y plane of the light absorption anisotropic layer 13 is inclined by 30° and 60° in the incident direction of the linearly polarized light, and the absorbance Az in the z direction can be estimated by measurement.

[0026] Specifically, it can be estimated by the following methods or the like. With the y-axis as the rotation axis, in a state where the light absorption anisotropic layer 13 is rotated by 30° and 60°, the same linearly polarized light as the linearly polarized light for measuring Ax is made incident, and the absorbance Ax(z = 30°) and the absorbance Ax(z = 60°) are measured respectively. Similarly, with the x-axis as the rotation axis, in a state where the light absorption anisotropic layer 13 is rotated by 30° and 60°, the same linearly polarized light as the linearly polarized light for measuring Ay is made incident, and the absorbance Ay(z = 30°) and the absorbance Ay(z = 60°) are measured respectively. At this time, if Ax(z = 30°) < Ax(z = 60°) and Ay(z = 30°) = Ay(z = 60°), then Ax(z = 30°) < Ax(z = 60°) < Ax(z = 90°) = Az, and if Ay(z = 30°) < Ay(z = 60°) and Ax(z = 30°) = Ax(z = 60°), then Ay(z = 30°) < Ay(z = 60°) < Ay(z = 90°) = Az. Therefore, it can be said that the relationship of formula (1) is necessarily satisfied. Here, Ax(z = 90°) is the absorbance measured by making the same linearly polarized light as the linearly polarized light for measuring Ax incident in a state where the light absorption anisotropic layer 13 is rotated by 90° with the y-axis as the rotation axis. Ay(z = 90°) is the absorbance measured by making the same linearly polarized light as the linearly polarized light for measuring Ax incident in a state where the light absorption anisotropic layer 13 is rotated by 90° with the x-axis as the rotation axis.

[0027] In particular, when there is no absorption anisotropy in the x-y plane of the light absorption anisotropic layer 13, that is, when Ax and Ay are equal, Ax(z = 30°) = Ay(z = 30°) and Ax(z = 60°) = Ay(z = 60°). Here, let Ax(z = 30°) = Ay(z = 30°) = A(z = 30°), Ax(z = 60°) = Ay(z = 60°) = A(z = 60°), and Ax(z = 90°) = Ay(z = 90°) = A(z = 90°). Then, if A(z = 30°) < A(z = 60°), the relationship A(z = 30°) < A(z = 60°) < A(z = 90°) = Az is satisfied. Further, if A(z = 30°) > (Ax + Ay) / 2, it can be said that Az necessarily satisfies equation (1).

[0028] The above Ax and Ay represent the absorbance in the front direction of the light absorption anisotropic layer 13. The smaller the values of Ax and Ay, the more accurately the dichroic dyes in the light absorption anisotropic layer 13 are oriented perpendicular to the plane. It is preferable that both values of Ax and Ay are 0.3 or less. When both values of Ax and Ay exceed 0.3, the coloring in the front direction of the light absorption anisotropic layer 13 becomes strong, so the front transmission hue tends to be inferior when the light absorption anisotropic layer 13 is applied to a display device. The values of Ax and Ay are each independently preferably 0.1 or less, more preferably 0.05 or less, and even more preferably 0.02 or less. Also, the lower limit values of the values of Ax and Ay are each independently usually 0.001 or more, may be 0.003 or more, or may be 0.005 or more. It can be said that in the light absorption anisotropic layer 13 that satisfies the relationship of the above formula (2), the absorption axes of the dichroic dyes are accurately oriented perpendicular to the plane of the light absorption anisotropic layer 13. When the absorbance Ax exceeds 0.3, the coloring in the front direction of the light absorption anisotropic layer 13 becomes strong, so the front hue tends to be inferior when applied to an organic EL display device in combination with, for example, a circular polarizing plate or the like.

[0029] In the light absorption anisotropic layer 13, it is preferable that Ax and Ay have the same value. When Ax and Ay are different, absorption anisotropy is present in the plane of the light absorption anisotropic layer 13. When the light absorption anisotropic layer 13 is applied to a display device, the coloring of the front color phase tends to increase.

[0030] In the formula (3), the larger the numerical value of Ax(z = 60°) / Ax, the more excellent the light absorption anisotropy is shown. Each of these is independently preferably greater than 5, more preferably 7 or more, still more preferably 10 or more, and preferably 50 or less.

[0031] Since the light absorption anisotropic layer 13 satisfying the relationship of the above formula (3) is considered to have the absorption axis of the dichroic dye oriented in the direction perpendicular to its plane, the light absorption anisotropic layer 13 can effectively absorb light from an oblique direction.

[0032] The above Ax(z = 60°) means the absorbance of the light absorption anisotropic layer 13 in an oblique direction and can be appropriately selected according to the light leaking obliquely from the display device. Ax(z = 60°) is preferably 1.0 or less, more preferably 0.5 or less, still more preferably 0.3 or less. Also, the lower limit value is usually 0.001 or more, may be 0.003 or more, and is 0.01 or more due to its necessity.

[0033] The light absorption anisotropic layer 13 satisfying the relationships of the above formulas (1) to (3) can be adjusted, for example, by the thickness of the light absorption anisotropic layer 13, the conditions of the manufacturing process of the light absorption anisotropic layer 13, the types or contents of the dichroic dye and the polymerizable liquid crystal compound contained in the composition for forming the light absorption anisotropic layer for obtaining the light absorption anisotropic layer 13, and the like.

[0034] Details of each layer included in the optical laminates 1 to 4 will be described later.

[0035] (Method for manufacturing an optical laminate) Figs. 5 and 6 are cross-sectional views schematically showing the manufacturing process of an optical laminate according to an embodiment of the present invention. The method for manufacturing an optical laminate is, for example, the method for manufacturing the above-described optical laminates 1 to 4, and is a method for manufacturing an optical laminate in which a base material layer 11, a light absorption anisotropic layer 13, a horizontal alignment layer 15, and a liquid crystal polarizer 16 are laminated in this order.

[0036] As described above, the light absorption anisotropic layer 13 contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and satisfies the relationships of the above-described formulas (1) to (3). As described above, the liquid crystal polarizer 16 contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and has an absorption axis in the horizontal direction with respect to the plane of the liquid crystal polarizer 16.

[0037] The optical laminates 1 to 4 may further have the above-described protective layer 17. In the optical laminates 1 to 4, the above-described distance D (the distance from the surface on the base material layer 11 side of the light absorption anisotropic layer 13 to the surface on the side opposite to the horizontal alignment layer 15 side of the liquid crystal polarizer 16) may be within the above-described range.

[0038] The optical laminates 1 to 4 may further have the above-described first liquid crystal retardation layer 22 and may have the above-described first alignment layer. The optical laminates 1 to 4 may further have the above-described second liquid crystal retardation layer 24 and may have the above-described second alignment layer. When the optical laminates 3 and 4 have the first liquid crystal retardation layer 22 (Figs. 3 and 4), they may further have the first adhesive layer 21. When the optical laminates 3 and 4 have the second liquid crystal retardation layer 24 in addition to the first liquid crystal retardation layer 22 (Figs. 3 and 4), they may further have the second adhesive layer 23.

[0039] The method for manufacturing the optical laminates 1 to 4 is a step of forming the light absorption anisotropic layer 13 so as to be in direct contact with the base material layer 11 or so as to be in direct contact with the vertical alignment layer 12 formed on the surface of the base material layer 11 (Figs. 5(a) and 6(a)), a step of forming the horizontal alignment layer 15 directly on the light absorption anisotropic layer 13 or via the coating layer 14 (Figs. 5(b) and 6(c)), A step of directly applying a composition for forming a liquid crystal polarizer 16, which contains a polymerizable liquid crystal compound and a dichroic dye, onto a horizontal alignment layer 15 is included. Thereby, the liquid crystal polarizer 16 is formed on the horizontal alignment layer 15 ((c) in FIG. 5, (d) in FIG. 6).

[0040] The step of forming the horizontal alignment layer 15 includes the following step [a] or [b]. [a] A step of directly applying a composition for forming a horizontal alignment layer for forming the horizontal alignment layer 15 onto the light absorption anisotropic layer 13. [b] A step of directly applying a composition for forming a coating layer for forming the coating layer 14 onto the light absorption anisotropic layer 13, and a step of directly applying a composition for forming a horizontal alignment layer onto the coating layer 14. By the step [a], the horizontal alignment layer 15 is formed on the light absorption anisotropic layer 13 ((b) in FIG. 5). By the step [b], the coating layer 14 is formed on the light absorption anisotropic layer 13 ((b) in FIG. 6), and the horizontal alignment layer 15 is formed on the coating layer 14 ((c) in FIG. 6).

[0041] In the manufacturing method of the optical laminates 1 to 4, the horizontal alignment layer 15 is formed on the light absorption anisotropic layer 13 by the above step [a] or [b], and a composition for forming a liquid crystal polarizer is directly applied onto this horizontal alignment layer 15 to form the liquid crystal polarizer 16. Therefore, the optical laminates 1 and 3 in which the light absorption anisotropic layer 13 and the horizontal alignment layer 15 are in direct contact, and the horizontal alignment layer 15 and the liquid crystal polarizer 16 are in direct contact, or the optical laminates 2 and 4 which have only the coating layer 14 between the light absorption anisotropic layer 13 and the horizontal alignment layer 15 and the horizontal alignment layer 15 and the liquid crystal polarizer 16 are in direct contact can be manufactured. Thereby, the thinning of the optical laminates 1 to 4 can be achieved. Thus, in the manufacturing method of the optical laminates 1 to 4, the composition for forming a liquid crystal polarizer is directly applied onto the horizontal alignment layer 15 formed on the light absorption anisotropic layer 13 or the coating layer 14. Therefore, the manufacturing process of the optical laminates 1 to 4 can also be simplified.

[0042] The step of forming the light absorption anisotropic layer 13 may include a step of directly applying a composition for forming a light absorption anisotropic layer containing a polymerizable liquid crystal compound and a dichroic dye onto the base material layer 11 or the vertical alignment layer 12. Thereby, the optical laminate 1, 3 in which the base material layer 11 and the light absorption anisotropic layer 13 are in direct contact, or the optical laminate 2, 4 having only the vertical alignment layer 12 between the base material layer 11 and the light absorption anisotropic layer 13 can be manufactured.

[0043] The manufacturing method of the optical laminates 1 to 4 may further include a step of directly applying a composition for forming a protective layer for forming the protective layer 17 onto the surface of the liquid crystal polarizer 16 on the side opposite to the horizontal alignment layer 15 side. Thereby, the optical laminates 1 to 4 in which the liquid crystal polarizer 16 and the protective layer 17 are in direct contact can be manufactured, and the optical laminates 1 to 4 can be made thinner.

[0044] The manufacturing method of the optical laminates 3, 4 may further include a step of providing the first liquid crystal retardation layer 22, or the first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24 on the liquid crystal polarizer 16 or the protective layer 17 of the optical laminates 1, 2.

[0045] The first liquid crystal retardation layer 22 may be laminated on the liquid crystal polarizer 16 or the protective layer 17 via the first adhesive layer 21. Alternatively, the first alignment layer and the first liquid crystal retardation layer 22 may be formed in this order on the liquid crystal polarizer 16 or the protective layer 17.

[0046] When the optical laminates 3, 4 have the first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24, the first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24 may be sequentially provided on the liquid crystal polarizer 16 or the protective layer 17 of the optical laminates 1, 2. Alternatively, after creating a laminate of the first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24, this laminate may be bonded onto the liquid crystal polarizer 16 or the protective layer 17 of the optical laminates 1, 2. The first liquid crystal retardation layer 22 and the second liquid crystal retardation layer 24 may be laminated via the second adhesive layer 23, and the second alignment layer and the second liquid crystal retardation layer may be formed in this order on the first liquid crystal retardation layer 22 or the first alignment layer.

[0047] Hereinafter, the layers of the optical laminate, the components contained in the layers, etc. will be described in detail.

[0048] (Base material layer) The base material layer 11 can include one or more of a resin film (film base material), a coating resin layer, and a glass base material. The base material layer 11 may have a single-layer structure or a multilayer structure. The base material layer 11 preferably includes a resin film or a coating layer, and may be a laminate of a resin film and other layers such as a coating resin layer.

[0049] When the base material layer 11 is a resin film, the base material layer 11 can support, for example, the light absorption anisotropic layer 13. The base material layer 11 can be a layer on which a composition for forming a light absorption anisotropic layer for forming the light absorption anisotropic layer 13 is applied. When the vertical alignment layer 12 is used to form the light absorption anisotropic layer 13, the vertical alignment layer 12 may be formed on the surface of the base material layer 11 on the side where the light absorption anisotropic layer 13 is formed.

[0050] When the base material layer 11 includes a coating resin layer, the base material layer 11 may be a coating resin layer, or may be one in which a coating resin layer is formed on one or both sides of a resin film. When the base material layer 11 is a coating resin layer, it may be a layer formed by applying and curing a resin composition on the light absorption anisotropic layer 13 or the vertical alignment layer 12.

[0051] Examples of the resin constituting the resin film include olefin resins such as polyethylene and polypropylene; cyclic olefin resins having a cyclic or norbornene structure; polyvinyl alcohol; polyester resins such as polyethylene terephthalate and polyethylene naphthalate; (meth)acrylic resins; cellulose ester resins such as triacetyl cellulose, diacetyl cellulose, and cellulose acetate propionate; polyimide resins; polycarbonate; polysulfone; polyethersulfone; polyether ketone; polyphenylene sulfide; polyphenylene oxide, etc. (Meth)acrylic refers to at least one of acrylic and methacrylic. The same applies to notations such as (meth)acryloyl.

[0052] As the resin film, a commercially available cellulose ester resin film may be used. Examples of such cellulose ester resin films include "Fujitac Film" (manufactured by Fujifilm Corporation); "KC8UX2M", "KC8UY", and "KC4UY" (all manufactured by Konica Minolta Opto Inc.).

[0053] When the base material layer 11 is a coating resin layer, for example, a coating resin layer is formed on the resin film, and after forming the light absorption anisotropic layer 13 on the coating resin layer, the resin film is peeled off, and the coating resin layer may be used as the base material layer 11. In this case, a release treatment for forming a release layer by applying a release agent or the like is performed on the surface of the resin film on the side where the coating resin layer is formed, so that the resin film can be easily peeled off. The resin film to be peeled off may be used as a surface protection film.

[0054] Examples of the coating resin layer include a layer formed by applying a hard coat composition, a resin composition containing a water-soluble polymer used in a coating layer forming composition for forming a coating layer described later (water-soluble polymer-containing resin composition), an easy adhesion composition, or a coupling agent or the like on the surface of a resin film; a layer formed by irradiating a reactive monomer or a polymer having reactivity with active energy rays and graft-polymerizing them. As the resin film having a coating resin layer, a hard coat film having a hard coat layer as the coating resin layer is preferable. When the base material layer is a hard coat film, the light absorption anisotropic layer 13 may be laminated on the hard coat layer side. The hard coat layer is preferable as the coating resin layer.

[0055] The hard coat layer is preferably a cured product layer of a curable composition containing an active energy ray-curable resin (hard coat composition), and more preferably a cured product layer of a composition containing an ultraviolet ray-curable resin. The curable composition containing an ultraviolet ray-curable resin preferably contains a (meth)acrylic compound as a curable component, and the hard coat layer is preferably formed of a (meth)acrylic resin. The (meth)acrylic compound is a compound having at least one (meth)acryloyl group, and may be a monomer, an oligomer or a polymer.

[0056] Examples of the (meth)acrylic compound include (meth)acrylate compounds such as monofunctional (meth)acrylate compounds and polyfunctional (meth)acrylate compounds; urethane (meth)acrylate compounds such as polyfunctional urethane (meth)acrylate compounds; epoxy (meth)acrylate compounds such as polyfunctional epoxy (meth)acrylate compounds; carboxyl group-modified epoxy (meth)acrylate compounds; polyester (meth)acrylate compounds and the like. These can be used alone or in combination of two or more. Among these, polyfunctional (meth)acrylate compounds or urethane (meth)acrylate compounds are preferable, and it is more preferable to combine a polyfunctional (meth)acrylate compound and urethane (meth)acrylate.

[0057] The content of the polyfunctional (meth)acrylate compound is preferably 50 parts by mass or more and 100 parts by mass or less, more preferably 60 parts by mass or more and 95 parts by mass or less, and still more preferably 70 parts by mass or more and 90 parts by mass or less with respect to 100 parts by mass of the solid content of the curable composition. In this specification, the solid content of the curable composition means the total amount of components obtained by removing the solvent from the curable composition when the curable composition contains a solvent.

[0058] In addition to the curable components, the curable composition can contain a polymerization initiator. Examples of the polymerization initiator include a photopolymerization initiator and a radical polymerization initiator, and known polymerization initiators can be used. Examples of the photopolymerization initiator include a photo cationic polymerization initiator.

[0059] After the curable composition is applied to the film substrate, it can be cured by irradiating active energy rays to polymerize the curable components such as (meth)acrylic compounds.

[0060] The hard coat layer preferably shows a pencil hardness of 8B or harder (measured with the film substrate placed on a glass plate) in the pencil hardness test defined in JIS K 5600-5-4:1999 "General Test Methods for Paints - Part 5: Mechanical Properties of Paint Films - Section 4: Scratch Hardness (Pencil Method)", and may also be 5B or harder.

[0061] The surface of the substrate layer 11 on the side where the light absorption anisotropic layer 13 is formed may be subjected to a surface treatment. Examples of the surface treatment method include a method of corona treatment or plasma treatment on the above surface of the substrate layer 11 in an atmosphere from vacuum to atmospheric pressure, a laser treatment method, an ozone treatment method, a flame treatment method, a method of saponifying the above surface of the substrate layer 11, and the like.

[0062] The thickness of the base material layer 11 is preferably 0.5 μm or more and 30 μm or less, and may be 0.5 μm or more and 28 μm or less, may be 1 μm or more and 25 μm or less, may be 1 μm or more and 15 μm or less, may be 1 μm or more and 10 μm or less, and may be 1 μm or more and 5 μm or less.

[0063] In terms of the mass being of a practical handling level, the thickness of the resin film that the base material layer 11 may contain is preferably thinner. However, if it is too thin, the strength will decrease and the processability will tend to be inferior. From this perspective, the thickness of the resin film is preferably 5 μm or more and 30 μm or less, more preferably 10 μm or more and 28 μm or less, still more preferably 10 μm or more and 25 μm or less, and may also be 10 μm or more and 23 μm or less.

[0064] If the thickness of the coating resin layer that the base material layer 11 may contain is too thin, the strength will decrease, and if it is too thick, cracks and the like tend to occur. From this perspective, the thickness of the coating resin layer is preferably 0.5 μm or more and 20 μm or less, more preferably 1 μm or more and 15 μm or less, still more preferably 1 μm or more and 10 μm or less, and even more preferably 1 μm or more and 5 μm or less.

[0065] (Vertical alignment layer) The vertical alignment layer 12 has an alignment regulating force capable of aligning the polymerizable liquid crystal compound in the polymerizable liquid crystal compound-containing composition for forming the light absorption anisotropic layer 13 in a direction perpendicular to the plane of the light absorption anisotropic layer 13. That the polymerizable liquid crystal compound is aligned in the vertical direction means that the major axis of the polymerizable liquid crystal compound is aligned in the vertical direction, and the vertical direction means 90° ± 20° with respect to the plane of the light absorption anisotropic layer 13. The state of the liquid crystal alignment changes depending on the properties of the vertical alignment layer 12 and the polymerizable liquid crystal compound, and the combination thereof can be arbitrarily selected.

[0066] When the alignment control force is formed from an alignment polymer, it can be arbitrarily adjusted according to the surface state and rubbing conditions. When the alignment layer is formed from a photo-alignment polymer, the alignment control force can be arbitrarily adjusted according to the polarized light irradiation conditions and the like. In addition, by selecting physical properties such as the surface tension and liquid crystallinity of the polymerizable liquid crystal compound, the liquid crystal alignment can also be controlled.

[0067] As the vertical alignment layer 12, it is preferably insoluble in the solvent used when forming the light absorption anisotropic layer 13 on the vertical alignment layer 12, and also has heat resistance in the heat treatment for solvent removal and liquid crystal alignment. The vertical alignment layer 12 can be formed using a composition for forming a vertical alignment layer. Examples of the vertical alignment layer 12 include a polymer alignment layer made of an alignment polymer, a photo-alignment layer, a groove alignment layer, a stretched film stretched in the alignment direction, etc. When applied to a long roll-shaped film, the photo-alignment layer is preferable in terms of being able to easily control the alignment direction.

[0068] The thickness of the vertical alignment layer 12 is usually in the range of 10 nm to 5000 nm, preferably in the range of 10 nm to 1000 nm, and more preferably in the range of 30 nm to 300 nm.

[0069] The composition for forming a vertical alignment layer used for forming a rubbed alignment layer contains an alignment polymer. Examples of the alignment polymer include polyamides having an amide bond in the molecule, gelatins, polyimides having an imide bond in the molecule and polyamic acids which are hydrolysis products thereof, polyvinyl alcohol, alkyl-modified polyvinyl alcohol, polyacrylamide, polyoxazole, polyethyleneimine, polystyrene, polyvinylpyrrolidone, polyacrylic acid, and polyacrylic acid esters. Among them, polyvinyl alcohol is preferable from the viewpoint of suppressing the migration of azo dyes from adjacent layers. These alignment polymers may be used alone or in combination of two or more.

[0070] The alignment polymer composition (composition for forming a vertical alignment layer) containing an alignment polymer for forming a rubbing alignment layer may be a resin composition (water-soluble polymer-containing resin composition) containing a water-soluble polymer used for a coating layer-forming composition for forming a coating layer described later.

[0071] As a method of rubbing, there is a method in which an alignment polymer composition is applied to a film substrate, annealed, and the film of the alignment polymer formed so as to constitute the surface of the film substrate is brought into contact with a rubbing roll wrapped with a rubbing cloth and rotating.

