Method for manufacturing a functional optical film and method for manufacturing a laminated optical film

Abstract

To provide a method for manufacturing an optical film with a functional layer that offers excellent productivity and can impart superior functionality, and a method for manufacturing a laminated optical film comprising an optical film with a functional layer manufactured by the said method. [Solution] A method for manufacturing an optical film with a functional layer, wherein a functional layer is laminated onto an optical film, comprising: a coating step of coating an optical film with a radical polymerizable curable composition; and an irradiation step of curing at least a portion of the radical polymerizable curable composition by irradiating the coated surface of the optical film with the radical polymerizable curable composition with active energy rays, wherein the irradiation step is a step of irradiating with active energy rays in an atmosphere with an oxygen concentration of 5% or more, the radical polymerizable curable composition contains at least one selected from the group consisting of amino-based photopolymerization initiators and thiol compounds, and the thickness of the functional layer is less than 5 μm.

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing an optical film with a functional layer and a method for manufacturing a laminated optical film. The optical film with a functional layer and the laminated optical film manufactured by these methods can be used to form image display devices such as mobile phones, car navigation systems, personal computer monitors, and televisions. [Background technology]

[0002] Image display devices such as mobile phones, car navigation systems, computer monitors, and televisions are equipped with laminated optical films in which multiple optical films are laminated with adhesive or tack layers in between. Transparent resin films such as phase difference films, polarizers, and transparent protective films are used as optical films.

[0003] In recent years, there has been a strong demand for improved functionality, such as durability, for laminated optical films and the various optical films that constitute them. For example, Patent Document 1 below describes an optical laminate having a polarizer containing a polyvinyl alcohol-based resin and a phase difference body containing a cured polymerizable liquid crystal compound, wherein the optical laminate has a first adhesive layer provided in contact with the polarizer and a second adhesive layer provided in contact with the phase difference body between the polarizer and the phase difference body. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2022-110684 [Overview of the project] [Problems that the invention aims to solve]

[0005] As a result of diligent research by the present inventors, it has been found that the technology described in Patent Document 1 above has room for further improvement in terms of improving the functionality of the laminated optical film and the various optical films that constitute the laminated optical film.

[0006] In recent years, there has been a strong desire to manufacture laminated optical films with superior functionality and various optical films that constitute laminated optical films with high productivity, but the technology described in Patent Document 1 above does not adequately address this point.

[0007] The present invention was developed in view of the above circumstances, and aims to provide a method for manufacturing an optical film with a functional layer that is highly productive and can impart excellent functionality, and a method for manufacturing a laminated optical film comprising an optical film with a functional layer manufactured by the said method. [Means for solving the problem]

[0008] The above problems can be solved by the following configuration. That is, the present invention relates to a method for manufacturing an optical film with a functional layer, wherein a functional layer is laminated on an optical film, and comprises a coating step of coating the optical film with a radical polymerizable curable composition, and an irradiation step of curing at least a portion of the radical polymerizable curable composition by irradiating the coated surface of the optical film with the radical polymerizable curable composition with active energy rays, wherein the irradiation step is a step of irradiating with active energy rays in an atmosphere with an oxygen concentration of 5% or more, the radical polymerizable curable composition contains at least one selected from the group consisting of amino-based photopolymerization initiators and thiol compounds, and the thickness of the functional layer is less than 5 μm.

[0009] In the above method for producing an optical film with a functional layer (1), the method for producing an optical film with a functional layer (2) is preferred, in which the amino-based photopolymerization initiator is a compound containing a tertiary amino group.

[0010] In the above method for producing an optical film with a functional layer (1) or (2), the method for producing an optical film with a functional layer (3) is preferred, in which the amino-based photopolymerization initiator is a benzophenone-based photopolymerization initiator or an acetophenone-based photopolymerization initiator.

[0011] In any of the above methods (1) to (3) for producing an optical film with a functional layer, method (4) is preferred, wherein the radical polymerizable curable composition contains at least the amino-based photopolymerization initiator, and when the total amount of curable components is 100 parts by mass, it contains 1 to 10 parts by mass of the amino-based photopolymerization initiator.

[0012] In any of the above methods (1) to (4) for producing an optical film with a functional layer, method (5) is preferred, wherein the thiol compound is a compound having at least two or more secondary mercapto groups.

[0013] In any of the above methods (1) to (5) for producing an optical film with a functional layer, method (6) is preferred, wherein the radical polymerizable curable composition contains at least the thiol compound, and when the total amount of curable components is 100 parts by mass, it contains 1 to 30 parts by mass of the thiol compound.

[0014] In any of the above methods (1) to (3) for producing an optical film with a functional layer, method (7) is preferred, wherein the radical polymerizable curable composition contains the amino-based photopolymerization initiator and the thiol compound, and when the total amount of curable components is 100 parts by mass, it contains 1 to 5 parts by mass of the amino-based photopolymerization initiator and 1 to 10 parts by mass of the thiol compound.

[0015] In any of the manufacturing methods (1) to (7) of the optical film with a functional layer, the irradiation step is a step of irradiating, as the active energy ray, a UV-LED having a maximum emission wavelength in the wavelength region of 280 to 420 nm to the coating surface of the radical-polymerizable curable composition of the optical film. The manufacturing method (8) of the optical film with a functional layer is preferred.