[0072] The composition for forming a vertical alignment layer used for forming a photo-alignment layer contains a polymer, oligomer or monomer having a photoreactive group. The photo-alignment layer can obtain an alignment regulating force by irradiating polarized light on a coating layer obtained by applying a composition (composition for forming a vertical alignment layer) for forming a photo-alignment layer to a film substrate. The photo-alignment layer is more preferable in that the direction of the alignment regulating force can be arbitrarily controlled by selecting the polarization direction of the polarized light to be irradiated.

[0073] The photoreactive group means a group that generates a liquid crystal alignment ability by irradiating light. Specifically, it generates an alignment induction of molecules, or a photoreaction that is the origin of the liquid crystal alignment ability, such as an isomerization reaction, a dimerization reaction, a photocrosslinking reaction or a photodegradation reaction, by irradiating light. Among the photoreactive groups, those that cause a dimerization reaction or a photocrosslinking reaction are preferable in terms of excellent alignment properties. As the photoreactive group capable of causing the above reactions, those having an unsaturated bond, particularly a double bond, are preferable, and a group having at least one selected from the group consisting of a carbon-carbon double bond (C = C bond), a carbon-nitrogen double bond (C = N bond), a nitrogen-nitrogen double bond (N = N bond), and a carbon-oxygen double bond (C = O bond) is more preferable.

[0074] Examples of the photoreactive group having a C═C bond include a vinyl group, a polyene group, a stilbene group, a stilbazoyl group, a stilbazolium group, a chalcone group, a cinnamoyl group, and the like. From the viewpoint of easy control of reactivity and manifestation of the orientation control force during photoorientation, a chalcone group and a cinnamoyl group are preferable. Examples of the photoreactive group having a C═N bond include groups having structures such as an aromatic Schiff base and an aromatic hydrazone. Examples of the photoreactive group having an N═N bond include an azobenzene group, an azonaphthalene group, an aromatic heterocyclic azo group, a bisazo group, a formazan group, and those having an azoxybenzene as a basic structure. Examples of the photoreactive group having a C═O bond include a benzophenone group, a coumarin group, an anthraquinone group, a maleimide group, and the like. These groups may have substituents such as an alkyl group, an alkoxy group, an aryl group, an allyloxy group, a cyano group, an alkoxycarbonyl group, a hydroxyl group, a sulfonic acid group, and an alkyl halide group. From the viewpoint of excellent orientation and reactivity, the photoorientable polymer preferably has a photoreactive group that causes a dimerization reaction or a photocrosslinking reaction, and more preferably has a photoreactive group that causes a dimerization reaction. Examples of such a photoreactive group include a group having a cinnamoyl structure, a group having a chalcone structure, a group having a coumarin structure, a group having a benzophenone structure, a group having an anthracene structure, and the like. Among these, a group having a cinnamoyl structure and a group having a chalcone structure are preferable, and a group having a cinnamoyl structure is more preferable.

[0075] The form of irradiating polarized light may be a form of directly irradiating polarized light from the film surface of the coating layer of the composition for forming the photo-alignment layer, or a form of irradiating polarized light from the film substrate side and irradiating after transmitting the polarized light. Further, it is particularly preferable that the polarized light is substantially parallel light. The wavelength of the polarized light to be irradiated is preferably in the wavelength range in which the photoreactive group of the polymer or monomer having a photoreactive group can absorb light energy. Specifically, UV (ultraviolet light) in the range of wavelengths of 250 to 400 nm is particularly preferable. Examples of the light source used for the polarized light irradiation include xenon lamps, high-pressure mercury lamps, ultra-high-pressure mercury lamps, metal halide lamps, ultraviolet lasers such as KrF and ArF, and high-pressure mercury lamps, ultra-high-pressure mercury lamps, and metal halide lamps are more preferable. These lamps are preferable because they have a high emission intensity of ultraviolet light with a wavelength of 313 nm. By passing the light from the above-described light source through an appropriate polarizer and irradiating, polarized light can be irradiated. As such a polarizer, a polarizing filter, a polarizing prism such as a Glan-Taylor or Glan-Foucault, or a wire grid type polarizer can be used.

[0076] (Light absorption anisotropic layer) The light absorption anisotropic layer 13 contains a polymer of a polymerizable liquid crystal compound and a dichroic dye. The light absorption anisotropic layer 13 may contain a polymer of one kind of polymerizable liquid crystal compound, or may contain polymers of two or more kinds of polymerizable liquid crystal compounds. The light absorption anisotropic layer 13 may contain one kind of dichroic dye, or may contain two or more kinds of dichroic dyes.

[0077] The light absorption anisotropic layer 13 can be formed using a composition for forming a light absorption anisotropic layer containing a polymerizable liquid crystal compound and a dichroic dye. The composition for forming a light absorption anisotropy may contain, as a solid content, in addition to the polymerizable liquid crystal compound and the dichroic dye, a non-liquid crystal compound having a polymerizable group, and additives such as a polymerization initiator, a leveling agent, an alignment promoter, a reactive additive, an antioxidant, and a photosensitizer, as described later. Therefore, the light absorption anisotropic layer 13 may contain a polymer of a non-liquid crystal compound having a polymerizable group and additives.

[0078] The polymerizable liquid crystal compound is preferably a liquid crystal compound that forms a smectic phase. The polymer of the polymerizable liquid crystal compound may or may not exhibit liquid crystallinity. The light absorption anisotropic layer 13 can be formed from a composition for forming a light absorption anisotropic layer containing a polymerizable liquid crystal compound and a dichroic dye, and may be a liquid crystal cured film (a cured product layer of the polymerizable liquid crystal compound) in which the polymerizable liquid crystal compound in the composition for forming a light absorption anisotropic layer is polymerized and cured. The polymer of the polymerizable liquid crystal compound is a polymer of polymerizable liquid crystal compounds, but a non-liquid crystal compound having a polymerizable group may be polymerized with the polymerizable liquid crystal compound, or a dichroic dye may be polymerized with the polymerizable liquid crystal compound.

[0079] The content of the polymer of the polymerizable liquid crystalline compound in the light absorption anisotropic layer 13 is preferably 40 parts by mass or more and 99.9 parts by mass or less, may be 60 parts by mass or more and 99 parts by mass or less, or may be 70 parts by mass or more and 99 parts by mass or less with respect to 100 parts by mass of the light absorption anisotropic layer 13. When the content of the polymer of the polymerizable liquid crystalline compound is within the above range, the orientation of the polymer of the polymerizable liquid crystalline compound tends to be high when forming the light absorption anisotropic layer 13. The content ratio of the polymer of the polymerizable liquid crystalline compound in the light absorption anisotropic layer 13 can be calculated as the ratio of the polymerizable liquid crystal compound (the total amount when two or more kinds are included) to 100 parts by mass of the solid content of the composition for forming a light absorption anisotropic layer used to form the light absorption anisotropic layer. The solid content of the composition for forming a light absorption anisotropic layer means all components obtained by removing volatile components such as organic solvents from the composition for forming a light absorption anisotropic layer.

[0080] The content of the dichroic dye in the light absorption anisotropic layer 13 is preferably 0.1 part by mass or more and 30 parts by mass or less, may be 0.5 part by mass or more and 20 parts by mass or less, may be 1 part by mass or more and 10 parts by mass or less, or may be 1 part by mass or more and 5 parts by mass or less with respect to 100 parts by mass of the light absorption anisotropic layer 13. The content ratio of the dichroic dye in the light absorption anisotropic layer 13 can be calculated as the ratio of the dichroic dye to 100 parts by mass of the solid content of the composition for forming a light absorption anisotropic layer. When the light absorption anisotropic layer 13 contains two or more kinds of dichroic dyes, the content of the dichroic dye means the total amount.

[0081] The thickness of the light absorption anisotropic layer 13 is preferably 0.2 μm or more and 5.0 μm or less, more preferably 0.5 μm or more and 4.0 μm or less, and even more preferably 0.5 μm or more and 3.0 μm or less. When the thickness of the light absorption anisotropic layer 13 is small, the light absorption from the oblique direction tends to be weak. When the thickness is large, the alignment of the dichroic dye tends to be disturbed, so the transmission characteristics in the front direction tend to deteriorate.

[0082] The surface on the side opposite to the base material layer 11 side of the light absorption anisotropic layer 13 may be subjected to surface treatment. Examples of the surface treatment method include a method of corona treatment or plasma treatment in an atmosphere from vacuum to atmospheric pressure on the above surface of the light absorption anisotropic layer 13, a method of laser treatment, a method of ozone treatment, a method of flame treatment, and the like.

[0083] (Polymerizable liquid crystal compound) The polymerizable liquid crystal compound contained in the composition for forming the light absorption anisotropic layer is used to align the dichroic dye by host-guest interaction. The polymerizable liquid crystal compound is a compound having one or more polymerizable groups in the molecule and having liquid crystallinity.

[0084] The polymerizable group means a group involved in a polymerization reaction, and is preferably a photopolymerizable group. Here, the photopolymerizable group refers to a group that can participate in a polymerization reaction by an active radical, an acid, or the like generated from a photopolymerization initiator described later. Examples of the polymerizable group include a vinyl group, a vinyloxy group, a 1-chlorovinyl group, an isopropenyl group, a 4-vinylphenyl group, a (meth)acryloyl group, a (meth)acryloyloxy group, an oxiranyl group, and an oxetanyl group. Among them, a (meth)acryloyl group, a (meth)acryloyloxy group, a vinyloxy group, an oxiranyl group, and an oxetanyl group are preferable, and a (meth)acryloyl group and a (meth)acryloyloxy group are more preferable. The liquid crystallinity may be thermotropic liquid crystal or lyotropic liquid crystal, but when mixed with the above-described dichroic dye, thermotropic liquid crystal is preferable.

[0085] By a polymerization reaction, a polymer of a polymerizable liquid crystal compound is formed. When forming a film containing the polymer and a dichroic dye and exhibiting light absorption anisotropy, the liquid crystal state exhibited by the polymerizable liquid crystal compound is preferably a smectic phase, and more preferably a higher-order smectic phase from the viewpoint of improving optical performance. Among them, higher-order smectic polymerizable liquid crystal compounds that form a smectic B phase, a smectic D phase, a smectic E phase, a smectic F phase, a smectic G phase, a smectic H phase, a smectic I phase, a smectic J phase, a smectic K phase, or a smectic L phase are more preferable, and higher-order smectic polymerizable liquid crystal compounds that form a smectic B phase, a smectic F phase, or a smectic I phase are even more preferable. When the liquid crystal phase formed by the polymerizable liquid crystal compound is these higher-order smectic phases, a light absorption anisotropic layer 13 with higher light absorption anisotropy can be manufactured. Thus, the light absorption anisotropic layer 13 with high light absorption anisotropy is one in which Bragg peaks derived from higher-order structures such as a hexatic phase and a crystal phase can be obtained in X-ray diffraction measurement. The Bragg peak is a peak derived from the periodic structure of molecular orientation, and the light absorption anisotropic layer 13 can have a periodic interval of 3 to 6 Å. It is preferable from the viewpoint of obtaining higher light absorption anisotropy that the light absorption anisotropic layer 13 contains a polymer of a polymerizable liquid crystal compound oriented in the smectic phase state.

[0086] The polymerizable liquid crystal compound may be a monomer, an oligomer in which polymerizable groups are polymerized, or a polymer. As such polymerizable liquid crystal compounds, known ones can be used, and examples include those described in JP-A-2020-76920 and Japanese Patent No. 6728581.

[0087] (Dichroic dye) A dichroic dye refers to a dye having the property that the absorbance in the long axis direction of the molecule is different from the absorbance in the short axis direction of the molecule. As the dichroic dye, it preferably has the property of absorbing visible light, and more preferably has an absorption maximum wavelength (λmax) in the range of 380 to 680 nm.

[0088] Examples of such dichroic dyes include acridine dyes, oxazine dyes, cyanine dyes, naphthalene dyes, azo dyes, and anthraquinone dyes, among others. Among them, azo dyes are preferred. Examples of azo dyes include monoazo dyes, bisazo dyes, trisazo dyes, tetrakisazo dyes, and stilbene azo dyes, with bisazo dyes and trisazo dyes being preferred. The dichroic dyes may be used alone or in combination of two or more. However, depending on the wavelength range in which light absorption anisotropy is required in the light absorption anisotropic layer, it is preferable to use a combination of two or more.

[0089] Examples of azo dyes include compounds represented by formula (I) (hereinafter also referred to as "compound (I)"). K 1 (-N=N-K 2 ) p -N=N-K 3 (I) [In formula (I), K 1 and K 3 each independently represent a phenyl group which may have a substituent, a naphthyl group which may have a substituent, or a monovalent heterocyclic group which may have a substituent. K 2 represents a p-phenylene group which may have a substituent, a naphthalene-1,4-diyl group which may have a substituent, or a divalent heterocyclic group which may have a substituent. p represents an integer from 1 to 4. When p is an integer of 2 or more, the plurality of K 2 may be the same as or different from each other. In the range showing absorption in the visible region, the -N=N- bond may be replaced by a -C=C-, -COO-, -NHCO-, or -N=CH- bond.

[0090] Examples of the monovalent heterocyclic group include groups obtained by removing one hydrogen atom from heterocyclic compounds such as quinoline, thiazole, benzothiazole, thienothiazole, imidazole, benzimidazole, oxazole, and benzoxazole. Examples of the divalent heterocyclic group include groups obtained by removing two hydrogen atoms from the above heterocyclic compounds.

[0091] K 1 and K 3 The phenyl group, naphthyl group and monovalent heterocyclic group in, and K 2 The substituents optionally possessed by the p-phenylene group, naphthalene-1,4-diyl group and divalent heterocyclic group in include alkyl groups having 1 to 4 carbon atoms; alkoxy groups having 1 to 4 carbon atoms such as methoxy group, ethoxy group, butoxy group, etc.; alkyl fluoride groups having 1 to 4 carbon atoms such as trifluoromethyl group; cyano group; nitro group; halogen atoms; substituted or unsubstituted amino groups such as amino group, diethylamino group, pyrrolidino group (a substituted amino group means an amino group having one or two alkyl groups having 1 to 6 carbon atoms, or an amino group in which two substituted alkyl groups are bonded to each other to form an alkanediyl group having 2 to 8 carbon atoms. An unsubstituted amino group is -NH 2 is. ).

[0092] Among the compounds (I), the compounds represented by any of the formulas (I-1) to (I-8) are preferred, the compounds represented by any of the formulas (I-1) to (I-3) are more preferred, and the compounds represented by any of the formulas (I-1) and (I-3) are even more preferred. [Chemical formula] [In the formulas (I-1) to (I-8), B 1 ~B 30 are, independently of each other, a hydrogen atom, an alkyl group having 1 to 6 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cyano group, a nitro group, a substituted or unsubstituted amino group (the definitions of the substituted amino group and the unsubstituted amino group are as described above), a chlorine atom or a trifluoromethyl group. n1 to n4 each independently represent an integer of 0 to 3. When n1 is 2 or more, the plurality of B 2 may be the same as or different from each other, When n2 is 2 or more, the plurality of B 6 may be the same as or different from each other, When n3 is 2 or more, the plurality of B9 may be the same as or different from each other, when n4 is 2 or more, a plurality of Bs 14 may be the same as or different from each other.]

[0093] As the above anthraquinone dye, a compound represented by the formula (I-9) is preferable.

Chemical formula

[0094] As the above oxazone dye, a compound represented by the formula (I-10) is preferable.

Chemical formula

[0095] As the above acridine dye, a compound represented by the formula (I-11) is preferable.

Chemical formula

[0096] In formula (I-9), formula (I-10) and formula (I-11), examples of the alkyl group having 1 to 6 carbon atoms of R x include a methyl group, an ethyl group, a propyl group, a butyl group, a pentyl group and a hexyl group, and examples of the aryl group having 6 to 12 carbon atoms include a phenyl group, a toluyl group, a xylyl group and a naphthyl group.

[0097] As the above cyanine dye, a compound represented by formula (I-12) and a compound represented by formula (I-13) are preferable.

Chemical formula

Chemical formula

[0098]

Chemical formula

[0099] Among these dichroic dyes, azo dyes are preferred from the viewpoint of orientation.

[0100] The content of the dichroic dye in the composition for forming a light absorption anisotropic layer (when two or more are included, the total amount thereof) is usually 1 part by mass or more and 60 parts by mass or less, preferably 1 part by mass or more and 40 parts by mass or less, and more preferably 1 part by mass or more and 20 parts by mass or less with respect to 100 parts by mass of the polymerizable liquid crystal compound, from the viewpoint of obtaining good light absorption characteristics. If the content of the dichroic dye is less than this range, light absorption becomes insufficient and sufficient light absorption anisotropic properties cannot be obtained. If it is more than this range, the orientation of the liquid crystal molecules of the polymerizable liquid crystal compound may be inhibited.

[0101] (Method for forming a light absorption anisotropic layer) The light absorption anisotropic layer 13 can be formed, for example, by applying a composition for forming a light absorption anisotropic layer on a film substrate. The composition for forming a light absorption anisotropic layer contains a polymerizable liquid crystal compound and a dichroic dye, and may also contain a non-liquid crystalline compound having a polymerizable group, a solvent, an additive, and the like, which will be described later. The film substrate may be a substrate layer 11 including a resin film, or may be a resin film that does not constitute the substrate layer 11.

[0102] A drying treatment for removing a solvent or the like is performed on the coating layer formed by applying the composition for forming a light absorption anisotropic layer. By irradiating the coating layer after the drying treatment with active energy rays or the like to polymerize the polymerizable liquid crystal compound, the light absorption anisotropic layer 13 as a cured product layer (liquid crystal cured film) of the composition for forming a light absorption anisotropic layer can be formed on the film substrate. The composition for forming a light absorption anisotropic layer may be applied to the surface of the film substrate, or may be applied to the surface of the vertical alignment layer 12 formed on the surface of the film substrate.

[0103] As methods for applying the composition for forming the light absorption anisotropic layer, known methods such as coating methods such as spin coating method, extrusion method, gravure coating method, die coating method, bar coating method, applicator method, and printing methods such as flexo method can be mentioned.

[0104] It is preferable to perform a drying treatment on the coating layer of the composition for forming the light absorption anisotropic layer formed on the film substrate. When the composition for forming the light absorption anisotropic layer contains a solvent, the solvent in the coating layer can be removed by drying the coating layer. As the drying method, known methods can be mentioned, and one or more methods among natural drying method, heat drying method, ventilation drying method, reduced pressure drying method, etc. can be mentioned.

[0105] The drying conditions in the drying treatment can be appropriately determined according to the components contained in the composition for forming the light absorption anisotropic layer. For example, the drying temperature in the drying treatment is 50°C or higher and 150°C or lower, and it may be 60°C or higher and 120°C or lower. The drying time in the drying treatment is 15 seconds or longer and 10 minutes or shorter, and it may be 0.5 minutes or longer and 5 minutes or shorter.

[0106] When performing a heat treatment in the drying treatment, by heating to a temperature equal to or higher than the liquid crystal phase transition temperature at which the polymerizable liquid crystal compound contained in the composition for forming the light absorption anisotropic layer undergoes a phase transition, while removing the solvent in the coating layer, the polymerizable liquid crystal compound can be oriented. In particular, when orienting the polymerizable liquid crystal compound forming a smectic phase in a direction perpendicular to the surface of the light absorption anisotropic layer 13, it is preferable to heat in the temperature range where it transitions to the smectic phase. Thereby, the polymerizable liquid crystal compound can be oriented in a direction perpendicular to the surface of the light absorption anisotropic layer 13, and along with the orientation of the polymerizable liquid crystal compound, the dichroic dye can also be oriented.

[0107] After drying the coating layer formed on the film substrate, by irradiating active energy rays in a state where the polymerizable liquid crystal compound and the dichroic dye are oriented to polymerize and cure the polymerizable liquid crystal compound, the light absorption anisotropic layer 13 can be formed.

[0108] As a method for polymerizing a polymerizable liquid crystal compound, photopolymerization is preferred. Photopolymerization is carried out by irradiating a laminated structure including a coating layer on which a composition for forming a photoabsorbing anisotropic layer is coated with active energy rays. As the active energy rays to be irradiated, they are appropriately selected according to the type of the polymerizable liquid crystal compound contained in the coating layer (particularly, the type of the photopolymerizable functional group possessed by the polymerizable liquid crystal compound), the type of the photoinitiator when a photoinitiator is included, and their amounts. Specifically, examples include one or more types of light selected from the group consisting of visible light, ultraviolet light, infrared light, X-rays, α-rays, β-rays, and γ-rays. Among them, ultraviolet light is preferred in terms of the ease of controlling the progress of the polymerization reaction and the availability of widely used ones in the art as a photopolymerization apparatus. It is preferable to select the type of the polymerizable liquid crystal compound so that it can be photopolymerized by ultraviolet light.

[0109] Examples of the light source for the active energy rays include a low-pressure mercury lamp, a medium-pressure mercury lamp, a high-pressure mercury lamp, an ultra-high-pressure mercury lamp, a xenon lamp, a halogen lamp, a carbon arc lamp, a tungsten lamp, a gallium lamp, an excimer laser, an LED light source emitting in the wavelength range of 380 to 440 nm, a chemical lamp, a black light lamp, a microwave-excited mercury lamp, a metal halide lamp, and the like.

[0110] The ultraviolet irradiation intensity is usually 10 mW / cm 2 ~3,000 mW / cm 2 . The ultraviolet irradiation intensity is preferably the intensity in the wavelength region effective for activating the cationic polymerization initiator or the radical polymerization initiator. The time for irradiating light is usually from 0.1 second to 10 minutes, preferably from 1 second to 5 minutes, more preferably from 5 seconds to 3 minutes, and still more preferably from 10 seconds to 1 minute. When irradiated once or a plurality of times with such an ultraviolet irradiation intensity, the integrated light amount is 10 mJ / cm 2 ~3,000 mJ / cm 2 , preferably 50 mJ / cm 2 ~2,000 mJ / cm 2 , more preferably 100 mJ / cm 2~1,000 mJ / cm 2 If the integrated light quantity is below this range, the curing of the polymerizable liquid crystal compound may be insufficient. Conversely, if the integrated light quantity is above this range, the light absorption anisotropic layer 13 may be colored.

[0111] (Non-liquid crystal compound having a polymerizable group) A non-liquid crystal compound having a polymerizable group (hereinafter also referred to as a "non-liquid crystal compound") is a compound having a polymerizable group and no liquid crystallinity. Examples of the polymerizable group of the non-liquid crystal compound include a vinyl group, a vinyloxy group, a 1-chlorovinyl group, an isopropenyl group, a 4-vinylphenyl group, a (meth)acryloyl group, a (meth)acryloyloxy group, an oxiranyl group, and an oxetanyl group. Among these, preferred polymerizable groups are a (meth)acryloyl group, a (meth)acryloyloxy group, a vinyloxy group, an oxiranyl group, and an oxetanyl group; more preferred polymerizable groups are a (meth)acryloyl group and a (meth)acryloyloxy group; and even more preferred is a (meth)acryloyloxy group. The polymerizable group in the non-liquid crystal compound may be one type or a combination of two or more types, but is preferably the same polymerizable group as the polymerizable group of the polymerizable liquid crystal compound.

[0112] The number of polymerizable groups of the non-liquid crystal compound is not particularly limited and may be, for example, 1 to 20, but from the viewpoint of more easily increasing the film strength of the light absorption anisotropic layer, it is preferably 2 to 10, more preferably 3 to 6. When the non-liquid crystal compound has two or more polymerizable groups, the polymerizable groups may be the same or different from each other.

[0113] Examples of non-liquid crystalline compounds include monofunctional (meth)acrylates and polyfunctional (meth)acrylates. Since monofunctional acrylates and polyfunctional acrylates as non-liquid crystalline compounds having a polymerizable group are non-liquid crystalline, those having no mesogenic structure are preferred. The monofunctional acrylate and polyfunctional acrylate may contain a urethane structure, an amino structure, an epoxy structure, an ethylene glycol structure, and / or a polyester structure in the molecule.

[0114] (Solvent) The solvent that may be included in the composition for forming a photoabsorption anisotropic layer is preferably one that can completely dissolve the polymerizable liquid crystal compound, and is preferably a solvent inert to the polymerization reaction of the polymerizable liquid crystal compound. Examples of the solvent include alcohol solvents such as methanol, ethanol, ethylene glycol, isopropyl alcohol, propylene glycol, ethylene glycol methyl ether, ethylene glycol butyl ether, and propylene glycol monomethyl ether; ester solvents such as ethyl acetate, butyl acetate, ethylene glycol methyl ether acetate, γ-butyrolactone, propylene glycol methyl ether acetate, and ethyl lactate; ketone solvents such as acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, 2-heptanone, and methyl isobutyl ketone; aliphatic hydrocarbon solvents such as pentane, hexane, and heptane; aromatic hydrocarbon solvents such as toluene and xylene; nitrile solvents such as acetonitrile; ether solvents such as tetrahydrofuran and dimethoxyethane; chlorine-containing solvents such as chloroform and chlorobenzene; amide solvents such as dimethylacetamide, dimethylformamide, N-methyl-2-pyrrolidone, and 1,3-dimethyl-2-imidazolidinone. These solvents may be used alone or in combination of two or more.

[0115] The content of the solvent in the composition for forming the light absorption anisotropic layer is preferably 50 to 98% by mass with respect to the total amount of the composition for forming the light absorption anisotropic layer. In other words, the content of the solid component in the composition for forming the light absorption anisotropic layer is preferably 2 to 50% by mass, more preferably 5 to 30% by mass. When the content of the solid component is 50% by mass or less, the viscosity of the composition for forming the light absorption anisotropic layer becomes low, so that it becomes easy to form the light absorption anisotropic layer with a substantially uniform thickness, and unevenness is less likely to occur in the light absorption anisotropic layer 13. Such a content of the solid component can be determined in consideration of the thickness of the light absorption anisotropic layer 13 to be manufactured.

[0116] (Additive) The composition for forming the light absorption anisotropic layer may contain additives such as a polymerization initiator such as a photoinitiator or a thermal polymerization initiator, a leveling agent, an alignment promoter, a reactive additive, an antioxidant, and a photosensitizer.

[0117] (Polymerization initiator) The composition for forming the light absorption anisotropic layer may contain a polymerization initiator. The polymerization initiator is used when the composition for forming the light absorption anisotropic layer contains a compound involved in a polymerization reaction such as a polymerizable liquid crystal compound, and is a compound capable of initiating the polymerization reaction of the compound. From the viewpoint of not depending on the phase state of the thermotropic liquid crystal, a photoinitiator that generates active radicals by the action of light is preferable as the polymerization initiator for initiating the polymerization reaction of the polymerizable liquid crystal compound.

[0118] As long as the photoinitiator is a compound capable of initiating a polymerization reaction such as a polymerizable liquid crystal compound, a known photoinitiator can be used. Specifically, photoinitiators capable of generating active radicals or acids by the action of light can be mentioned. Among them, photoinitiators that generate radicals by the action of light are preferable. The photoinitiator can be used alone or in combination of two or more.

[0119] As the photoinitiator, a known photoinitiator can be used. For example, as the photoinitiator that generates active radicals, Self-cleaving benzoin compounds, acetophenone compounds, hydroxyacetophenone compounds, α-aminoacetophenone compounds, oxime ester compounds, acylphosphine oxide compounds, azo compounds, etc., and Hydrogen abstraction type benzophenone compounds, alkylphenone compounds, benzoin ether compounds, benzyl ketal compounds, dibenzosuberone compounds, anthraquinone compounds, xanthone compounds, thioxanthone compounds, halogenoacetophenone compounds, dialkoxyacetophenone compounds, halogenobisimidazole compounds, halogenotriazine compounds, triazine compounds, etc. can be used.

[0120] As the photoinitiator that generates an acid, iodonium salts, sulfonium salts, etc. can be used.

[0121] From the viewpoint of excellent reaction efficiency at low temperatures, the photoinitiator is preferably a self-cleaving photoinitiator, and particularly preferably an acetophenone compound, a hydroxyacetophenone compound, an α-aminoacetophenone compound, or an oxime ester compound.

[0122] The content of the photoinitiator in the composition for forming a photoabsorption anisotropic layer can be appropriately adjusted according to the type and amount of the polymerizable liquid crystal compound. However, it is usually 0.1 to 30 parts by mass, preferably 0.5 to 10 parts by mass, more preferably 0.5 to 8 parts by mass with respect to 100 parts by mass of the polymerizable liquid crystal compound. When the content of the photoinitiator is within the above range, polymerization can be carried out without disturbing the alignment of the polymerizable liquid crystal compound.

[0123] (Leveling agent) The composition for forming the light absorption anisotropic layer may contain a leveling agent. The leveling agent is an additive that adjusts the fluidity of the composition for forming the light absorption anisotropic layer and has the function of making the film obtained by coating the composition for forming the light absorption anisotropic layer flatter. The composition for forming the light absorption anisotropic layer can contain a silicone-based leveling agent, a polyacrylate-based leveling agent, a fluorine-based leveling agent such as a perfluoroalkyl-based leveling agent, and preferably contains a silicone leveling agent. When the composition for forming the light absorption anisotropic layer contains a silicone-based leveling agent, it becomes easier to suppress the blocking of the light absorption anisotropic layer. When the composition for forming the light absorption anisotropic layer contains a silicone leveling agent, the content thereof can be, for example, within the range described later as the content in the light absorption anisotropic layer.

[0124] The silicone-based leveling agent is a leveling agent containing a silicon atom, and it is preferable to use a leveling agent having a polyorganosiloxane skeleton. Examples of the group bonded to the silicon atom (the silicon atom forming a siloxane bond) in the polyorganosiloxane include a hydrocarbon group. Among them, an alkyl group having 1 to 10 carbon atoms, an alkoxy group having 1 to 10 carbon atoms, an ester group having 1 to 10 carbon atoms, and an aryl group are preferable, a methyl group and a phenyl group are more preferable, and a methyl group is even more preferable. The group bonded to the silicon atom may be only one kind or two or more kinds. The number of repetitions (degree of polymerization) of the siloxane unit is not particularly limited, but is preferably 2 to 10000, more preferably 3 to 5000, and even more preferably 5 to 1000.

[0125] Commercially available silicon leveling agents can be used. Examples of commercially available silicon leveling agents include BYK-300, BYK-302, BYK-306, BYK-307, BYK-310, BYK-313, BYK-315N, BYK-320, BYK-322, BYK-323, BYK-325, BYK-330, BYK-331, BYK-333, BYK-337, BYK-342, BYK-345, BYK-346, BYK-347, BYK-348, BYK-349, BYK-370, BYK-377, BYK-378, BYK-3455, BYK-UV3510 (manufactured by BYK-Chemie Japan Co., Ltd.), KF-945, KF-6015, KF-6020 (manufactured by Shin-Etsu Chemical Co., Ltd.), TEGORad2300, TEGORad2200N, TEGORad2011 (manufactured by Degussa), and those with radical polymerizable groups such as (meth)acryloyl groups added to the polyether chain, including BYK-UV3500, BYK-UV3505, BYK-3510, BYK-UV3530, BYK-UV3570, BYK-UV3575, BYK-UV3576 (manufactured by BYK-Chemie Japan Co., Ltd.), KP-422, KP-416, KP-418, KP-410, KP-411, KP-412, KP-413, KP-423, KP-414, KP-415, KP-420, KP-983 (manufactured by Shin-Etsu Chemical Co., Ltd.), etc.

[0126] The silicone leveling agent is preferably 0.01 parts by mass or more and 5.0 parts by mass or less, more preferably 0.05 parts by mass or more and 3.0 parts by mass or less, still more preferably 0.05 parts by mass or more and 2.0 parts by mass or less, even more preferably 0.1 parts by mass or more and 1.0 parts by mass or less, and particularly preferably 0.1 parts by mass or more and 0.5 parts by mass or less, based on 100 parts by mass of the polymer of the polymerizable liquid crystal compound contained in the light absorption anisotropic layer 13. The content of the polymerizable liquid crystal compound polymer and the content of the silicone leveling agent can be calculated as the content of the polymerizable liquid crystal compound and the silicone leveling agent in the composition for forming the light absorption anisotropic layer. When the content of the silicone leveling agent is within the above range, it becomes easier to form the light absorption anisotropic layer 13 flat and to suppress blocking. When the content of the silicone leveling agent is 5.0 parts by mass or less, it becomes easier to suppress repellency when the composition for forming the light absorption anisotropic layer is applied to the film substrate. Further, when forming a horizontal alignment layer by applying a composition for forming a horizontal alignment layer, which will be described later, on the light absorption anisotropic layer 13, it can be easily overcoated on the light absorption anisotropic layer 13, and unevenness can also be suppressed.

[0127] (Alignment promoter) When applying the composition for forming the light absorption anisotropic layer directly to the surface of the film substrate (when not using a vertical alignment layer), the composition for forming the light absorption anisotropic layer preferably contains an alignment promoter. The alignment promoter means a material that promotes the liquid crystal alignment of the polymerizable liquid crystal compound in a desired direction. Examples of the alignment promoter that promotes the vertical alignment of the polymerizable liquid crystal compound include ionic compounds composed of non-metal atoms and non-ionic silane compounds. The composition for forming the light absorption anisotropic layer 13 preferably contains at least one of an ionic compound composed of non-metal atoms and a non-ionic silane compound, and more preferably contains both an ionic compound composed of non-metal atoms and a non-ionic silane compound.

[0128] As the silane compound, a nonionic silane compound described later, a silane-containing ionic compound, etc. can be used, and by using these silane compounds, the vertical alignment regulating force can be enhanced. These silane compounds may be used alone, in combination of two or more, or mixed with other materials. When the silane compound is a nonionic silane compound, a silane compound having an alkyl group at the molecular end is preferable from the viewpoint of easily enhancing the vertical alignment regulating force, and a silane compound having an alkyl group with 3 to 30 carbon atoms is more preferable.

[0129] When the composition for forming a light absorption anisotropic layer contains an ionic compound composed of non-metal atoms, in the dry coating film of the composition for forming a light absorption anisotropic layer formed on the film substrate, the vertical alignment regulating force for the polymerizable liquid crystal compound is developed by electrostatic interaction, and the polymerizable liquid crystal compound tends to be aligned in the vertical direction with respect to the surface of the film substrate in the dry coating film. Thereby, it is possible to form the light absorption anisotropic layer 13 which is a liquid crystal cured film while maintaining the state where the polymerizable liquid crystal compound is vertically aligned.

[0130] Examples of the ionic compound composed of non-metal atoms include onium salts (more specifically, quaternary ammonium salts in which a nitrogen atom has a positive charge, tertiary sulfonium salts, and quaternary phosphonium salts in which a phosphorus atom has a positive charge, etc.). Among these onium salts, a quaternary onium salt is preferable from the viewpoint of further improving the vertical alignment property of the polymerizable liquid crystal compound, and a quaternary phosphonium salt or a quaternary ammonium salt is more preferable from the viewpoints of improving availability and mass productivity. The onium salt may have two or more quaternary onium salt sites in the molecule, and may be an oligomer or a polymer.

[0131] The molecular weight of the ionic compound is preferably 100 or more and 10,000 or less. When the molecular weight is within the above range, it is easy to improve the vertical alignment property of the polymerizable liquid crystal compound while ensuring the coatability of the composition for forming a light absorption anisotropic layer. The molecular weight of the ionic compound is more preferably 5000 or less, and even more preferably 3000 or less.

[0132] Examples of the cation component of the ionic compound include inorganic cations and organic cations. Among them, organic cations are preferred because they are less likely to cause alignment defects in the polymerizable liquid crystal compound. Examples of the organic cation include imidazolium cation, pyridinium cation, ammonium cation, sulfonium cation, phosphonium cation, and the like.

[0133] An ionic compound generally has a counter anion. Examples of the anion component that serves as the counter ion for the cation component include inorganic anions and organic anions. Among them, organic anions are preferred because they are less likely to cause alignment defects in the polymerizable liquid crystal compound. Note that the cation and the anion do not necessarily have a one-to-one correspondence.

[0134] Specific examples of the anion component include the following. Chloride anion [Cl - , Bromide anion [Br - , Iodide anion [I - , Tetrachloroaluminate anion [AlCl 4 - , Heptachlorodialuminate anion [Al 2 Cl 7 - , Tetrafluoroborate anion [BF 4 - , Hexafluorophosphate anion [PF 6 - , Perchlorate anion [ClO 4 - , Nitrate anion [NO 3 - , Acetate anion [CH 3 COO -〕, Trifluoroacetate anion [CF 3 COO - 〕, Fluorosulfonate anion [FSO 3 - 〕, Methanesulfonate anion [CH 3 SO 3 - 〕, Trifluoromethanesulfonate anion [CF 3 SO 3 - 〕, p-Toluenesulfonate anion [p-CH 3 C 6 H 4 SO 3 - 〕, Bis(fluorosulfonyl)imide anion [(FSO 2 ) 2 N - 〕, Bis(trifluoromethanesulfonyl)imide anion [(CF 3 SO 2 ) 2 N - 〕, Tris(trifluoromethanesulfonyl)methanide anion [(CF 3 SO 2 ) 3 C - 〕, Hexafluoroarsenate anion [AsF 6 - 〕, Hexafluoroantimonate anion [SbF 6 - 〕, Hexafluoroniobate anion [NbF 6 - 〕, Hexafluorotantalate anion [TaF 6 - 〕, Dimethylphosphinate anion [(CH 3 ) 2 POO - 〕, (Poly)hydrofluoride anion [F(HF) n - (where n represents an integer from 1 to 3), dicyanamide anion [(CN) 2 N - , thiocyanate anion [SCN - , perfluorobutanesulfonate anion [C 4 F 9 SO 3 - , bis(pentafluoroethanesulfonyl)imide anion [(C 2 F 5 SO 2 ) 2 N - , perfluorobutanoate anion [C 3 F 7 COO-], and (trifluoromethanesulfonyl)(trifluoromethylcarbonyl)imide anion [(CF 3 SO 2 )(CF 3 CO)N - .

[0135] Specific examples of the ionic compound can be appropriately selected from the combinations of the above cation components and anion components. Compounds that are specific combinations of cation components and anion components include the following.

[0136] (Pyridinium salt) N-Hexylpyridinium hexafluorophosphate, N-Octylpyridinium hexafluorophosphate, N-Methyl-4-hexylpyridinium hexafluorophosphate, N-Butyl-4-methylpyridinium hexafluorophosphate, N-Octyl-4-methylpyridinium hexafluorophosphate, N-Hexylpyridinium bis(fluorosulfonyl)imide, N-Octylpyridinium bis(fluorosulfonyl)imide, N-Methyl-4-hexylpyridinium bis(fluorosulfonyl)imide, N-Butyl-4-methylpyridinium bis(fluorosulfonyl)imide, N-Octyl-4-methylpyridinium bis(fluorosulfonyl)imide, N-Hexylpyridinium bis(trifluoromethanesulfonyl)imide, N-Octylpyridinium bis(trifluoromethanesulfonyl)imide, N-Methyl-4-hexylpyridinium bis(trifluoromethanesulfonyl)imide, N-Butyl-4-methylpyridinium bis(trifluoromethanesulfonyl)imide, N-Octyl-4-methylpyridinium bis(trifluoromethanesulfonyl)imide, N-Hexylpyridinium p-toluenesulfonate, N-Octylpyridinium p-toluenesulfonate, N-Methyl-4-hexylpyridinium p-toluenesulfonate, N-Butyl-4-methylpyridinium p-toluenesulfonate, and, N-Octyl-4-methylpyridinium p-toluenesulfonate.

[0137] (Imidazolium salt) 1-Ethyl-3-methylimidazolium hexafluorophosphate, 1-Ethyl-3-methylimidazolium bis(fluorosulfonyl)imide, 1-Ethyl-3-methylimidazolium bis(trifluoromethanesulfonyl)imide, 1-Ethyl-3-methylimidazolium p-toluenesulfonate, 1-Butyl-3-methylimidazolium methanesulfonate, etc.

[0138] (Pyrrolidinium salt) N-Butyl-N-methylpyrrolidinium hexafluorophosphate, N-Butyl-N-methylpyrrolidinium bis(fluorosulfonyl)imide, N-Butyl-N-methylpyrrolidinium bis(trifluoromethanesulfonyl)imide, N-Butyl-N-methylpyrrolidinium p-toluenesulfonate, etc.

[0139] (Ammonium salt) Tetrabutylammonium hexafluorophosphate, Tetrabutylammonium bis(fluorosulfonyl)imide, Tetrahexylammonium bis(fluorosulfonyl)imide, Trioctylmethylammonium bis(fluorosulfonyl)imide, (2-Hydroxyethyl)trimethylammonium bis(fluorosulfonyl)imide, Tetrabutylammonium bis(trifluoromethanesulfonyl)imide, Tetrahexylammonium bis(trifluoromethanesulfonyl)imide, Trioctylmethylammonium bis(trifluoromethanesulfonyl)imide, (2-Hydroxyethyl)trimethylammonium bis(trifluoromethanesulfonyl)imide, Tetrabutylammonium p-toluenesulfonate, Tetrahexylammonium p-toluenesulfonate, Trioctylmethylammonium p-toluenesulfonate, (2-Hydroxyethyl)trimethylammonium p-toluenesulfonate, (2-Hydroxyethyl)trimethylammonium dimethylphosphinate, 1-(3-Trimethoxysilylpropyl)-1,1,1-tributylammonium bis(trifluoromethanesulfonyl)imide, 1-(3-Trimethoxysilylpropyl)-1,1,1-trimethylammonium bis(trifluoromethanesulfonyl)imide, 1-(3-Trimethoxysilylbutyl)-1,1,1-tributylammonium bis(trifluoromethanesulfonyl)imide, 1-(3-Trimethoxysilylbutyl)-1,1,1-trimethylammonium bis(trifluoromethanesulfonyl)imide, N-{(3-Triethoxysilylpropyl)carbamoyloxyethyl)}-N,N,N-trimethylammonium bis(trifluoromethanesulfonyl)imide, and, N-[2-{3-(3-Trimethoxysilylpropylamino)-1-oxopropoxy}ethyl]-N,N,N-trimethylammonium bis(trifluoromethanesulfonyl)imide.

[0140] (Phosphonium salt) Tributyl(2-methoxyethyl)phosphonium bis (trifluoromethanesulfonyl)imide, Tributylmethylphosphonium bis (trifluoromethanesulfonyl)imide, 1,1,1-Trimethyl-1-[(trimethoxysilyl)methyl]phosphonium bis (trifluoromethanesulfonyl)imide, 1,1,1-Trimethyl-1-[2-(trimethoxysilyl)ethyl]phosphonium bis(trifluoromethanesulfonyl)imide, 1,1,1-Trimethyl-1-[3-(trimethoxysilyl)propyl]phosphonium bis(trifluoromethanesulfonyl)imide, 1,1,1-Trimethyl-1-[4-(trimethoxysilyl)butyl]phosphonium bis(trifluoromethanesulfonyl)imide, 1,1,1-Tributyl-1-[(trimethoxysilyl)methyl]phosphonium bis(trifluoromethanesulfonyl)imide, 1,1,1-Tributyl-1-[2-(trimethoxysilyl)ethyl]phosphonium bis(trifluoromethanesulfonyl)imide, and 1,1,1-Tributyl-1-[3-(trimethoxysilyl)propyl]phosphonium bis(trifluoromethanesulfonyl)imide. These ionic compounds may each be used alone or in combination of two or more.

[0141] From the viewpoint of further improving the vertical alignment property of the polymerizable liquid crystal compound, it is preferable that the ionic compound has an Si element and / or an F element in the molecular structure of the cation moiety. When the ionic compound has an Si element and / or an F element in the molecular structure of the cation moiety, it becomes easier to segregate the ionic compound on the surface of the photoabsorptive anisotropic layer. Among them, as ionic compounds in which all constituent elements are non-metal elements, the following ionic compounds (ii) to (iv) etc. are preferable.

[0142] Ionic compound (ii):

Chemical formula

Chemical formula

Chemical formula

[0143] As a method for improving the vertical alignment property of a polymerizable liquid crystal compound, for example, a method of treating the surface of a film substrate using a surfactant having an alkyl group with a certain chain length is known (see, for example, Chapter 2, Alignment and Physical Properties of Liquid Crystals in "Liquid Crystal Handbook" published by Maruzen Co., Ltd., etc.). The method of improving the vertical alignment property of a liquid crystal compound with such a surfactant can also be applied to ionic compounds. That is, by treating the surface of a film substrate using an ionic compound having an alkyl group with a certain chain length, the vertical alignment property of the polymerizable liquid crystal compound can be effectively improved.

[0144] Specifically, the ionic compound satisfies the following relationship: 5 < M < 16 is preferably satisfied. M in the above relationship is represented by the following formula: M = (the number of covalent bonds from the positively charged atom to the molecular chain end of the substituent having the largest number of covalent bonds to the molecular chain end among the substituents directly bonded to the positively charged atom) ÷ (the number of positively charged atoms) is represented by. By the ionic compound satisfying the above-described relationship, the vertical alignment property of the polymerizable liquid crystal compound can be effectively improved.

[0145] When there are two or more positively charged atoms in the molecule of the ionic compound, for a substituent having two or more positively charged atoms, the number of covalent bonds from the positively charged atom considered as the base point to another positively charged atom closest to it is defined as the "number of covalent bonds from the positively charged atom to the molecular chain end" in the definition of M above. When the ionic compound is an oligomer or polymer having two or more repeating units, the constituent unit is considered as one molecule and the above M is calculated. When the positively charged atom is incorporated into a ring structure, the larger of the number of covalent bonds from the positively charged atom to the same positively charged atom via the ring structure or the number of covalent bonds to the end of the substituent bonded to the ring structure is defined as the "number of covalent bonds from the positively charged atom to the molecular chain end" in the definition of M above.

[0146] When the composition for forming a light absorption anisotropic layer contains an ionic compound, its content is usually preferably 0.01 to 5% by mass, more preferably 0.05 to 4% by mass, and still more preferably 0.1 to 3% by mass based on the solid content of the composition for forming a light absorption anisotropic layer. When the content of the ionic compound is within the above range, the vertical alignment property of the polymerizable liquid crystal compound can be effectively promoted while maintaining good coatability of the composition for forming a light absorption anisotropic layer.

[0147] When the composition for forming a light absorption anisotropic layer contains a nonionic silane compound, the nonionic silane compound reduces the surface tension of the composition for forming a light absorption anisotropic layer. In the dry coating film of the composition for forming a light absorption anisotropic layer formed on the film substrate, the nonionic silane compound exists on the surface opposite to the film substrate of the dry coating film, enhancing the vertical alignment regulating force for the polymerizable liquid crystal compound, and the polymerizable liquid crystal compound tends to be aligned in the vertical direction with respect to the film substrate surface within the dry coating film. Thereby, the light absorption anisotropic layer 13 which is a liquid crystal cured film can be formed while maintaining the state where the polymerizable liquid crystal compound is vertically aligned.

[0148] The nonionic silane compound is a nonionic compound containing Si element. Examples of the nonionic silane compound include silicon polymers such as polysilane, silicone resins such as silicone oil and silicone resin, and organo-inorganic silane compounds such as silicone oligomers, silsesquioxane, and alkoxysilane (more specifically, silane coupling agents, etc.), and silane-containing compounds described in the section of leveling agents.

[0149] The nonionic silane compound may be of the silicone monomer type or of the silicone oligomer (polymer) type. When the silicone oligomer is represented in the form of a (monomer)-(monomer) copolymer, it includes mercaptopropyl group-containing copolymers such as 3-mercaptopropyltrimethoxysilane-tetramethoxysilane copolymer, 3-mercaptopropyltrimethoxysilane-tetraethoxysilane copolymer, 3-mercaptopropyltriethoxysilane-tetramethoxysilane copolymer, and 3-mercaptopropyltriethoxysilane-tetraethoxysilane copolymer; mercaptomethyl group-containing copolymers such as mercaptomethyltrimethoxysilane-tetramethoxysilane copolymer, mercaptomethyltrimethoxysilane-tetraethoxysilane copolymer, mercaptomethyltriethoxysilane-tetramethoxysilane copolymer, and mercaptomethyltriethoxysilane-tetraethoxysilane copolymer; methacryloyloxypropyl group-containing copolymers such as 3-methacryloyloxypropyltrimethoxysilane-tetramethoxysilane copolymer, 3-methacryloyloxypropyltrimethoxysilane-tetraethoxysilane copolymer, 3-methacryloyloxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-methacryloyloxypropyltriethoxysilane-tetraethoxysilane copolymer, 3-methacryloyloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-methacryloyloxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-methacryloyloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer, and 3-methacryloyloxypropylmethyldiethoxysilane-tetraethoxysilane copolymer;Acryloyloxypropyl group-containing copolymers such as 3-acryloyloxypropyltrimethoxysilane-tetramethoxysilane copolymer, 3-acryloyloxypropyltrimethoxysilane-tetraethoxysilane copolymer, 3-acryloyloxypropyltriethoxysilane-tetramethoxysilane copolymer, 3-acryloyloxypropyltriethoxysilane-tetraethoxysilane copolymer, 3-acryloyloxypropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-acryloyloxypropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-acryloyloxypropylmethyldiethoxysilane-tetramethoxysilane copolymer and 3-acryloyloxypropylmethyldiethoxysilane-tetraethoxysilane copolymer; Vinyl group-containing copolymers such as vinyltrimethoxysilane-tetramethoxysilane copolymer, vinyltrimethoxysilane-tetraethoxysilane copolymer, vinyltriethoxysilane-tetramethoxysilane copolymer, vinyltriethoxysilane-tetraethoxysilane copolymer, vinylmethyldimethoxysilane-tetramethoxysilane copolymer, vinylmethyldimethoxysilane-tetraethoxysilane copolymer, vinylmethyldiethoxysilane-tetramethoxysilane copolymer and vinylmethyldiethoxysilane-tetraethoxysilane copolymer;Examples include amino group-containing copolymers such as 3-aminopropyltrimethoxysilane-tetramethoxysilane copolymer, 3-aminopropyltrimethoxysilane-tetraethoxysilane copolymer, 3-aminopropyltriethoxysilane-tetramethoxysilane copolymer, 3-aminopropyltriethoxysilane-tetraethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane-tetramethoxysilane copolymer, 3-aminopropylmethyldimethoxysilane-tetraethoxysilane copolymer, 3-aminopropylmethyldiethoxysilane-tetramethoxysilane copolymer, and 3-aminopropylmethyldiethoxysilane-tetraethoxysilane copolymer. These nonionic silane compounds may be used alone or in combination of two or more. Among them, silane coupling agents are preferred from the viewpoint of further improving the adhesion to the adjacent layer.;

[0150] The silane coupling agent is a compound containing Si element having at least one functional group selected from the group consisting of a vinyl group, an epoxy group, a styryl group, a methacryl group, an acrylic group, an amino group, an isocyanurate group, a ureido group, a mercapto group, an isocyanate group, a carboxy group, and a hydroxy group at the terminal, and at least one alkoxysilyl group or silanol group. By appropriately selecting these functional groups, specific effects such as improvement of the mechanical strength of the light absorption anisotropic layer 13, surface modification of the light absorption anisotropic layer 13, and improvement of the adhesion with the layer adjacent to the light absorption anisotropic layer 13 (for example, the base material layer 11) can be imparted. From the viewpoint of adhesion, it is preferable that the silane coupling agent is a silane coupling agent having an alkoxysilyl group and another different reactive group (for example, the above functional group). It is preferable that the silane coupling agent is a silane coupling agent having an alkoxysilyl group and a polar group. When the silane coupling agent has at least one alkoxysilyl group and at least one polar group in its molecule, the vertical alignment property of the polymerizable liquid crystal compound is more likely to be improved, and a remarkable vertical alignment promoting effect tends to be obtained. Examples of the polar group include an epoxy group, an amino group, an isocyanurate group, a mercapto group, a carboxy group, and a hydroxy group. The polar group may have a substituent or a protecting group as appropriate to control the reactivity of the silane coupling agent.

[0151] Examples of the silane coupling agent include, specifically, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris(2-methoxyethoxy)silane, N-(2-aminoethyl)-3-aminopropylmethyldimethoxysilane, N-(2-aminoethyl)-3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilyl-N-(1,3-dimethyl-butylidene)propylamine, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-chloropropylmethyldimethoxysilane, 3-chloropropyltrimethoxysilane, 3-methacryloyloxypropyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-glycidoxypropyldimethoxymethylsilane, and 3-glycidoxypropylethoxydimethylsilane.

[0152] Examples of the commercially available silane coupling agent include silane coupling agents manufactured by Shin-Etsu Chemical Co., Ltd. such as KP321, KP323, KP324, KP326, KP340, KP341, X22-161A, KF6001, KBM-1003, KBE-1003, KBM-303, KBM-402, KBM-403, KBE-402, KBE-403, KBM-1403, KBM-502, KBM-503, KBE-502, KBE-503, KBM-5103, KBM-602, KBM-603, KBM-903, KBE-903, KBE-9103, KBM-573, KBM-575, KBM-9659, KBE-585, KBM-802, KBM-803, KBE-846, and KBE-9007.

[0153] When the composition for forming a light absorption anisotropic layer contains a nonionic silane compound, its content is usually preferably 0.01% by mass to 5% by mass, more preferably 0.05% by mass to 4% by mass, and even more preferably 0.1% by mass to 3% by mass, based on the solid content of the composition for forming a light absorption anisotropic layer. When the content of the nonionic silane compound is within the above range, while maintaining good coatability of the composition for forming a light absorption anisotropic layer, the perpendicular alignment property of the polymerizable liquid crystal compound can be effectively promoted.

[0154] When the composition for forming a light absorption anisotropic layer contains both an ionic compound and a nonionic silane compound, in the dried coating film of the composition for forming a light absorption anisotropic layer formed on a film substrate, due to the electrostatic interaction derived from the ionic compound and the surface tension reduction effect derived from the nonionic silane compound, the perpendicular alignment of the polymerizable liquid crystal compound is more likely to be promoted. Thereby, the light absorption anisotropic layer 13, which is a liquid crystal cured film, can be formed while the polymerizable liquid crystal compound maintains a more precisely vertically aligned state.

[0155] (Reactive Additive) The composition for forming a light absorption anisotropic layer may contain a reactive additive. As the reactive additive, those having a carbon-carbon unsaturated bond and an active hydrogen reactive group in its molecule are preferred. Here, the "active hydrogen reactive group" means a group having reactivity with a group having active hydrogen such as a carboxyl group (-COOH), a hydroxyl group (-OH), an amino group (-NH 2 ) etc., and typical examples thereof include a glycidyl group, an oxazoline group, a carbodiimide group, an aziridine group, an imide group, an isocyanate group, a thioisocyanate group, a maleic anhydride group, etc. The number of carbon-carbon unsaturated bonds or active hydrogen reactive groups possessed by the reactive additive is usually 1 to 20 each, preferably 1 to 10 each.

[0156] In the reactive additive, it is preferable that at least two active hydrogen reactive groups are present. In this case, the plurality of active hydrogen reactive groups present may be the same or different.

[0157] The carbon-carbon unsaturated bond of the reactive additive may be a carbon-carbon double bond, a carbon-carbon triple bond, or a combination thereof, but is preferably a carbon-carbon double bond. Among them, as the reactive additive, it is preferable to contain a carbon-carbon unsaturated bond as a vinyl group and / or a (meth)acrylic group. Further, a reactive additive in which the active hydrogen reactive group is at least one selected from the group consisting of an epoxy group, a glycidyl group, and an isocyanate group is preferable, and a reactive additive having an acrylic group and an isocyanate group is more preferable.

[0158] Specific examples of the reactive additive include compounds having a (meth)acrylic group and an epoxy group such as glycidyl methacrylate and glycidyl acrylate; compounds having a (meth)acrylic group and an oxetane group such as oxetane acrylate and oxetane methacrylate; compounds having a (meth)acrylic group and a lactone group such as lactone acrylate and lactone methacrylate; compounds having a vinyl group and an oxazoline group such as vinyl oxazoline and isopropenyl oxazoline; oligomers of compounds having a (meth)acrylic group and an isocyanate group such as isocyanatomethyl acrylate, isocyanatomethyl methacrylate, 2-isocyanatoethyl acrylate, or 2-isocyanatoethyl methacrylate. Further, compounds having a vinyl group or a vinylene group and an acid anhydride such as methacrylic anhydride, acrylic anhydride, maleic anhydride, or vinyl maleic anhydride are also included. Among them, glycidyl methacrylate, glycidyl acrylate, isocyanatomethyl acrylate, isocyanatomethyl methacrylate, vinyl oxazoline, 2-isocyanatoethyl acrylate, 2-isocyanatoethyl methacrylate, or the above oligomers are preferable, and isocyanatomethyl acrylate, 2-isocyanatoethyl acrylate, or the above oligomers are particularly preferable.

[0159] The reactive additive can be used as a commercial product as it is, or purified as necessary. Examples of commercial products include Laromer (registered trademark) LR-9000 (manufactured by BASF).

[0160] When the composition for forming the light absorption anisotropic layer contains a reactive additive, the content of the reactive additive is usually 0.01 to 10 parts by mass, preferably 0.1 to 5 parts by mass, based on 100 parts by mass of the polymerizable liquid crystal compound.

[0161] (Coating layer) The coating layer 14 can suppress the diffusion of the dichroic dye contained in the light absorption anisotropic layer 13 and suppress the damage of the light absorption anisotropic layer 13. The coating layer 14 can be formed from a composition for forming a coating layer. As described above, the coating layer is usually a resin layer other than the adhesive layer. The adhesive layer is a layer for bonding between two pre-formed (molded) layers, but the coating layer is not a layer for bonding between two pre-formed (molded) layers.

[0162] Examples of the composition for forming a coating layer include a layer formed from a resin composition containing a water-soluble polymer (hereinafter also referred to as a "water-soluble polymer-containing resin composition"), a photocurable composition containing a radiation curable resin, and the like. Since the water-soluble polymer generally has a significantly different polarity from the dichroic dye and thus has an excellent effect of preventing the diffusion of the dichroic dye, the coating layer 14 is preferably a layer formed from a water-soluble polymer-containing resin composition.

[0163] Examples of the water-soluble polymer include polyacrylamide-based polymers; vinyl alcohol-based polymers such as polyvinyl alcohol, ethylene-vinyl alcohol copolymers, and (meth)acrylic acid or its anhydride-vinyl alcohol copolymers; carboxyvinyl-based polymers; polyvinylpyrrolidone; starches; sodium alginate; polyethylene oxide-based polymers; water-soluble polyamide epoxy resins, and the like. These polymers may be used alone or in combination of two or more.

[0164] When the coating layer 14 is a layer formed from a water-soluble polymer-containing resin composition, the content of the water-soluble polymer in the layer is preferably 75% by mass or more, more preferably 80% by mass or more, and still more preferably 85% by mass or more.

[0165] When the coating layer 14 is a layer formed from a water-soluble polymer-containing resin composition, a crosslinked structure may be introduced by using a crosslinking agent to enhance the denseness of the layer. Examples of the crosslinking agent include ionic crosslinking agents such as glyoxylate and water-soluble crosslinking agents such as epoxy-based crosslinking agents; hydrophobic crosslinking agents such as isocyanate-based crosslinking agents, polyvalent aldehyde-based crosslinking agents such as glyoxal and glyoxal derivatives, and metal compound-based crosslinking agents such as zirconium chloride-based or titanium lactate-based crosslinking agents for the purpose of imparting water resistance.

[0166] The addition amount of the crosslinking agent may be appropriately determined according to the type of the crosslinking agent and the like. For example, it may be 0.1 to 100 parts by mass, preferably 1 to 50 parts by mass, and more preferably 10 to 30 parts by mass with respect to 100 parts by mass of the water-soluble polymer. When the content of the crosslinking agent is within the above range, a dense coating layer 14 can be formed.

[0167] The water-soluble polymer-containing resin composition is usually prepared as a solution in which the water-soluble polymer is dissolved in a solvent. The solvent may be selected according to the water-soluble polymer to be used, and typically includes water, alcohol, a mixture of water and alcohol, etc., and water is preferred.

[0168] The solid content concentration of the water-soluble polymer-containing resin composition obtained by adding a solvent to the components constituting the coating layer 14 such as the water-soluble polymer and the crosslinking agent is preferably 1 to 50% by mass, more preferably 2 to 30% by mass, and still more preferably 3 to 15% by mass. When the solid content concentration of the water-soluble polymer-containing resin composition is within the above range, the viscosity of the composition becomes low, so that the coatability and handleability are good.

[0169] The water-soluble polymer-containing resin composition may contain other components such as additives in addition to the water-soluble polymer, crosslinking agent, and solvent such as water. Examples of the other components include preservatives, leveling agents, and the like. When the water-soluble polymer-containing resin composition contains other components such as additives, the amount thereof is preferably 10% by mass or less, more preferably 5% by mass or less, based on the solid content of the resin composition.

[0170] The water-soluble polymer-containing resin composition prepared by dissolving the necessary components such as the water-soluble polymer and the crosslinking agent in a solvent is applied to the surface on the side opposite to the base material layer 11 of the light absorption anisotropic layer 13, and the solvent in the coating film is dried, removed, and cured, whereby the coating layer 14 can be formed.

[0171] The method of applying the water-soluble polymer-containing resin composition is not particularly limited, and examples thereof include the same methods as those for applying the composition for forming the light absorption anisotropic layer. Further, the surface on the side where the coating layer 14 of the light absorption anisotropic layer 13 is formed may be subjected to a surface treatment such as corona treatment or plasma treatment.

[0172] The drying temperature, time, etc. for forming the coating layer 14 from the coating film of the water-soluble polymer-containing resin composition are not particularly limited, and may be appropriately determined according to the composition of the water-soluble polymer-containing resin composition used. The drying treatment can be performed, for example, by blowing hot air, and the temperature is usually in the range of 40 to 100°C, preferably 60 to 100°C, more preferably 60 to 80°C. If the temperature becomes too high, it will approach the phase transition temperature of the polymerizable liquid crystal compound in the light absorption anisotropic layer 13, and there is a risk that the orientation of the polymerizable liquid crystal compound will be disturbed. Further, the drying time is usually 10 to 600 seconds.

[0173] Examples of the active energy ray-curable resin contained in the photocurable composition include (meth)acrylic resins, urethane resins, (meth)acrylic urethane resins, epoxy resins, and silicone resins. The active energy ray-curable resin is preferably an epoxy resin.

[0174] The photocurable composition may be a curable composition such as the hard coat composition described in the coating resin layer constituting the base material layer 11. The photocurable composition may be a cationic curable composition containing a cationic polymerizable compound and a photo cationic polymerization initiator. Examples of the cationic polymerizable compound include alicyclic epoxy compounds, aromatic epoxy compounds, and oxetane compounds having an oxetanyl group.

[0175] The photocurable composition can be applied to the surface of the light absorption anisotropic layer 13 on the side opposite to the base material layer 11 side and irradiated with active energy rays to form the coating layer 14. As described above, surface treatment may be performed on the surface of the light absorption anisotropic layer 13 on the side where the coating layer 14 is formed.

[0176] The thickness of the coating layer 14 is preferably 0.05 μm or more and 15 μm or less, may be 0.1 μm or more and 12 μm or less, preferably 0.5 μm or more and 10 μm or less, and more preferably 1 μm or more and 5 μm or less.

[0177] (Horizontal alignment layer) The horizontal alignment layer 15 has an alignment regulating force capable of aligning the polymerizable liquid crystal compound in the composition for forming the liquid crystal polarizer 16 for forming the liquid crystal polarizer 16 in the horizontal direction with respect to the plane of the liquid crystal polarizer 16. That the polymerizable liquid crystal compound is aligned in the horizontal direction means that the long axis of the polymerizable liquid crystal compound is aligned in the horizontal direction, and the horizontal direction means 0° ± 20° with respect to the plane of the liquid crystal polarizer 16. The state of liquid crystal alignment changes depending on the properties of the horizontal alignment layer 15 and the polymerizable liquid crystal compound, and the combination thereof can be arbitrarily selected.

[0178] The horizontal alignment layer 15 can include a polymer alignment layer formed of an alignment polymer, a photo-alignment layer formed of a photo-alignment polymer, and a groove alignment layer having an uneven pattern or a plurality of grooves (grooves) on the layer surface. The horizontal alignment layer 15 is preferably a photo-alignment layer from the viewpoints of the accuracy and quality of the alignment angle. Examples of each of the alignment layers constituting the horizontal alignment layer 15 include those described for the vertical alignment layer 12.

[0179] The thickness of the horizontal alignment layer 15 is usually in the range of 10 nm or more and 10,000 nm or less, preferably 10 nm or more and 2,500 nm or less, more preferably 10 nm or more and 1,000 nm or less, still more preferably 10 nm or more and 500 nm or less, and particularly preferably 20 nm or more and 250 nm or less. The thickness of the horizontal alignment layer can be measured by a laser microscope, an ellipsometer, or the like.

[0180] The composition for forming a horizontal alignment layer for forming a horizontal alignment layer is preferably a composition for forming a photo-alignment layer, and includes a photo-alignment polymer, a photo-alignment oligomer, or a photo-alignment monomer, which is a polymer having a photoreactive group. Examples of the photoreactive group include those described for the vertical alignment layer 12.

[0181] The molecular weight of the photo-alignment polymer is the weight average molecular weight in terms of polystyrene determined by gel permeation chromatography (GPC) measurement, preferably 10,000 or more and 1,000,000 or less, more preferably 15,000 or more, still more preferably 20,000 or more, also more preferably 500,000 or less, and still more preferably 250,000 or less. When the weight average molecular weight of the photo-alignment polymer is within the above range, the solvent resistance is good, and it is easy to obtain a horizontal alignment layer that exhibits excellent liquid crystal alignment ability while ensuring high adhesion to the liquid crystal polarizer 16 formed later on the horizontal alignment layer.

[0182] The photo-alignment polymer is more preferably a (meth)acrylic polymer. In particular, when the polymerizable liquid crystal compound forming the liquid crystal polarizer 16 has a (meth)acryloyl group as a polymerizable group, if the photo-alignment polymer is a (meth)acrylic polymer, it is expected to have excellent affinity and improve the adhesion between the liquid crystal polarizer 16 and the horizontal alignment layer 15. In this specification, among all the structural units constituting the polymer main chain, for example, a polymer in which the proportion of structural units based on a (meth)acrylic structure such as a (meth)acrylate unit or a (meth)acrylamide unit is the largest is collectively referred to as a "meta(acrylic) polymer".

[0183] The content of the photo-alignment polymer in the composition for forming a horizontal alignment layer can be appropriately determined according to the type of the photo-alignment polymer used, the desired thickness of the horizontal alignment layer 15, etc. It is not particularly limited as long as it is an amount in which the photo-alignment polymer used can be completely dissolved, but the content (concentration) thereof is preferably 1.0 to 25.0% by mass, more preferably 2.5 to 22.5% by mass, based on the total mass of the composition for forming a horizontal alignment layer. In the composition for forming a horizontal alignment layer, the photo-alignment polymer may be only one kind or a combination of two or more kinds. When two or more kinds are included, it is preferable that their total content is within the above range.

[0184] The composition for forming a horizontal alignment layer may contain, in addition to the photo-alignment polymer, a compound having an active hydrogen-reactive group (hereinafter also referred to as "compound (AH)"). In this specification, the "active hydrogen-reactive group" means a group having reactivity with a group having active hydrogen such as a carboxyl group (-COOH), a hydroxyl group (-OH), an amino group (-NH 2 ) or a mercapto group (-SH). When the horizontal alignment layer 15 is formed from the composition for forming a horizontal alignment layer containing the compound (AH), it is easy to control the adhesion between the composition for forming a horizontal alignment layer and the layer to be coated (in this embodiment, the light absorption anisotropic layer 13 or the coating layer 14), and the adhesion between the layer to be coated and the horizontal alignment layer 15 can be improved.

[0185] Examples of the active hydrogen reactive group include an epoxy group, a glycidyl group, an oxazoline group, a carbodiimide group, an aziridine group, an imide group, an alkoxysilyl group, an isocyanate group, a thioisocyanate group, a maleic anhydride group, and the like. Among them, from the viewpoint of adhesion, it is preferable that the compound (AH) has at least one group selected from the group consisting of an alkoxysilyl group and an isocyanate group, and more preferably has an alkoxysilyl group.

[0186] The number of active hydrogen reactive groups possessed by the compound (AH) is 1 or more. When a plurality of active hydrogen reactive groups are present, the plurality of active hydrogen reactive groups present may be the same or different.

[0187] In addition to the active hydrogen reactive group, the compound (AH) preferably further has an active hydrogen-containing group. In the present specification, the "active hydrogen-containing group" means a functional group containing active hydrogen. By the compound (AH) having an active hydrogen-containing group, the adhesion between the horizontal alignment layer 15 and the liquid crystal polarizer 16 can be improved.

[0188] Examples of the active hydrogen-containing group include a hydroxyl group, a carboxyl group, an amino group, a mercapto group, a primary amide group, a secondary amide group, a hydrazide group, and the like. Among them, from the viewpoints of reactivity, adhesion, etc., it is preferable that the compound (AH) has at least one group selected from the group consisting of a hydroxyl group, an amino group, and a mercapto group, and it is preferable to have at least one of an amino group and a mercapto group.

[0189] The number of active hydrogen-containing groups possessed by the compound (AH) is 1 or more. When a plurality of active hydrogen-containing groups are present, the plurality of active hydrogen-containing groups present may be the same or different.

[0190] The compound (AH) is, for example, a silane coupling agent. When a silane coupling agent is used as the compound (AH), it becomes easier to control the adhesion between the coated layer on which the composition for forming a horizontal alignment layer is coated and / or the liquid crystal polarizer 16 and the horizontal alignment layer 15. The silane coupling agent may be used alone or in combination of two or more.

[0191] As the silane coupling agent, a compound known in the art can be used. Specifically, the nonionic silane compound described as the alignment accelerator that may be included in the composition for forming photoabsorptive anisotropy can be mentioned.

[0192] When the compound (AH) is a silane coupling agent, the silane coupling agent preferably has an active hydrogen-containing group. Specifically, it more preferably has at least one functional group selected from the group consisting of amino groups (primary, secondary), hydroxyl groups, and mercapto groups, more preferably has a primary amino group or a secondary amino group, and is further preferably a compound containing an Si element having the at least one functional group and at least one alkoxysilyl group or silanol group. Amino groups (primary, secondary), hydroxyl groups, and mercapto groups have polarity, and by appropriately selecting these functional groups, the adhesion between the obtained horizontal alignment layer 15 and the liquid crystal polarizer 16 can be controlled. From this viewpoint, it is preferable that the silane coupling agent has an alkoxysilyl group and the at least one functional group. The functional group may appropriately have a substituent or a protecting group in order to control the reactivity of the silane coupling agent. Examples of the silane coupling agent having a protecting group include KBE-9103P (ketimine type) and X-12-1172ES (aldimine type) manufactured by Shin-Etsu Chemical Co., Ltd. as the amino group-protected type, and X-12-1056ES as the mercapto group-protected type.

[0193] The content of compound (AH) in the composition for forming a horizontal alignment layer can be appropriately determined according to the type of compound (AH), the type and surface state of the layer to be coated on which the composition for forming a horizontal alignment layer is coated, the composition of the liquid crystal polarizer 16, etc. The content of compound (AH) is, for example, preferably 1 part by mass or more and 30 parts by mass or less, more preferably 2.5 parts by mass or more and 25 parts by mass or less, still more preferably 5.0 parts by mass or more, and also more preferably 23 parts by mass or less, based on 100 parts by mass of the photo-aligning polymer. When the content of compound (AH) is within the above range, it can be expected to improve the adhesion between the horizontal alignment layer 15 and the layer to be coated and / or the liquid crystal polarizer 16.

[0194] The composition for forming a horizontal alignment layer usually contains a solvent. The solvent is not particularly limited as long as it can dissolve the components contained in the composition for forming a horizontal alignment layer. For example, water; alcohol solvents such as methanol, ethanol, ethylene glycol, isopropyl alcohol, propylene glycol, methyl cellosolve, butyl cellosolve and propylene glycol monomethyl ether; ester solvents such as ethyl acetate, butyl acetate, ethylene glycol methyl ether acetate, γ - butyrolactone, propylene glycol methyl ether acetate and ethyl lactate; ketone solvents such as acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, methyl amyl ketone and methyl isobutyl ketone; aliphatic hydrocarbon solvents such as pentane, hexane and heptane; aromatic hydrocarbon solvents such as toluene and xylene, nitrile solvents such as acetonitrile; ether solvents such as tetrahydrofuran and dimethoxyethane; chlorine - substituted hydrocarbon solvents such as chloroform and chlorobenzene, etc. These solvents may be used alone or in combination of two or more.

[0195] The composition for forming a horizontal alignment layer may contain optional components within a range where the characteristics of the horizontal alignment layer 15 are not significantly impaired, in addition to the above - described components. Such components include polymer materials, photosensitizers, etc.

[0196] The composition for forming a horizontal alignment layer can be prepared, for example, by dissolving a photo-alignment polymer (or an oligomer or monomer that can constitute the photo-alignment polymer), a compound (AH), and, if necessary, other components in a solvent. The horizontal alignment layer 15, which is a photo-alignment layer, can be formed by using the composition for forming a horizontal alignment layer and by the method described in the section of the vertical alignment layer 12.

[0197] (Liquid crystal polarizer) The liquid crystal polarizer 16 contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and has an absorption axis in the horizontal direction with respect to the plane of the liquid crystal polarizer 16. When unpolarized light is incident on the liquid crystal polarizer 16, it has the property of transmitting linearly polarized light having a vibration plane orthogonal to the absorption axis. The liquid crystal polarizer 16 has an absorption axis and a transmission axis orthogonal thereto in the plane, and has the property of absorbing a polarization component parallel to the absorption axis and transmitting a polarization component parallel to the transmission axis. The liquid crystal polarizer 16 can exhibit a polarization function by anisotropic absorption of light by the dichroic dye encapsulated in the polymer of the polymerizable liquid crystal compound.

[0198] The liquid crystal polarizer 16 is a liquid crystal cured film obtained by applying a composition for forming a liquid crystal polarizer on the horizontal alignment layer 15 of the optical laminate 1 to 4 and polymerizing the polymerizable liquid crystal compound in a state where the dichroic dye contained in the composition for forming a liquid crystal polarizer is aligned. The dichroic dye and the polymer of the polymerizable liquid crystal compound contained in the liquid crystal polarizer 16 are horizontally aligned with respect to the plane of the liquid crystal polarizer 16.

[0199] The thickness of the liquid crystal polarizer 16 is preferably 0.1 μm or more and 5 μm or less, more preferably 0.3 μm or more and 4 μm or less, and even more preferably 0.5 μm or more and 3 μm or less. If the above thickness is smaller than this range, necessary light absorption may not be obtained, and if the above thickness is larger than this range, the alignment regulating force by the horizontal alignment layer 15 decreases, and alignment defects tend to occur.

[0200] The liquid crystal polarizer 16 preferably has a ratio (dichroic ratio; A1 / A2) of the absorbance A1(λ) in the alignment direction to the absorbance A2(λ) in the direction perpendicular to the in-plane of the alignment direction for light with a wavelength λ [nm] of 7 or more, more preferably 20 or more, and even more preferably 40 or more. The larger the value of the dichroic ratio, the better the absorption selectivity. Although it depends on the type of dichroic dye, when the liquid crystal polarizer 16 is cured in the nematic liquid crystal phase state, the dichroic ratio is about 5 to 10.

[0201] By mixing two or more types of dichroic dyes with different absorption wavelengths, liquid crystal polarizers 16 with various hues can be produced, and a liquid crystal polarizer 16 having absorption over the entire visible light range can be obtained. By using such a liquid crystal polarizer 16 having such absorption characteristics, it can be applied to various uses.

[0202] Examples of the dichroic dye used for the liquid crystal polarizer 16 include the dichroic dye used for forming the light absorption anisotropic layer 13. As the polymerizable liquid crystal compound, a rod-shaped liquid crystal compound, a disc-shaped liquid crystal compound, and a mixture thereof can be used. The polymerizable liquid crystal compound may be a thermotropic liquid crystal compound showing a nematic liquid crystal phase or a thermotropic liquid crystal compound showing a smectic liquid crystal phase. The polymerizable liquid crystal compound used for forming the light absorption anisotropic layer 13 can also be used.

[0203] (Protective layer) The protective layer 17 can suppress the diffusion of the dichroic dye contained in the liquid crystal polarizer 16 and suppress the damage of the liquid crystal polarizer 16. The protective layer 17 may be a polarizing element coating layer formed by coating on the liquid crystal polarizer 16, or may be a polarizing element protective film laminated on the liquid crystal polarizer 16 via an adhesive layer.

[0204] The polarizing element coating layer can be formed by applying a composition for forming the polarizing element coating layer onto the surface of the liquid crystal polarizer 16. Examples of the composition include the composition described as the coating layer forming composition used for forming the coating layer 14, and it is preferably the above-described water-soluble polymer-containing resin composition.

[0205] The thickness of the polarizing element coating layer is preferably 15 μm or less, and may be 0.1 μm or more and 12 μm or less, preferably 0.5 μm or more and 10 μm or less, and more preferably 1 μm or more and 5 μm or less.

[0206] The polarizing element protective film is a resin film that cannot be peeled off while maintaining the shape of the liquid crystal polarizer 16. As the polarizing element protective film, a thermoplastic resin film can be used. The thermoplastic resin film may be surface-treated (for example, corona treatment, etc.) or a thin layer such as a primer layer (also referred to as an undercoat layer) may be formed in order to improve the adhesion to the polarizing element.

[0207] The thermoplastic resin constituting the thermoplastic resin film is preferably a transparent film. Examples thereof include cellulose resins such as triacetyl cellulose; polyester resins such as polyethylene terephthalate and polyethylene naphthalate; polyethersulfone resins; polysulfone resins; polycarbonate resins; polyamide resins such as nylon and aromatic polyamides; polyimide resins; polyolefin resins such as polyethylene, polypropylene, and ethylene-propylene copolymers; cyclic polyolefin resins having a cyclic and norbornene structure (also referred to as norbornene resins); (meth)acrylic resins; polyarylate resins; polystyrene resins; polyvinyl alcohol resins, and the like. Among them, the thermoplastic resin film is preferably a cyclic polyolefin-based resin film, a cellulose ester-based resin film, a polyester-based resin film, or a (meth)acrylic-based resin film.

[0208] The polarizing element protection film may have a hard coat layer formed on a thermoplastic resin film. The hard coat layer may be formed on one surface of the thermoplastic resin film or on both surfaces. By providing the hard coat layer, a thermoplastic resin film with improved hardness and scratch resistance can be obtained. The hard coat layer is, for example, a cured layer of an active energy ray-curable resin, preferably an ultraviolet-curable resin. Examples of the ultraviolet-curable resin include poly(meth)acrylic resins, silicone resins, polyester resins, urethane resins, amide resins, epoxy resins, and the like. The hard coat layer may contain an additive in order to improve the strength. The additive is not particularly limited, and examples thereof include inorganic fine particles, organic fine particles, or a mixture thereof.

[0209] The thickness of the polarizing element protection film is preferably 5 μm or more and 150 μm or less, and may be 10 μm or more and 100 μm or less, or may be 10 μm or more and 80 μm or less.

[0210] (Retardation element (first liquid crystal retardation layer, second liquid crystal retardation layer)) The optical laminate 1 to 4 may contain a retardation element (FIGS. 3 and 4). The retardation element may be a retardation layer that is a stretched film, or may be a liquid crystal retardation layer containing a polymer of a polymerizable liquid crystal compound like the above-described first liquid crystal retardation layer 22 and second liquid crystal retardation layer 24. The retardation element is preferably a liquid crystal retardation layer.

[0211] When the optical laminate 1 to 4 constitutes an elliptical polarizing plate, the in-plane retardation R(λ) of the retardation element with respect to light having a wavelength λ [nm] preferably satisfies the optical characteristics shown in the following formula (4), and preferably satisfies the optical characteristics shown in the following formula (4), the following formula (5), and the following formula (6). 100 nm < Re(550) < 160 nm (4) Re(450) / Re(550) ≤ 1.00 (5) 1.00 ≤ Re(650) / Re(550) (6) [In formulas (4) to (6), Re(550) represents the in-plane phase difference value (in-plane retardation) of the phase difference element with respect to light of a wavelength of 550 nm, and Re(450) represents the in-plane phase difference value of the phase difference element with respect to light of a wavelength of 450 nm, and Re(650) represents the in-plane phase difference value of the phase difference element with respect to light of a wavelength of 650 nm.]

[0212] When "Re(450) / Re(550)" in the above formula (5) exceeds 1.0, light leakage on the short wavelength side in the elliptical polarizing plate including the λ / 4 phase difference element increases. "Re(450) / Re(550)" is preferably 0.70 or more and 1.00 or less, more preferably 0.80 or more and 0.95 or less, still more preferably 0.80 or more and 0.92 or less, and particularly preferably 0.82 or more and 0.88 or less. The value of "Re(450) / Re(550)" can be arbitrarily adjusted by adjusting the lamination angle and phase difference value of a plurality of phase difference elements constituting the phase difference element, or by adjusting the mixing ratio of the polymerizable liquid crystal compound constituting the phase difference element.

[0213] The in-plane phase difference value of the phase difference element can be adjusted by the thickness of the phase difference element. Since the in-plane phase difference value is determined by the following formula (7), in order to make the in-plane phase difference value (Re(λ)) at a wavelength λ [nm] a desired value, it is only necessary to adjust Δn(λ) and the film thickness d. The thickness of the phase difference element is preferably 0.5 μm to 5 μm, and more preferably 1 μm to 3 μm. The said thickness can be measured with an interference film thickness meter, a laser microscope, or a stylus type film thickness meter. In addition, when the phase difference element is a liquid crystal phase difference layer, Δn(λ) will depend on the molecular structure of the said polymerizable liquid crystal compound. Re(λ)=d×Δn(λ) (7) [In formula (7), Re(λ) represents the in-plane phase difference value of the phase difference element at a wavelength λ [nm], d represents the thickness of the phase difference layer, Δn(λ) represents the birefringence of the phase difference element at a wavelength λ [nm].]

[0214] The optical laminate may include a positive C-plate as a retardation element. The retardation value Rth(550) in the thickness direction of the positive C-plate at a wavelength of 550 nm is usually in the range of -170 nm or more and -10 nm or less, preferably in the range of -150 nm or more and -20 nm or less, more preferably in the range of -100 nm or more and -40 nm or less. If the retardation value in the thickness direction of the positive C-plate is within this range, the antireflection characteristics from an oblique direction can be further improved.

[0215] As the retardation layer which is a stretched film, those known in the art can be used, and those obtained by imparting retardation by uniaxially stretching or biaxially stretching a resin film can be used. Examples of the resin film include cellulose films such as triacetyl cellulose and diacetyl cellulose, polyester films such as polyethylene terephthalate, polyethylene isophthalate and polybutylene terephthalate, acrylic resin films such as polymethyl (meth) acrylate and polyethyl (meth) acrylate, polycarbonate films, polyethersulfone films, polysulfone films, polyimide films, polyolefin films, polynorbornene films, etc., but are not limited thereto.

[0216] The thickness of the retardation layer is usually 5 μm or more and 200 μm or less, preferably 10 μm or more and 80 μm or less, more preferably 40 μm or less.

[0217] When the retardation element is a liquid crystal retardation layer such as a first liquid crystal retardation layer or a second liquid crystal retardation layer, the liquid crystal retardation layer can include a liquid crystal cured film formed by applying a composition for forming a liquid crystal retardation layer containing a polymerizable liquid crystal compound to a film substrate. The liquid crystal retardation layer may be a liquid crystal cured film or a laminate of a liquid crystal cured film and an alignment layer. The liquid crystal retardation layer exhibits retardation in the in-plane direction or the thickness direction.

[0218] The thickness of the liquid crystal retardation layer is preferably 0.5 μm or more and 5 μm or less, more preferably 1 μm or more and 3 μm or less.

[0219] As the film substrate on which the composition for forming a liquid crystal retardation layer is coated, those exemplified as the film substrate used for coating the composition for forming a light absorption anisotropic layer can be mentioned. The film substrate may be peeled off and removed when forming the optical laminate 3, 4, or may be used as a protective film for the liquid crystal retardation layer without being peeled off and removed. As the polymerizable liquid crystal compound, a polymerizable liquid crystal compound having a photopolymerizable group as a polymerizable group can be particularly used. As the polymerizable liquid crystal compound, for example, a polymerizable liquid crystal compound conventionally known in the field of liquid crystal retardation layers can be used. The photopolymerizable group refers to a group that can participate in a polymerization reaction by reaction active species generated from a photopolymerization initiator, such as active radicals and acids. Examples of the photopolymerizable group include a vinyl group, a vinyloxy group, a 1-chlorovinyl group, an isopropenyl group, a 4-vinylphenyl group, an acryloyloxy group, a methacryloyloxy group, an oxiranyl group, and an oxetanyl group. Among them, an acryloyloxy group, a methacryloyloxy group, a vinyloxy group, an oxiranyl group, and an oxetanyl group are preferable, and an acryloyloxy group is more preferable. The liquid crystallinity may be thermotropic liquid crystal or lyotropic liquid crystal, but thermotropic liquid crystal is preferable in terms of enabling precise film thickness control. Further, as the phase order structure in the thermotropic liquid crystal, a nematic liquid crystal or a smectic liquid crystal may be used. Further, it may be a rod-shaped liquid crystal or a disc-shaped liquid crystal. The polymerizable liquid crystal compound can be used alone or in combination of two or more.

[0220] As the polymerizable liquid crystal compound contained in the λ / 4 liquid crystal retardation layer contained in the liquid crystal retardation layer, a liquid crystal having a mesogen structure in a T-shape or an H-shape having further birefringence in a direction perpendicular to the molecular long axis direction is preferable from the viewpoint of expressing reverse wavelength dispersion, and a T-shaped liquid crystal is more preferable from the viewpoint of obtaining stronger dispersion. Specific examples of the structure of the T-shaped liquid crystal include, for example, a compound represented by the following formula (II). [Chemical formula] [In formula (II), Ar represents a divalent aromatic group which may have a substituent. It is preferable that at least one of a nitrogen atom, an oxygen atom, and a sulfur atom is contained in the divalent aromatic group. When there are two or more aromatic groups contained in the divalent group Ar, the two or more aromatic groups may be bonded to each other by a divalent bonding group such as a single bond, -CO-O-, -O-. G 1 and G 2 each independently represents a divalent aromatic group or a divalent alicyclic hydrocarbon group. Here, the hydrogen atom contained in the divalent aromatic group or the divalent alicyclic hydrocarbon group may be substituted with a halogen atom, an alkyl group having 1 to 4 carbon atoms, a fluoroalkyl group having 1 to 4 carbon atoms, an alkoxy group having 1 to 4 carbon atoms, a cyano group, or a nitro group, and the carbon atom constituting the divalent aromatic group or the divalent alicyclic hydrocarbon group may be substituted with an oxygen atom, a sulfur atom, or a nitrogen atom. L 1 L 2 B 1 and B 2 each independently represents a single bond or a divalent linking group. k and l each independently represent an integer of 0 to 3 and satisfy the relationship of 1 ≦ k + l. Here, when 2 ≦ k + l, B 1 and B 2 G 1 and G 2 may be the same as or different from each other. E 1 and E 2 each independently represents an alkanediyl group having 1 to 17 carbon atoms. Here, the hydrogen atom contained in the alkanediyl group may be substituted with a halogen atom, and -CH 2 - contained in the alkanediyl group may be substituted with -O-, -S-, -COO-, and when there are a plurality of -O-, -S-, -COO-, they are not adjacent to each other. P 1 and P 2 each independently represents a polymerizable group or a hydrogen atom, and at least one is a polymerizable group.

[0221] G 1 and G 2is, independently of each other, preferably a 1,4-phenylene diyl group which may be substituted with at least one substituent selected from the group consisting of a halogen atom and an alkyl group having 1 to 4 carbon atoms, a 1,4-cyclohexane diyl group which may be substituted with at least one substituent selected from the group consisting of a halogen atom and an alkyl group having 1 to 4 carbon atoms, more preferably a 1,4-phenylene diyl group substituted with a methyl group, an unsubstituted 1,4-phenylene diyl group, or an unsubstituted 1,4-trans-cyclohexane diyl group, particularly preferably an unsubstituted 1,4-phenylene diyl group or an unsubstituted 1,4-trans-cyclohexane diyl group. Also, a plurality of Gs 1 and G 2 Among them, at least one is preferably a divalent alicyclic hydrocarbon group. Also, L 1 or L 2 The G bonded to 1 and G 2 Among them, it is more preferable that at least one is a divalent alicyclic hydrocarbon group.

[0222] L 1 and L 2 are each independently, preferably a single bond, an alkylene group having 1 to 4 carbon atoms, -O-, -S-, -R a1 OR a2 -, -R a3 COOR a4 -, -R a5 OCOR a6 -, R a7 OC=OOR a8 -, -N=N-, -CR c =CR d -, or C≡C-. Here, R a1 ~R a8 each independently represents a single bond or an alkylene group having 1 to 4 carbon atoms, and R c and R d represent an alkyl group having 1 to 4 carbon atoms or a hydrogen atom. L 1 and L 2 are each independently, more preferably a single bond, -O Ra2-1 -, -CH 2 -, -CH 2 CH2 -, -COOR a4-1 -, or OCOR a6-1 -. Here, R a2-1 , R a4-1 , R a6-1 each independently represents a single bond, -CH 2 -, -CH 2 CH 2 -. L 1 and L 2 each independently, more preferably a single bond, -O-, -CH 2 CH 2 -, -COO-, -COOCH 2 CH 2 -.

[0223] B 1 and B 2 each independently, preferably a single bond, an alkylene group having 1 to 4 carbon atoms, -O-, -S-, -R a9 OR a10 -, -R a11 COOR a12 -, -R a13 OCOR a14 -, or R a15 OC=OOR a16 -. Here, R a9 ~R a16 each independently represents a single bond or an alkylene group having 1 to 4 carbon atoms. B 1 and B 2 each independently, more preferably a single bond, -OR a10-1 -, -CH 2 -, -CH 2 CH 2 -, -COOR a12-1 -, or OCOR a14-1 -. Here, R a10-1 , R a12-1 , R a14-1 each independently represents a single bond, -CH 2 -, -CH 2 CH 2 -. B 1 and B 2 each independently, even more preferably a single bond, -O-, -CH 2 CH 2-, -COO-, -COOCH 2 CH 2 -, -OCO-, or OCOCH 2 CH 2 - is.

[0224] From the viewpoint of expressing inverse wavelength dispersion, 2 ≤ k + l ≤ 6 is preferable, k + l = 4 is more preferable, and k = 2 and l = 2 are even more preferable. When k = 2 and l = 2, a symmetric structure is formed, which is preferable.

[0225] E 1 and E 2 are each independently preferably an alkanediyl group having 1 to 17 carbon atoms, and more preferably an alkanediyl group having 4 to 12 carbon atoms.

[0226] P 1 or P 2 Examples of the polymerizable group represented by - include an epoxy group, a vinyl group, a vinyloxy group, a 1-chlorovinyl group, an isopropenyl group, a 4-vinylphenyl group, an acryloyloxy group, a methacryloyloxy group, an oxiranyl group, and an oxetanyl group. Among them, an acryloyloxy group, a methacryloyloxy group, a vinyloxy group, an oxiranyl group, and an oxetanyl group are preferable, and an acryloyloxy group is more preferable.

[0227] Ar preferably has at least one selected from an aromatic hydrocarbon ring which may have a substituent, an aromatic heterocyclic ring which may have a substituent, and an electron-withdrawing group. Examples of the aromatic hydrocarbon ring include a benzene ring, a naphthalene ring, an anthracene ring, etc., and a benzene ring and a naphthalene ring are preferred. Examples of the aromatic heterocyclic ring include a furan ring, a benzofuran ring, a pyrrole ring, an indole ring, a thiophene ring, a benzothiophene ring, a pyridine ring, a pyrazine ring, a pyrimidine ring, a triazole ring, a triazine ring, a pyrroline ring, an imidazole ring, a pyrazole ring, a thiazole ring, a benzothiazole ring, a thienothiazole ring, an oxazole ring, a benzoxazole ring, and a phenanthroline ring, etc. Among them, it is preferable to have a thiazole ring, a benzothiazole ring, or a benzofuran ring, and it is more preferable to have a benzothiazole group. When Ar contains a nitrogen atom, the nitrogen atom preferably has π electrons.

[0228] In formula (II), the total number Nπ of π electrons contained in the divalent aromatic group represented by Ar is preferably 8 or more, more preferably 10 or more, still more preferably 14 or more, and particularly preferably 16 or more. Also, it is preferably 30 or less, more preferably 26 or less, and still more preferably 24 or less.

[0229] Examples of the aromatic group represented by Ar preferably include the following groups.

Chemical formula

[0230] Y 1 Y 2 and Y 3Examples of the aromatic hydrocarbon group in the formula (I) include aromatic hydrocarbon groups having 6 to 20 carbon atoms, such as a phenyl group, a naphthyl group, an anthryl group, a phenanthryl group, and a biphenyl group, of which a phenyl group and a naphthyl group are preferred, and a phenyl group is more preferred. Examples of the aromatic heterocyclic group in the formula (I) include aromatic heterocyclic groups having 4 to 20 carbon atoms and containing at least one heteroatom, such as a nitrogen atom, an oxygen atom, or a sulfur atom, such as a furyl group, a pyrrolyl group, a thienyl group, a pyridinyl group, a thiazolyl group, and a benzothiazolyl group, of which a furyl group, a thienyl group, a pyridinyl group, a thiazolyl group, and a benzothiazolyl group are preferred.

[0231] Y 1 , Y 2 and Y 3 may each independently be an optionally substituted polycyclic aromatic hydrocarbon group or polycyclic aromatic heterocyclic group. The polycyclic aromatic hydrocarbon group refers to a condensed polycyclic aromatic hydrocarbon group or a group derived from an aromatic ring assembly. The polycyclic aromatic heterocyclic group refers to a condensed polycyclic aromatic heterocyclic group or a group derived from an aromatic ring assembly.

[0232] Z 0 , Z 1 and Z 2 are each preferably independently a hydrogen atom, a halogen atom, an alkyl group having 1 to 12 carbon atoms, a cyano group, a nitro group, or an alkoxy group having 1 to 12 carbon atoms; Z 0 is more preferably a hydrogen atom, an alkyl group having 1 to 12 carbon atoms, or a cyano group; Z 1 and Z 2 is more preferably a hydrogen atom, a fluorine atom, a chlorine atom, a methyl group, or a cyano group.

[0233] Q 1 and Q 2 -NH-, -S-, -NR 2’ -, -O- are preferred, R 2’ is preferably a hydrogen atom, and among these, -S-, -O-, and -NH- are particularly preferable.

[0234] Among the compounds represented by formulas (Ar-1) to (Ar-23), the compounds represented by formulas (Ar-6) and (Ar-7) are preferred from the viewpoint of molecular stability.

[0235] In the compounds represented by formulas (Ar-16) to (Ar-23), Y 1 may, together with the nitrogen atom to which it is attached and Z 0 form an aromatic heterocyclic group. Examples of the aromatic heterocyclic group include those described above as the aromatic heterocyclic group that Ar may have, such as a pyrrole ring, an imidazole ring, a pyrroline ring, a pyridine ring, a pyrazine ring, a pyrimidine ring, an indole ring, a quinoline ring, an isoquinoline ring, a purine ring, a pyrrolidine ring, etc. This aromatic heterocyclic group may have a substituent. Also, Y 1 may, together with the nitrogen atom to which it is attached and Z 0 be the above-described optionally substituted polycyclic aromatic hydrocarbon group or polycyclic aromatic heterocyclic group. For example, a benzofuran ring, a benzothiazole ring, a benzoxazole ring, etc. may be mentioned.

[0236] Among the polymerizable liquid crystal compounds, compounds having a maximum absorption wavelength of 300 to 400 nm are preferred. When a photopolymerization initiator is included in the liquid crystal retardation layer-forming composition containing the polymerizable liquid crystal compound, there is a possibility that the polymerization reaction and gelation of the polymerizable liquid crystal compound may proceed during long-term storage. However, if the maximum absorption wavelength of the polymerizable liquid crystal compound is 300 to 400 nm, even when exposed to ultraviolet light during storage, the generation of reactive species from the photopolymerization initiator and the progress of the polymerization reaction and gelation of the polymerizable liquid crystal compound by the reactive species can be effectively suppressed. Therefore, it is advantageous in terms of the long-term stability of the liquid crystal retardation layer-forming composition, and the alignment and film thickness uniformity of the liquid crystal retardation layer can be improved. The maximum absorption wavelength of the polymerizable liquid crystal compound can be measured using an ultraviolet-visible spectrophotometer in a solvent. The solvent is a solvent capable of dissolving the polymerizable liquid crystal compound, and examples thereof include chloroform, etc.

[0237] The content of the polymerizable liquid crystal compound in the composition for forming a liquid crystal retardation layer is, for example, 70 to 99.5 parts by mass, preferably 80 to 99 parts by mass, more preferably 85 to 98 parts by mass, and still more preferably 90 to 95 parts by mass with respect to 100 parts by mass of the solid content of the composition for forming a liquid crystal retardation layer. If the content of the polymerizable liquid crystal compound is within the above range, it is advantageous from the viewpoint of the alignment of the obtained liquid crystal cured film.

[0238] The liquid crystal retardation layer may include an alignment layer. The alignment layer may be selected according to the direction in which the polymerizable liquid crystal compound is aligned. For example, it may be a vertical alignment layer or a horizontal alignment layer. If the alignment layer is a material that exhibits horizontal alignment as an alignment regulating force, the polymerizable liquid crystal compound can form a horizontal alignment or a hybrid alignment. If it is a material that exhibits vertical alignment, the polymerizable liquid crystal compound can form a vertical alignment or an inclined alignment. Expressions such as horizontal and vertical represent the direction of the major axis of the aligned polymerizable liquid crystal compound with respect to the plane of the liquid crystal retardation layer. For example, vertical alignment means having the major axis of the aligned polymerizable liquid crystal compound in a direction perpendicular to the plane of the liquid crystal retardation layer. Here, the vertical means 90° ± 20° with respect to the plane of the liquid crystal retardation layer. Examples of the alignment layer include those described above for the vertical alignment layer and the horizontal alignment layer.

[0239] (First adhesive layer, second adhesive layer, adhesive layer) The first adhesive layer 21, the second adhesive layer 23, which may be used in the optical laminate 1 to 4, and the adhesive layer other than the first adhesive layer 21 and the second adhesive layer 23 (hereinafter, these are also collectively referred to as the "adhesive layer") are an adhesive layer or an adhesive layer.

[0240] The adhesive layer can be formed using an adhesive composition. The adhesive composition or the reaction product of the adhesive composition exhibits adhesiveness by attaching itself to the adherend and is so-called a pressure-sensitive adhesive. In addition, the adhesive layer formed using the active energy ray-curable adhesive composition described later can adjust the degree of crosslinking and the adhesive force by irradiating active energy rays.

[0241] As the adhesive composition, an adhesive having excellent conventionally known optical transparency can be used without particular limitation. For example, an adhesive composition containing a base polymer such as an acrylic polymer, a urethane polymer, a silicone polymer, or a polyvinyl ether can be used. Further, the adhesive composition may be an active energy ray curable adhesive composition, a thermosetting adhesive composition, or the like. Among these, an adhesive composition based on an acrylic resin excellent in transparency, adhesive strength, peelability (reworkability), weather resistance, heat resistance, etc. is preferable. The adhesive layer is preferably composed of a reaction product of an adhesive composition containing a (meth)acrylic resin, a crosslinking agent, and a silane compound, and may contain other components.

[0242] The adhesive composition for forming the adhesive layer can contain, for example, a base polymer such as an acrylic polymer, a urethane polymer, a silicone polymer, or a polyvinyl ether. The adhesive composition may be an active energy ray curable adhesive, a thermosetting adhesive, or the like. Among these, an adhesive based on a (meth)acrylic resin excellent in transparency, adhesive strength, peelability (reworkability), weather resistance, heat resistance, etc. is preferable. The adhesive layer is preferably composed of a reaction product of an adhesive containing a (meth)acrylic resin, a crosslinking agent, and a silane compound, and may contain other components.

[0243] The adhesive layer may be formed using an active energy ray curable adhesive. The active energy ray curable adhesive can form a harder adhesive layer by blending an ultraviolet curable compound such as a polyfunctional acrylate into the above-described adhesive composition and irradiating ultraviolet rays after forming the adhesive layer to cure it. The active energy ray curable adhesive has the property of curing upon irradiation with energy rays such as ultraviolet rays or electron beams. Since the active energy ray curable adhesive has adhesiveness even before irradiation with energy rays, it can adhere to the adherend and has the property of adjusting the adhesive strength by curing upon irradiation with energy rays.

[0244] The thickness of the adhesive layer is not particularly limited, but is usually 5 μm or more and 300 μm or less, may be 10 μm or more and 250 μm or less, may be 15 μm or more and 100 μm or less, or may be 20 μm or more and 50 μm or less.

[0245] The adhesive layer can be formed using an adhesive composition. Examples of the adhesive composition for forming the adhesive layer include adhesives other than pressure-sensitive adhesives, such as aqueous adhesives and active energy ray-curable adhesives.

[0246] Examples of the aqueous adhesive include an adhesive obtained by dissolving or dispersing a polyvinyl alcohol resin in water. The drying method when using an aqueous adhesive is not particularly limited, and for example, a method of drying using a hot air dryer or an infrared dryer can be adopted.

[0247] Examples of the active energy ray-curable adhesive include a solvent-free active energy ray-curable adhesive containing a curable compound that cures by irradiation with active energy rays such as ultraviolet rays, visible light, electron beams, and X-rays. By using a solvent-free active energy ray-curable adhesive, the adhesion between layers can be improved.

[0248] The thickness of the adhesive layer is preferably 0.1 μm or more, may be 0.5 μm or more, is preferably 10 μm or less, and may be 5 μm or less.

[0249] (Use of the optical laminate) The optical laminate 1 to 4 can be applied to a display device. Examples of the display device include an organic EL display device. The organic EL display device can have a structure in which the above-described optical laminate is laminated on an image display element via an adhesive layer. In the organic EL display device, the optical laminate is incorporated so as to be arranged in the order of the light absorption anisotropic layer 13, the liquid crystal polarizer 16, and the image display element from the viewing side. Examples of the adhesive layer include the adhesive layer described above. As described above, when the optical laminate is an elliptical polarizing plate, the optical laminate can be used as an antireflection film.

Example

[0250] Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples, but the present invention is not limited to these examples. In the Examples and Comparative Examples, “%” and “parts” are mass % and parts by mass, respectively, unless otherwise specified.

[0251] [Preparation of Base Material Layer] (Base Material Layer: TAC Film 1 (25TAC)) A triacetyl cellulose (TAC) film (“KC2UA-TAC” manufactured by Konica Minolta) was prepared.

[0252] [Preparation of Composition for Forming Light Absorption Anisotropic Layer] (Preparation of Composition for Forming Light Absorption Anisotropic Layer (1)) The following components were mixed and stirred at 80° C. for 1 hour to obtain a composition for forming a light absorption anisotropic layer (1). Polymerizable liquid crystal compound (1): 75 parts Polymerizable liquid crystal compound (2): 25 parts Dichroic dye (azo dye) (1): 1.2 parts Dichroic dye (azo dye) (2): 1.7 parts Polymerization initiator (2-dimethylamino-2-benzyl-1-(4-morpholinophenyl)butan-1-one (Irgacure 369, manufactured by BASF): 6 parts Leveling agent (BYK-333, manufactured by BYK-Chemie): 0.25 part Solvent (o-xylene): 670 parts

[0253] The polymerizable liquid crystal compounds (1) and (2) have the structures shown below and were synthesized according to the method described in Recl. Trav. Chim. Pays-Bas, 115, 321-328 (1996), such as lub, etc. · Polymerizable liquid crystal compound (1):

Chemical formula

Chemical formula

[0254] The dichroic dyes (1) and (2) used azo dyes having the structures shown below. · Dichroic dye (1):

Chemical formula

Chemical formula

[0255] (Preparation of the composition for forming the light absorption anisotropic layer (2)) By mixing the following components and stirring at 80 °C for 1 hour, the composition for forming the light absorption anisotropic layer (2) was obtained. Polymerizable liquid crystal compound (1): 75 parts Polymerizable liquid crystal compound (2): 25 parts Dichroic dye (azo dye) (1): 1.2 parts Dichroic dye (azo dye) (2): 1.7 parts Polymerization initiator (2-dimethylamino-2-benzyl-1-(4-morpholinophenyl)butan-1-one (Irgacure 369, manufactured by BASF): 6 parts Leveling agent (BYK-333, manufactured by BYK-Chemie): 0.25 part Non-liquid crystalline compound having a polymerizable group (dipentaerythritol hexaacrylate (6-functional)): 1.5 parts Reactive additive (Laromer® LR-9000, manufactured by BASF): 2 parts Solvent (o-xylene): 670 parts

[0256] The reactive additive contains a compound having the structure shown below. [Chemical formula]

[0257] [Preparation of Composition for Forming Horizontal Alignment Layer] (Synthesis of Alignment Polymer) According to the synthesis scheme shown below, an alignment polymer composed of structural units represented by formula (1-1-1) (hereinafter also referred to as "alignment polymer (1-1-1)") was synthesized. [Chemical formula]

[0258] (Synthesis of Compound Represented by Formula (a1-1-1)) 50 g (258 mmol) of ferulic acid was dissolved in 360 g of methanol. To the resulting solution, 10 g of sulfuric acid was added at room temperature, and the temperature was raised until the solvent refluxed, and then reacted under reflux for 2 hours. After cooling the resulting reaction solution, 150 g of ice and 150 g of water were added. The supernatant was removed by decantation, and 150 g of water at 5 °C was further added for crystallization. The resulting white crystals were filtered. The filtered white crystals were further washed with 1M aqueous sodium hydrogen carbonate solution and water, and then dried under vacuum to obtain 22.2 g of a compound represented by formula (a1-1-1) (hereinafter also referred to as "compound (a1-1-1)"). The yield was 83% based on ferulic acid.

[0259] (Synthesis of Compound Represented by Formula (b1-1-1)) 25 g (120 mmol) of the compound (a1-1-1) was dissolved in 250 g of dimethylacetamide. To the resulting solution, 33.19 g (240 mmol) of potassium carbonate and 1.99 g (12 mmol) of potassium iodide were added. 6-Chlorohexanol was added dropwise to the resulting dispersion, and after stirring at room temperature for 1 hour, the mixture was stirred at 70 °C for 8 hours. The resulting reaction solution was filtered to remove insoluble substances. To the filtrate, 200 g of methyl isobutyl ketone and 300 g of water were added, stirred, allowed to stand, and separated to recover the organic layer. 200 g of water was added to the recovered organic layer, and a series of water washing operations of stirring, standing, and separating were repeated twice. The solvent was removed from the recovered organic layer by distillation under reduced pressure using an evaporator to obtain a crude product of the compound represented by the formula (b1-1-1) (hereinafter also referred to as "compound (b1-1-1)").

[0260] (Synthesis of the compound represented by the formula (c1-1-1)) The total amount of the crude product of compound (b1-1-1) was dissolved in 185 g of ethanol. To the resulting solution, 92 g of water and 14.41 g (360 mmol) of sodium hydroxide were added and stirred at 80 °C for 1 hour. After cooling the reaction solution to about 3 °C, a 2 M hydrochloric acid aqueous solution was added while maintaining the temperature at 5 °C or lower to adjust the pH to 2. The acid-precipitated white precipitate was collected by filtration, washed twice with a mixed solution of 100 g of water and 80 g of methanol, and then dried under vacuum to obtain 30.4 g of the compound represented by the formula (c1-1-1) (hereinafter also referred to as "compound (c1-1-1)"). The yield was 86% based on compound (a1-1-1).

[0261] (Synthesis of the compound represented by the formula (M1-1-1)) 27.46 g (93 mmol) of the compound (c1-1-1) was dissolved in 280 g of chloroform. To the resulting solution, 2.06 g of BHT (di-t-butyl-hydroxytoluene) as a polymerization inhibitor and 37.73 g (373 mmol) of triethylamine were added, and the mixture was stirred under ice-cooling. 29.26 g (260 mmol) of methacrylic acid chloride was added dropwise to the reaction solution, and the mixture was stirred for 5 hours while maintaining the temperature at 5 °C or lower. To the resulting reaction solution, 5.7 g of dimethylaminopyridine and 190 g of water were added, and the mixture was stirred at room temperature for 12 hours. After standing, the organic layer was recovered. 100 g of 2N hydrochloric acid aqueous solution was added to this organic layer, and a series of washing operations of stirring, standing, and liquid separation were repeated twice. The organic layer was recovered, 300 g of n-heptane was added, and the precipitated crystals were collected by filtration. After washing twice with a mixed solvent consisting of 100 g of water and 80 g of methanol, vacuum drying was performed to obtain 22.0 g of the compound represented by the formula (M1-1-1) (hereinafter also referred to as "compound (M1-1-1)"). The yield was 65% based on the compound (c1-1-1).

[0262] (Synthesis of the alignment polymer (1-1-1)) 1.00 g (2.76 mmol) of the compound (M1-1-1) and 10 g of tetrahydrofuran were added to a Schlenk tube. After deoxygenation, 2.27 mg of azobisisobutyronitrile (AIBN) was added while flowing nitrogen, and the mixture was stirred at 60 °C for 72 hours. The resulting reaction solution was added to 200 g of toluene. The precipitate was collected by filtration, washed with heptane, and then vacuum dried to obtain 0.75 g of the alignment polymer (1-1-1). The yield was 75% based on the compound (M1-1-1). From GPC measurement, the number average molecular weight of the obtained alignment polymer (1-1-1) was 28,200, the weight average molecular weight was about 51,300, Mw / Mn was 1.82, and the monomer content was 0.5%.

[0263] (Preparation of the composition (1) for forming a horizontal alignment layer) 2 parts of the alignment polymer (1-1-1) and 98 parts of o-xylene were mixed, and the mixture was stirred at 80 °C for 1 hour to obtain the composition (1) for forming a horizontal alignment layer.

[0264] (Preparation of Composition for Forming Horizontal Alignment Layer (2)) To the composition for forming a horizontal alignment layer (1) obtained above, 3-aminopropyltriethoxysilane ("KBE-903" manufactured by Shin-Etsu Chemical Co., Ltd.) was added and mixed so as to be 1.0 part with respect to 100 parts of the alignment polymer (1-1-1) to obtain a composition for forming a horizontal alignment layer (2).

[0265] [Preparation of Composition for Forming Liquid Crystal Polarizer] (Preparation of Composition for Forming Liquid Crystal Polarizer (1)) Each of the components shown below was mixed and stirred at 80°C for 1 hour to obtain a composition for forming a liquid crystal polarizer (1). Polymerizable liquid crystal compound (1): 75 parts Polymerizable liquid crystal compound (2): 25 parts Dichroic dye (azo dye) (3): 2.8 parts Dichroic dye (azo dye) (4): 2.8 parts Dichroic dye (azo dye) (5): 2.8 parts Polymerization initiator (2-dimethylamino-2-benzyl-1-(4-morpholinophenyl)butan-1-one (Irgacure 369, manufactured by BASF)): 6 parts Leveling agent (polyacrylate compound (BYK-361N, manufactured by BYK-Chemie)): 1.2 parts Solvent (cyclopentanone): 250 parts

[0266] The structures and synthesis methods of the polymerizable liquid crystal compounds (1) and (2) are as described above.

[0267] As the dichroic dyes (3) to (5), azo dyes having the structures shown below were used. · Dichroic dye (3):

Chemical formula

Chemical formula

[0268] (Preparation of Composition (2) for Forming Liquid Crystal Polarizer) By mixing the following components and stirring at 80 °C for 1 hour, Composition (1) for forming a liquid crystal polarizer was obtained. Polymerizable liquid crystal compound (1): 75 parts Polymerizable liquid crystal compound (2): 25 parts Dichroic dye (azo dye) (3): 2.8 parts Dichroic dye (azo dye) (4): 2.8 parts Dichroic dye (azo dye) (5): 2.8 parts Polymerization initiator (2-dimethylamino-2-benzyl-1-(4-morpholinophenyl)butan-1-one (Irgacure 369, manufactured by BASF)): 6 parts Leveling agent (polyacrylate compound (BYK-361N, manufactured by BYK-Chemie)): 1.2 parts Reactive additive (Laromer (registered trademark) LR-9000, manufactured by BASF): 2 parts Solvent (cyclopentanone): 250 parts

[0269] The structures and synthesis methods of polymerizable liquid crystal compounds (1) and (2), and the structure of the reactive additive are as described above.

[0270] [Preparation of Water-Soluble Polymer-Containing Resin Composition] To 100 parts of water, 3 parts of carboxyl group-modified polyvinyl alcohol (Kuraray Poval KL318, manufactured by Kuraray) and 1.5 parts of water-soluble polyamide epoxy resin (Sumirez Resin 650 (aqueous solution with a solid content concentration of 30%), manufactured by Sumika Chemtex) were added to prepare a water-soluble polymer-containing resin composition.

[0271] [Preparation of Composition for Forming Coating Layer] (Preparation of Hard Coat Composition) By mixing the following components and stirring at 80 °C for 1 hour, a hard coat composition was prepared. Acrylate compound (dipentaerythritol hexaacrylate): 50 parts Urethane acrylate compound (urethane acrylate (manufactured by Daicel Ornex Co., Ltd., "Ebecryl 4858")): 50 parts Radical polymerization initiator (2-[4-(methylthio)benzoyl]-2-(4-morpholinyl)propane (manufactured by BASF, "Irgacure 907")): 3 parts Solvent (methyl ethyl ketone): 10 parts

[0272] (Preparation of cation-curable composition) After mixing the components shown below, defoaming was carried out to prepare a cation-curable composition. The photo cationic polymerization initiator was formulated as a 50% propylene carbonate solution, and the number of parts is shown as the solid content. Cationically polymerizable compound (1) [3-ethyl-3-{[(3-ethyloxetan-3-yl)methoxy]methyl}oxetane (trade name: OXT-221, manufactured by Toagosei Co., Ltd.)]: 60.0 parts Cationically polymerizable compound (2) [3',4'-epoxycyclohexylmethyl 3,4-epoxycyclohexanecarboxylate (trade name: CEL2021P, manufactured by Daicel Corporation)]: 32.5 parts Cationically polymerizable compound (3) [1,2-epoxy-4-(2-oxiranyl)cyclohexane adduct of 2,2-bis(hydroxymethyl)-1-butanol (trade name: EHPE3150, manufactured by Daicel Corporation)]: 7.5 parts Photo cationic polymerization initiator [CPI-100P (manufactured by San-Apro Ltd., 50 mass% solution)]: 2.3 parts Photosensitizer [9,10-dibutoxyanthracene]: 1.0 part Photosensitizer assistant [1,4-diethoxynaphthalene]: 1.0 part

[0273] [Fabrication of the first liquid crystal retardation layer] (Preparation of the composition for forming a horizontal alignment layer (3)) 5 parts of a photo-alignment material having the structure shown below (weight average molecular weight: 30,000) and 95 parts of cyclopentanone (solvent) were mixed, and the resulting mixture was stirred at 80 °C for 1 hour to prepare a composition (3) for forming a horizontal alignment layer. Photo-alignment material:

Chemical formula

[0274] (Preparation of the composition (1) for forming a liquid crystal retardation layer) A polymerizable liquid crystal compound (3) and a polymerizable liquid crystal compound (4) having the structures shown below were each prepared. The polymerizable liquid crystal compound (3) was produced according to the method described in JP-A-2010-31223. The polymerizable liquid crystal compound (4) was produced according to the method described in JP-A-2009-173893. Polymerizable liquid crystal compound (3):

Chemical formula

Chemical formula

[0275] 1 mg of the polymerizable liquid crystal compound (3) was dissolved in 50 mL of tetrahydrofuran to obtain a solution. The resulting solution was placed in a measurement cell with an optical path length of 1 cm as a measurement sample, and the measurement sample was set in an ultraviolet-visible spectrophotometer (UV-2450, manufactured by Shimadzu Corporation) to measure the absorption spectrum. When the wavelength at which the maximum absorbance was obtained was read from the resulting absorption spectrum, the maximum absorption wavelength λmax in the wavelength range of 300 to 400 nm was 350 nm.

[0276] The polymerizable liquid crystal compound (3) and the polymerizable liquid crystal compound (4) were mixed at a mass ratio of 90:10 to obtain a mixture. To 100 parts of the obtained mixture, 0.1 part of a leveling agent (BYK-361N, manufactured by BM Chemie) and 6 parts of 2-dimethylamino-2-benzyl-1-(4-morpholinophenyl)butan-1-one (Irgacure (registered trademark) 369 (Irg369), manufactured by BASF Japan Ltd.) as a photopolymerization initiator were added. Further, N-methyl-2-pyrrolidone (NMP) was added so that the solid content concentration became 13%. The mixture was stirred at 80 °C for 1 hour to prepare a composition (1) for forming a liquid crystal retardation layer.

[0277] (Fabrication of the first liquid crystal retardation layer) After subjecting a cycloolefin (COP) film ("ZF-15-40" manufactured by Nippon Zeon Co., Ltd.) to corona treatment, the composition (3) for forming a horizontal alignment layer was coated with a bar coater, dried at 80 °C for 1 minute, and using a polarized UV irradiation device (SPOT CURE SP-9; manufactured by Ushio Inc.), the integrated light quantity at a wavelength of 313 nm: 100 mJ / cm 2 Polarized UV exposure was carried out to obtain a horizontal alignment layer (r1) for the first liquid crystal retardation layer.

[0278] Subsequently, the composition (1) for forming a liquid crystal retardation layer was coated on the horizontal alignment layer (r1) using a bar coater, heated at 120 °C for 60 seconds, and then using a high-pressure mercury lamp (Unicure VB-15201BY-A, manufactured by Ushio Inc.), ultraviolet rays were irradiated from the surface on which the composition (1) for forming a liquid crystal retardation layer was coated (under a nitrogen atmosphere, the integrated light quantity at a wavelength of 365 nm: 500 mJ / cm 2 ) to form a liquid crystal cured film. Thereby, a first retardation film having a layer structure of COP film / first liquid crystal retardation layer (horizontal alignment layer (r1) / liquid crystal cured film) was obtained.

[0279] Regarding the first retardation film, Re(450) and Re(550) were measured using KOBRA-WPR manufactured by Oji Scientific Instruments Co., Ltd., and α = Re(450) / Re(550) was calculated. As it was confirmed that the COP film used for the first retardation film had no retardation, α of the first retardation film is α of the first liquid crystal retardation layer.

[0280] [Fabrication of the Second Liquid Crystal Retardation Layer] (Preparation of the Composition (2) for Forming the Liquid Crystal Retardation Layer) To 100 parts of the polymerizable liquid crystal compound (5) (Paliocolor LC242, manufactured by BASF), 0.1 part of F-556 as a leveling agent and 3 parts of Irgacure 369 as a polymerization initiator were added. Cyclopentanone was added so that the solid content concentration became 13% to obtain the composition (2) for forming the liquid crystal retardation layer.

[0281] (Fabrication of the Second Liquid Crystal Retardation Layer) The cycloolefin (COP) film ("ZF-15-40" manufactured by Nippon Zeon Co., Ltd.) was subjected to corona treatment. The composition (2) for forming the liquid crystal retardation layer was coated on the corona-treated surface of the COP film, and then dried in a drying oven set at 100°C for 1 minute. Next, ultraviolet rays were irradiated (in a nitrogen atmosphere, wavelength: 365 nm, integrated light quantity at wavelength 365 nm: 500 mJ / cm 2 ) to form a liquid crystal cured film in which the polymerizable liquid crystal compound was vertically aligned with respect to the coating film plane. Thus, a second retardation film having a layer structure of COP film / second liquid crystal retardation layer (liquid crystal cured film) was obtained.

[0282] To confirm the alignment state of the polymerizable liquid crystal compound in the second liquid crystal retardation layer, the retardation value Rth in the thickness direction of the second retardation film was measured using a retardation measuring device (KOBRA-WPR, manufactured by Oji Scientific Instruments Co., Ltd.). It was confirmed that the COP film used for the second retardation film had no retardation. In the measurement, the incident angle of light to the second liquid crystal retardation layer was changed, and the front retardation value and the retardation value when tilted by 40° around the fast axis were measured. The average refractive index at each wavelength was measured using an ellipsometer M-220 manufactured by JASCO Corporation. Also, the thickness of the second liquid crystal retardation layer was measured using an Optical NanoGauge film thickness meter C12562-01 (manufactured by Hamamatsu Photonics).

[0283] From the measured front retardation value, the retardation value when tilted by 40° around the fast axis, the average refractive index, and the value of the thickness of the second retardation layer, the three-dimensional refractive index was calculated with reference to the technical data of Oji Scientific Instruments (https: / / oji-keisoku.co.jp / support / download / index.php). From the obtained three-dimensional refractive index, the retardation value Rth(λ) in the thickness direction at the wavelength λ [nm] of the second liquid crystal retardation layer was calculated according to the following formula. Rth(λ) =((nx(λ)+ny(λ)) / 2-nz(λ))×d2 [In the formula, nx(λ) represents the principal refractive index at the wavelength λ nm in the plane of the second liquid crystal retardation layer. ny(λ) represents the refractive index at the wavelength λ [nm] in the direction orthogonal to nx(λ) in the same plane as nx(λ). nz(λ) represents the refractive index at the wavelength λ [nm] in the thickness direction of the second liquid crystal retardation layer. When nx(λ)=ny(λ), nx(λ) can be the refractive index in any direction in the plane of the second retardation layer. d2 represents the thickness of the second liquid crystal retardation layer.]

[0284] As a result, Rth(550) of the second liquid crystal retardation layer was -70 nm, and Rth(450) / Rth(550) was 1.10.

[0285] [Preparation of Adhesive Layer] As the adhesive layer, an acrylic pressure-sensitive adhesive with a thickness of 20 μm (manufactured by Lintec Corporation) was prepared.

[0286] [Example 1] (Fabrication of Light-Absorbing Anisotropic Layer (1)) The base material layer (25TAC) was subjected to corona treatment once under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min using a corona treatment apparatus (AGF-B10, manufactured by Kasuga Electric Co., Ltd.). The light-absorbing anisotropic layer-forming composition (1) was applied to the corona-treated surface of the base material layer using a bar coater, and then dried in a drying oven set at 100°C for 1 minute. Next, ultraviolet rays were irradiated (in a nitrogen atmosphere, wavelength: 365 nm, integrated light quantity at wavelength 365 nm: 500 mJ / cm 2 ) to form a light-absorbing anisotropic layer (1) containing a polymer of a polymerizable liquid crystal compound and a dichroic dye. In the light-absorbing anisotropic layer (1), the polymerizable liquid crystal compound and the dichroic dye were vertically aligned with respect to the coating film plane. When the thickness of the light-absorbing anisotropic layer (1) was measured with an ellipsometer M-220 (manufactured by JASCO Corporation), it was 1 μm.

[0287] (Fabrication of Optical Laminate (1)) The surface of the light-absorbing anisotropic layer (1) opposite to the base material layer side was subjected to corona treatment once under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min using a corona treatment apparatus (AGF-B10, manufactured by Kasuga Electric Co., Ltd.). The horizontal alignment layer-forming composition (1) was applied to the corona-treated surface of the light-absorbing anisotropic layer (1) with a bar coater, dried at 80°C for 1 minute, and polarized UV exposure was performed with an integrated light quantity of 100 mJ / cm 2 to form a horizontal alignment layer (1). When the thickness of the obtained horizontal alignment layer (1) was measured with an ellipsometer M-220 (manufactured by JASCO Corporation), it was 40 nm.

[0288] After applying the liquid crystal polarizer-forming composition (1) onto the horizontal alignment layer (1) using a bar coater, it was dried for 1 minute in a drying oven set at 120°C. Then, using a high-pressure mercury lamp (Unicure VB-15201BY-A, manufactured by Ushio Inc.), ultraviolet rays were irradiated (under a nitrogen atmosphere, wavelength: 365 nm, integrated light quantity at a wavelength of 365 nm: 1000 mJ / cm 2 2) to form a liquid crystal polarizer (1) in which the polymerizable liquid crystal compound and the dichroic dye were horizontally aligned. When the thickness of the liquid crystal polarizer (1) was measured with an ellipsometer, it was 2 μm.

[0289] On the surface of the liquid crystal polarizer (1) opposite to the horizontal alignment layer (1) side, corona treatment was performed once using a corona treatment apparatus (AGF-B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. A water-soluble polymer-containing resin composition was applied onto the corona-treated surface of the liquid crystal polarizer (1) using a bar coater and dried at 100°C for 2 minutes to form a protective layer with a thickness of 1 μm. Thus, an optical laminate (1) having a layer structure of a substrate layer / light absorption anisotropic layer (1) / horizontal alignment layer (1) / liquid crystal polarizer (1) / protective layer was obtained.

[0290] (Production of the elliptical polarizing plate (1)) On the protective layer side of the optical laminate (1), using the adhesive layer prepared above, a first retardation film was laminated such that the first liquid crystal retardation layer side faced the adhesive layer side. Then, the horizontal alignment layer (r1) was peeled off together with the COP film from the first retardation film. Using the adhesive layer prepared above, a second retardation film was laminated on the first liquid crystal retardation layer exposed by this peeling such that the second liquid crystal retardation layer side faced the adhesive layer side to obtain an elliptical polarizing plate (1) as an optical laminate. The layer structure of the elliptical polarizing plate (1) was a substrate layer / light absorption anisotropic layer (1) / horizontal alignment layer (1) / liquid crystal polarizer (1) / protective layer / adhesive layer / first liquid crystal retardation layer (liquid crystal cured film) / adhesive layer / second liquid crystal retardation layer (liquid crystal cured film) / COP film.

[0291] [Examples 2 to 4] As the composition for forming the light absorption anisotropic layer and the composition for forming the liquid crystal polarizer, optical laminate (2) to (4) were produced in the same procedure as in Example 1 except that those described in Table 1 were used, and using these, elliptical polarizing plates (2) to (4) were produced.

[0292] [Example 5] Anisotropic light absorption layer (2) was formed on the substrate layer (25TAC) in the same procedure as in Example 1 except that the composition described in Table 1 was used as the composition for forming the light absorption anisotropic layer.

[0293] (Production of optical laminate (5) and elliptical polarizing plate (5)) On the surface of the anisotropic light absorption layer (2) opposite to the substrate layer side, corona treatment was performed once using a corona treatment apparatus (AGF - B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. A water-soluble polymer-containing resin composition was applied to the corona-treated surface of the anisotropic light absorption layer (2) with a bar coater and dried at 100°C for 2 minutes to form a polymer film. When the thickness of the obtained polymer film was measured with an ellipsometer M - 220 (manufactured by JASCO Corporation), it was 200 nm. A rubbing treatment was performed on the surface of the polymer film to form a horizontal alignment layer (2). The rubbing treatment was performed using a semi-automatic rubbing apparatus (LQ - 008 type, manufactured by Joho Kogyo Co., Ltd.) with a cloth (YA - 20 - RW, manufactured by Yoshikawa Chemical Industry Co., Ltd.) under the conditions of a pushing-in amount of 0.15 mm, a rotation speed of 500 rpm, and 16.7 mm / s.

[0294] An optical laminate (5) was produced in the same procedure as in Example 1 except that the liquid crystal polarizer-forming composition (2) was applied onto the horizontal alignment layer (2) using a bar coater, and using this, an elliptical polarizing plate (5) was produced. The layer structure of the optical laminate (5) was a substrate layer / anisotropic light absorption layer (2) / horizontal alignment layer (2) / liquid crystal polarizer (3) / protective layer. The layer structure of the elliptical polarizing plate (5) was a substrate layer / anisotropic light absorption layer (2) / horizontal alignment layer (2) / liquid crystal polarizer (3) / protective layer / adhesive layer / first liquid crystal retardation layer (liquid crystal cured film) / adhesive layer / second liquid crystal retardation layer (liquid crystal cured film) / COP film.

[0295] [Example 6] As the composition for forming the light absorption anisotropic layer, the composition for forming the horizontal alignment layer, and the composition for forming the liquid crystal polarizer, an optical laminate (6) was produced in the same procedure as in Example 1 except that those described in Table 1 were used, and an elliptical polarizing plate (6) was produced using this laminate.

[0296] [Example 7] A light absorption anisotropic layer (2) was formed on a base material layer (25TAC) in the same procedure as in Example 1 except that the composition described in Table 1 was used as the composition for forming the light absorption anisotropic layer. The surface of the light absorption anisotropic layer (2) opposite to the base material layer side was subjected to corona treatment in the same procedure as in Example 5, and a polymer film as a coating layer was formed. The thickness of the polymer film was 1 μm.

[0297] (Production of Optical Laminate (7) and Elliptical Polarizing Plate (7)) The polymer film was subjected to corona treatment once using a corona treatment apparatus (AGF - B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. An optical laminate (7) and an elliptical polarizing plate (7) were produced in the same procedure as in Example 1 except that the horizontal alignment layer forming composition (1) was applied to the corona - treated surface of the polymer film to form a horizontal alignment layer (1), and the liquid crystal polarizer forming composition (2) was used instead of the liquid crystal polarizer forming composition (1).

[0298] The layer structure of the optical laminate (7) was a base material layer / light absorption anisotropic layer (2) / coating layer (polymer film) / horizontal alignment layer (1) / liquid crystal polarizer (2) / protective layer. The layer structure of the elliptical polarizing plate (9) was a base material layer / light absorption anisotropic layer (2) / coating layer (polymer film) / horizontal alignment layer (1) / liquid crystal polarizer (2) / protective layer / adhesive layer / first liquid crystal retardation layer (liquid crystal cured film) / adhesive layer / second liquid crystal retardation layer (liquid crystal cured film) / COP film.

[0299] [Example 8] An optical laminate (8) and an elliptical polarizing plate (8) were produced in the same procedure as in Example 7 except that the horizontal alignment layer forming composition (2) was used instead of the horizontal alignment layer forming composition (1).

[0300] 〔Example 9〕 An optical absorption anisotropic layer (2) was formed on a base material layer (25TAC) in the same procedure as in Example 1, except that the composition described in Table 1 was used as the composition for forming the optical absorption anisotropic layer.

[0301] On the surface of the optical absorption anisotropic layer (2) opposite to the base material layer side, corona treatment was performed once using a corona treatment apparatus (AGF - B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. On the corona-treated surface of the optical absorption anisotropic layer (2), a hard coat composition was applied with a bar coater, dried at 80°C for 1 minute, and irradiated with ultraviolet rays (in a nitrogen atmosphere, wavelength: 365 nm, integrated light quantity at a wavelength of 365 nm: 500 mJ / cm 2 ) to form a hard coat layer as the coating layer. The thickness of the hard coat layer was 3 μm.

[0302] (Production of the optical laminate (9) and the elliptical polarizing plate (9)) On the hard coat layer, corona treatment was performed once using a corona treatment apparatus (AGF - B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. An optical laminate (9) and an elliptical polarizing plate (9) were produced in the same procedure as in Example 1, except that a horizontal alignment layer forming composition (1) was applied to the corona-treated surface of the hard coat layer to form a horizontal alignment layer (1), and a liquid crystal polarizer forming composition (2) was used instead of the liquid crystal polarizer forming composition (1).

[0303] The layer structure of the optical laminate (9) was a base material layer / optical absorption anisotropic layer (2) / coating layer (hard coat layer) / horizontal alignment layer (1) / liquid crystal polarizer (2) / protection layer. The layer structure of the elliptical polarizing plate (9) was a base material layer / optical absorption anisotropic layer (2) / coating layer (hard coat layer) / horizontal alignment layer (1) / liquid crystal polarizer (2) / protection layer / adhesive layer / first liquid crystal retardation layer (liquid crystal cured film) / adhesive layer / second liquid crystal retardation layer (liquid crystal cured film) / COP film.

[0304] 〔Example 10〕 An optical laminate (10) and an elliptical polarizing plate (10) were produced in the same procedure as in Example 9, except that the composition (2) for forming a horizontal alignment layer was used instead of the composition (1) for forming a horizontal alignment layer.

[0305] [Example 11] An optically anisotropic light-absorbing layer (2) was formed on a base material layer (25TAC) in the same procedure as in Example 1, except that the composition described in Table 1 was used as the composition for forming the optically anisotropic light-absorbing layer.

[0306] (Production of optical laminate (11) and elliptical polarizing plate (11)) On the surface of the optically anisotropic light-absorbing layer (2) opposite to the base material layer side, corona treatment was performed once using a corona treatment apparatus (AGF-B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. A cation-curable composition was applied to the corona-treated surface of the optically anisotropic light-absorbing layer (2) with a bar coater, and ultraviolet rays were irradiated using a high-pressure mercury lamp (Unicure VB-15201BY-A, manufactured by Ushio Electric Inc.) (in a nitrogen atmosphere, wavelength: 365 nm, integrated light quantity at wavelength 365 nm: 500 mJ / cm 2 ) to form a cured film as a coating layer. The thickness of the cured film was 2 μm.

[0307] On the cured film, corona treatment was performed once using a corona treatment apparatus (AGF-B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. An optical laminate (11) and an elliptical polarizing plate (11) were produced in the same procedure as in Example 1, except that a horizontal alignment layer (1) was formed by applying the composition (1) for forming a horizontal alignment layer to the corona-treated surface of the cured film and the composition (2) for forming a liquid crystal polarizer was used instead of the composition (1) for forming a liquid crystal polarizer.

[0308] The layer structure of the optical laminate (11) was a base material layer / light absorption anisotropic layer (2) / coating layer (hardened film) / horizontal alignment layer (1) / liquid crystal polarizer (2) / protective layer. The layer structure of the elliptical polarizing plate (11) was a base material layer / light absorption anisotropic layer (2) / coating layer (hardened film) / horizontal alignment layer (1) / liquid crystal polarizer (2) / protective layer / adhesive layer / first liquid crystal retardation layer (liquid crystal hardened film) / adhesive layer / second liquid crystal retardation layer (liquid crystal hardened film) / COP film.

[0309] [Example 12] An optical laminate (12) and an elliptical polarizing plate (12) were produced in the same procedure as in Example 11, except that the composition for forming a horizontal alignment layer (2) was used instead of the composition for forming a horizontal alignment layer (1).

[0310] [Comparative Example 1] (Production of a light absorption anisotropic layer (c1) with a film substrate) In the same procedure as in Example 1, a light absorption anisotropic layer (1) was formed on a base material layer (25TAC), and this was used as a light absorption anisotropic layer (c1) with a film substrate. The layer structure of the light absorption anisotropic layer (c1) with a film substrate was a film substrate (base material layer) / light absorption anisotropic layer (1).

[0311] (Production of a liquid crystal polarizer (c1) with a film substrate) As a film substrate, a triacetyl cellulose (TAC) film ("KC4UY-TAC" manufactured by Konica Minolta) was prepared. Corona treatment was performed once on this film substrate using a corona treatment apparatus (AGF-B10, manufactured by Kasuga Electric Co., Ltd.) under the conditions of an output of 0.3 kW and a treatment speed of 3 m / min. A horizontal alignment layer (1), a liquid crystal polarizer (1), and a protective layer were formed on the corona-treated surface of the film substrate in the same procedure as in Example 1 to obtain a liquid crystal polarizer (c1) with a film substrate. The layer structure of the liquid crystal polarizer (c1) with a film substrate was a film substrate / horizontal alignment layer (1) / liquid crystal polarizer (1) / protective layer.

[0312] (Production of a laminate (c1)) The light absorption anisotropic layer (1) side of the light absorption anisotropic layer (c1) with a film substrate and the protective layer side of the liquid crystal polarizer (c1) with a film substrate were bonded using the adhesive layer prepared above to obtain a laminate (c1). The layer structure of the laminate (c1) was film substrate / horizontal alignment layer (1) / liquid crystal polarizer (1) / protective layer / adhesive layer / light absorption anisotropic layer (1) / film substrate (substrate layer).

[0313] (Production of elliptical polarizing plate (c1)) On the film substrate (substrate layer) side of the light absorption anisotropic layer (1) side of the laminate (c1), the first liquid crystal retardation layer and the second liquid crystal retardation layer were laminated in this order using the adhesive layer prepared above by the procedure described in Example 1 to obtain an elliptical polarizing plate (c1). The layer structure of the elliptical polarizing plate (c1) was film substrate / horizontal alignment layer (1) / liquid crystal polarizer (1) / protective layer / adhesive layer / light absorption anisotropic layer (1) / film substrate (substrate layer) / adhesive layer / first liquid crystal retardation layer (liquid crystal cured film) / adhesive layer / second liquid crystal retardation layer (liquid crystal cured film) / COP film.

[0314] [Calculation of distance D of optical laminate] From the thickness of each layer included in the optical laminate, the distance D from the surface on the substrate layer side of the light absorption anisotropic layer to the surface on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer was calculated. The results are shown in Tables 1 and 2.

[0315] [Measurement of phase transition temperature of polymerizable liquid crystal compound] On the alignment layer formed on a glass substrate, while heating the polymerizable liquid crystal compound, the phase transition temperature was confirmed by texture observation using a polarizing microscope (BX-51, manufactured by Olympus Corporation).

[0316] (Phase transition temperature of polymerizable liquid crystal compound (1)) The polymerizable liquid crystal compound (1) exhibited a transition from the crystalline phase to the smectic A phase at 95 °C, a transition to the nematic phase at 111 °C, and a transition to the isotropic liquid phase at 113 °C during heating. During cooling, it was confirmed that the polymerizable liquid crystal compound (1) underwent a transition to the nematic phase at 112 °C, a transition to the smectic A phase at 110 °C, and a transition to the smectic B phase at 94 °C.

[0317] (Phase transition temperature of polymerizable liquid crystal compound (2)) Upon heating, the polymerizable liquid crystal compound (2) exhibited a smectic A phase from the crystalline phase at 81 °C, transferred to the nematic phase at 121 °C, and underwent a phase transition to the isotropic liquid phase at 137 °C. Upon cooling, it was confirmed that the compound underwent a phase transition to the nematic phase at 133 °C, a phase transition to the smectic A phase at 118 °C, and a phase transition to the smectic B phase at 78 °C.

[0318] (Phase transition temperatures of polymerizable liquid crystal compounds (3) to (5)) Regarding the polymerizable liquid crystal compound (3), the polymerizable liquid crystal compound (4), and the polymerizable liquid crystal compound (5) (Paliocolor LC242, manufactured by BASF), when texture observation was performed using a polarizing microscope, all showed only the nematic phase and did not show a distinct smectic phase.

[0319] [Measurement of absorbance of light absorption anisotropic layer] In accordance with the procedures described in the examples and comparative examples, a light absorption anisotropic layer was formed on the substrate layer (25TAC), and the side of the light absorption anisotropic layer was bonded to a glass with dimensions of 4 cm × 4 cm × thickness 0.7 mm via the adhesive layer prepared above. This was designated as the measurement sample (1). The measurement sample (1) was set in an ultraviolet-visible spectrophotometer ("UV-2450" manufactured by Shimadzu Corporation) to measure the absorbance, and Ax and Ax(z = 60) at the absorption maximum wavelength in the range of wavelengths from 380 nm to 780 nm were determined. Since the absorbance of the substrate layer can be regarded as 0 (zero), Ax and Ax(z = 60) measured for the measurement sample (1) can be said to be the absorbance of the light absorption anisotropic layer. The results are shown in Tables 1 and 2.

[0320] The x-axis means an arbitrary direction in the plane of the light absorption anisotropic layer, the y-axis means the direction perpendicular to the x-axis in the plane of the film, and the z-axis means the thickness direction of the light absorption anisotropic layer. Ax is the absorbance at the maximum absorption wavelength of the light absorption anisotropic layer and represents the absorbance of linearly polarized light vibrating in the x-axis direction. Ax(z = 60) is the absorbance at the maximum absorption wavelength when the light absorption anisotropic layer is rotated by 60° with the y-axis as the rotation axis and represents the absorbance of linearly polarized light vibrating in the x-axis direction.

[0321] When measuring the absorbance, the measurement sample (1) was set in an ultraviolet-visible spectrophotometer ("UV-2450" manufactured by Shimadzu Corporation), and after correcting so that the absorbance at a wavelength of 800 nm became zero, Ax was measured. For Ax(z = 60), similarly, after setting and tilting the measurement sample (1), after correcting so that the absorbance at a wavelength of 800 nm became zero, Ax(z = 60) was measured. For the absorbance described below, the absorbance was measured after performing correction in the same procedure.

[0322] The sufficiency of the relationship (Az > (Ax + Ay) / 2) of the above formula (1) for the light absorption anisotropic layer was judged by the following procedure. Ax(z = 30°) and Ax(z = 60°) were measured by making the same linearly polarized light incident when Ax was measured with the measurement sample (1) rotated 30° and 60° so as to include the y-axis, and similarly, Ay(z = 30°) and Ay(z = 60°) were measured by making the same linearly polarized light incident when Ay was measured with the measurement sample (1) rotated 30° and 60° so as to include the x-axis. When there is no absorption anisotropy in the x-y plane, that is, when Ax and Ay are equal, since Ax(z = 30°) = Ay(z = 30°) and Ax(z = 60°) = Ay(z = 60°), Ax(z = 30°) and Ay(z = 30°) were set as A(z = 30°), Ax(z = 60°) and Ay(z = 60°) were set as A(z = 60), and Ax(z = 90°) and Ay(z = 90°) were set as A(z = 90). When in the relationship of A(z = 30°) < A(z = 60°), in order to satisfy the relationship of A(z = 30°) < A(z = 60°) < A(z = 90°) = Az, if A(z = 30°) > (Ax + Ay) / 2 or A(z = 60°) > (Ax + Ay) / 2, it was judged that the relationship of the above formula (1) was satisfied. The results are shown in Table 1 and Table 2.

[0323] [Evaluation of Processability of Optical Laminate] In the production of the optical laminates (1) to (12) and the laminate (c1), the number of bonding steps for bonding the layers using an adhesive layer was counted and evaluated according to the following criteria. The results are shown in Tables 1 and 2. (Evaluation Criteria) A: The number of bonding steps is 0. B: The number of bonding steps is 1 or more.

[0324] [Evaluation of the Alignment of the Liquid Crystal Polarizer] To the optical laminates (1) to (12) and the laminate (c1), a glass plate with dimensions of 4 cm × 4 cm × thickness 0.7 mm was bonded via the adhesive layer prepared above, and this was used as the measurement sample (2). The measurement sample (2) was placed on the linear polarizer arranged on the backlight such that the linear polarizer on the backlight and the liquid crystal polarizer in the measurement sample (2) were in a cross Nicol configuration, and the light absorption anisotropic layer in the measurement sample (2) was located outside the cross Nicol. The measurement sample (2) was observed. The observed results were evaluated according to the following criteria. The results are shown in Tables 1 and 2. (Evaluation Criteria) A: It was black and no light leakage was felt. B: Slight light leakage was felt. C: Partial or overall light leakage was felt.

[0325] [Evaluation of the Adhesion of the Optical Laminate] The protective layer side of the optical laminates (1) to (12) and the film base material side on the liquid crystal polarizer side of the laminate (c1) were subjected to corona treatment, and a 4 cm × 4 cm glass plate was bonded via the adhesive layer prepared above. Then, from the substrate layer side of the optical laminates (1) to (12) and the film base material (substrate layer) side on the light absorption anisotropic layer side of the laminate (c1), 100 (10 × 10) cross-hatches with a 2 mm × 2 mm square were engraved in a grid pattern so as to penetrate the optical laminate and the laminate, and this was used as the measurement sample (3).

[0326] A pressure-sensitive adhesive tape (25 mm wide, manufactured by Nichiban Co., Ltd.) was affixed so as to cover the entire 100 cross-hatch patterns formed on the measurement sample (3). Then, the pressure-sensitive adhesive tape was peeled off in a direction 90° with respect to the cross-hatch surface. The measurement sample (3) after the pressure-sensitive adhesive tape was peeled off was placed on a linear polarizing plate disposed on a backlight. From the color tone of the measurement sample (3), the number of cross-hatch patterns remaining on the glass of the measurement sample (3) was counted and evaluated according to the following criteria. The results are shown in Tables 1 and 2. (Evaluation Criteria) A: In 80% or more of the cross-hatch patterns, there was no peeling between any of the layers, and the cross-hatch patterns remained. B: In 20% or more but less than 80% of the cross-hatch patterns, there was no peeling between any of the layers, and the cross-hatch patterns remained. C: In less than 20% of the cross-hatch patterns, there was no peeling between any of the layers, and the cross-hatch patterns remained.

[0327] [Appearance Evaluation of the Elliptical Polarizing Plate] (Appearance Evaluation of the Initial Elliptical Polarizing Plate (1)) An alkali-free glass with a thickness of 0.7 mm was bonded to the elliptical polarizing plates (1) to (12) and the second liquid crystal retardation layer side exposed by peeling off the COP film from (c1) via the adhesive layer prepared above to obtain a measurement sample (4). The front glass and polarizing plate were removed from "Galaxy S5" manufactured by Samsung Electronics Co., Ltd., and the display device was taken out. The measurement sample (4) was placed on the taken-out display device so that water was interposed between the taken-out display device and the alkali-free glass side of the measurement sample (4). Then, with the power of the display device turned off (black display), the color tone of the reflection when visually recognized with the light of a fluorescent lamp entering from an oblique direction was confirmed and evaluated according to the evaluation criteria shown below. The results are shown in Tables 1 and 2. (Evaluation Criteria) A: Almost no color tone was felt. B: A slight color tone was felt. C: A color tone was felt. D: A strong color tone was felt.

[0328] (Appearance Evaluation of the Elliptical Polarizing Plate after the Light Resistance Test (2)) The display device equipped with the measurement sample (4) was put into a light resistance tester (Suntest XLS +, manufactured by ATLAS) with the elliptical polarizing plate side facing up, and a light resistance test was conducted by irradiating light under the condition that the integrated light quantity was 288400 kJ / m 2 For the display device after the light resistance test, the change in the color tone of the reflection in the diagonal direction from the initial state was confirmed according to the procedure described in the appearance evaluation (1) of the initial elliptical polarizing plate, and the evaluation was carried out according to the following evaluation criteria. The results are shown in Table 1 and Table 2. (Evaluation Criteria) A: Almost no change in color tone was felt. B: A change in color tone was felt. C: A large change in color tone was felt.

[0329]

Table 1

[0330]

Table 2

Explanation of Symbols

[0331] 1 - 4 Optical laminate, 11 Substrate layer, 12 Vertical alignment layer, 13 Light absorption anisotropic layer, 14 Coating layer, 15 Horizontal alignment layer, 16 Liquid crystal polarizer, 17 Protective layer, 21 First adhesive layer, 22 First liquid crystal retardation layer, 23 Second adhesive layer, 24 Second liquid crystal retardation layer.

Claims

1. An optical laminate in which a substrate layer, a light absorption anisotropic layer, a horizontal alignment layer, and a liquid crystal polarizer are laminated in this order, wherein the light absorption anisotropic layer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye and satisfies the following relationships of formulas (1) to (3), the liquid crystal polarizer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye and has an absorption axis in the horizontal direction with respect to the plane of the liquid crystal polarizer, the substrate layer and the light absorption anisotropic layer are in direct contact, or there is only a vertical alignment layer between the substrate layer and the light absorption anisotropic layer, the light absorption anisotropic layer and the horizontal alignment layer are in direct contact, or there is only a coating layer between the light absorption anisotropic layer and the horizontal alignment layer, the horizontal alignment layer and the liquid crystal polarizer are in direct contact, an optical laminate, wherein the distance from the surface of the light absorption anisotropic layer on the substrate layer side to the surface of the liquid crystal polarizer on the side opposite to the horizontal alignment layer side is 10 μm or less. Az > (Ax + Ay) / 2 (1) 0.001 ≦ Ax ≦ 0.1 (2) Ax(z = 60°) / Ax ≧ 5 (3) [In formulas (1) to (3), Ax, Ay, and Az are the absorbances of the absorption maximum wavelengths in the wavelength range of 380 nm or more and 780 nm or less of the light absorption anisotropic layer, and represent the absorbances of linearly polarized light vibrating in the x-axis direction, y-axis direction, and z-axis direction, respectively. Ax(z = 60°) is the absorbance at the absorption maximum wavelength and represents the absorbance of linearly polarized light vibrating in the x-axis direction when the light absorption anisotropic layer is rotated by 60° with the y-axis as the rotation axis. Here, the x-axis is an arbitrary one direction in the plane of the light absorption anisotropic layer, the y-axis is a direction orthogonal to the x-axis in the plane of the light absorption anisotropic layer, and the z-axis is a direction orthogonal to the x-axis and the y-axis.]

2. Furthermore, the optical laminate according to claim 1, which has a protective layer on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer.

3. The optical laminate according to claim 2, wherein the liquid crystal polarizer and the protective layer are in direct contact.

4. Furthermore, on the side opposite to the liquid crystal polarizer side of the protective layer, there is a first liquid crystal retardation layer laminated via a first adhesive layer, the optical laminate according to claim 2 or 3, wherein the first liquid crystal retardation layer contains a polymer of a polymerizable liquid crystal compound aligned in the horizontal direction with respect to the plane of the first liquid crystal retardation layer.

5. Furthermore, it has a second liquid crystal retardation layer laminated via a second adhesive layer on the side of the first liquid crystal retardation layer opposite to the liquid crystal polarizer side, The second liquid crystal retardation layer contains a polymer of a polymerizable liquid crystal compound oriented in a direction perpendicular to the plane of the second liquid crystal retardation layer. The optical laminate according to claim 4.

6. The optical laminate according to any one of claims 1 to 3, wherein the base material layer is a resin film.

7. The base material layer includes a coating resin layer, The resin constituting the coating resin layer is at least one selected from the group consisting of a cellulose ester resin, an olefin resin, and a (meth)acrylic resin. The optical laminate according to any one of claims 1 to 3.

8. The dichroic dye contained in the liquid crystal polarizer is an azo dye. The optical laminate according to any one of claims 1 to 3.

9. A method for manufacturing an optical laminate in which a base material layer, a light absorption anisotropic layer, a horizontal alignment layer, and a liquid crystal polarizer are laminated in this order, The light absorption anisotropic layer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and satisfies the following relationships of formulas (1) to (3), The liquid crystal polarizer contains a polymer of a polymerizable liquid crystal compound and a dichroic dye, and has an absorption axis in a horizontal direction with respect to the plane of the liquid crystal polarizer, Forming the light absorption anisotropic layer so as to be in direct contact with the base material layer or so as to be in direct contact with a vertical alignment layer formed on the surface of the base material layer; Forming the horizontal alignment layer directly or via a coating layer on the light absorption anisotropic layer; Directly applying a liquid crystal polarizer-forming composition containing a polymerizable liquid crystal compound and a dichroic dye, which is a composition for forming the liquid crystal polarizer, on the horizontal alignment layer, and including: The step of forming the horizontal alignment layer is [a] directly applying a horizontal alignment layer-forming composition for forming the horizontal alignment layer on the light absorption anisotropic layer, or [b] directly applying a coating layer-forming composition for forming the coating layer on the light absorption anisotropic layer, and directly applying the horizontal alignment layer-forming composition on the coating layer. A method for manufacturing an optical laminate. Az > (Ax + Ay) / 2 (1) 0.001 ≦ Ax ≦ 0.1 (2) Ax(z = 60°) / Ax ≧ 5 (3) [In formulas (1) to (3), Ax, Ay, and Az are the absorbances at the absorption peak wavelengths in the wavelength range of 380 nm or more and 780 nm or less of the light absorption anisotropic layer, and represent the absorbances of linearly polarized light vibrating in the x-axis direction, y-axis direction, and z-axis direction, respectively. Ax(z = 60°) is the absorbance at the absorption peak wavelength, and represents the absorbance of linearly polarized light vibrating in the x-axis direction when the light absorption anisotropic layer is rotated 60° with the y-axis as the rotation axis. Here, the x-axis is an arbitrary one direction in the plane of the light absorption anisotropic layer, the y-axis is a direction perpendicular to the x-axis in the plane of the light absorption anisotropic layer, and the z-axis is a direction perpendicular to the x-axis and the y-axis. ]

10. In the optical laminate, the distance from the surface on the base material layer side of the light absorption anisotropic layer to the surface on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer is 10 μm or less. The method for manufacturing an optical laminate according to claim 9.

11. The step of forming the light absorption anisotropic layer includes a step of directly applying a composition for forming a light absorption anisotropic layer containing a polymerizable liquid crystal compound and a dichroic dye on the base material layer or the vertical alignment layer. The method for manufacturing an optical laminate according to claim 9 or 10.

12. The optical laminate further has a protective layer on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer, and further includes a step of directly applying a composition for forming a protective layer for forming the protective layer on the surface on the side opposite to the horizontal alignment layer side of the liquid crystal polarizer. The method for manufacturing an optical laminate according to claim 9 or 10.

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