[0016] In any of the manufacturing methods (1) to (8) of the optical film with a functional layer, the manufacturing method (9) of the optical film with a functional layer, wherein the optical film is an iodine-based polarizer, is preferred.

[0017] The present invention also relates to a method for manufacturing a laminated optical film in which at least an optical film and a second optical film are laminated via an adhesive layer. The optical film is an optical film with a functional layer manufactured by the method for manufacturing an optical film with a functional layer according to claim 1. The adhesive layer is a cured product layer of an adhesive composition. The method includes a second coating step of coating the second optical film with the adhesive composition, a bonding step of bonding the functional layer surface of the optical film and the coating surface of the adhesive composition of the second optical film, and an adhesion step of adhering the optical film and the second optical film via an adhesive layer formed by irradiating active energy rays from the optical film side or the second optical film side to cure at least the adhesive composition. The present invention relates to a method for manufacturing a laminated optical film (10).

[0018] In the method for manufacturing the laminated optical film (10), the method for manufacturing the laminated optical film (11), wherein the optical film is a polarizer, is preferred.

Advantages of the Invention

[0019] In the method for manufacturing an optical film with a functional layer according to the present invention, a thin functional layer, specifically, a functional layer with a thickness of less than 5 μm, can be laminated on an optical film in an atmosphere with an oxygen concentration of 5% or more, for example, in an air atmosphere, rather than in an inert gas atmosphere. That is, the productivity is excellent. Further, in the method for manufacturing an optical film with a functional layer according to the present invention, in the irradiation step of irradiating the coating surface of the radical-polymerizable curable composition of the optical film with active energy rays, at least a part of the radical-polymerizable curable composition is cured. That is, at least a part of the radical-polymerizable curable composition can be controlled to be in an unreacted state. Therefore, for example, when forming an adhesive layer with a cured product layer of an adhesive composition on the functional layer side of an optical film, at least a part of the unreacted radical-polymerizable curable composition is compatible with the applied adhesive composition, and the adhesion at the interface can be improved. For this reason, the adhesiveness between the optical film with a functional layer and another optical film can be improved. The degree of curing of the radical-polymerizable curable composition in the irradiation step can be adjusted, for example, by irradiating a UV-LED having a maximum emission wavelength in the wavelength range of 280 to 420 nm as the active energy rays under arbitrary conditions in the irradiation step.

[0020] In the method for manufacturing an optical film with a functional layer according to the present invention, when the optical film is an iodine-based polarizer, for example, a barrier function can be imparted to the iodine-based polarizer to suppress the elution and diffusion of iodine from the iodine-based polarizer. The barrier function of the iodine-based polarizer will be described below.

[0021] Image display devices equipped with iodine-based polarizers may be used under high temperature and high humidity conditions. For example, if a laminated optical film, in which at least an iodine-based polarizer and a phase difference film are laminated via an adhesive layer, is incorporated into an image display device and exposed to high temperature and high humidity conditions, the iodine in the iodine-based polarizer may penetrate the adhesive layer and phase difference film, either alone or via water, and eventually reach, for example, the panel or sensor of the image display device beyond the phase difference film, causing corrosion. As a result, the panel or sensor of the image display device may deteriorate, or the image display function may be significantly impaired. However, an optical film with a functional layer manufactured by the method for manufacturing an optical film with a functional layer according to the present invention (in this specification, when the optical film is an iodine-based polarizer, it may be referred to as an "iodine-based polarizer with a barrier functional layer") exhibits a barrier function in which the functional layer (in this specification, it may be referred to as a "barrier functional layer") significantly inhibits the movement of iodine. Therefore, iodine does not reach the panel or sensor of the image display device and remains inside the polarizer. As a result, even when an image display device incorporating an iodine-based polarizer with a barrier layer is used under high temperature and high humidity conditions, corrosion of the panel or sensor of the image display device by iodine can be sufficiently prevented. [Brief explanation of the drawing]

[0022] [Figure 1] This figure shows an example of an image display device equipped with an iodine-based polarizer with a barrier functional layer, manufactured by the method for manufacturing an optical film with a functional layer according to the present invention. [Modes for carrying out the invention]

[0023] The present invention relates to a method for manufacturing an optical film with a functional layer, in which a functional layer is laminated onto an optical film. The optical film on which the functional layer is provided is not particularly limited and includes, for example, iodine-based polarizers, phase difference films, liquid crystal phase difference films, and transparent protective films.

[0024] <Iodine-based polarizers> In the present invention, the iodine-based polarizer is not particularly limited, and various types can be used. Examples of iodine-based polarizers include hydrophilic polymer films such as polyvinyl alcohol-based films, partially formalized polyvinyl alcohol-based films, and partially saponified ethylene-vinyl acetate copolymer films, to which iodine is adsorbed and then uniaxially stretched. The thickness of the polarizer can be, for example, 3 to 20 μm.

[0025] However, in this invention, from the viewpoint of improving heat resistance in harsh environments at high temperatures, it is preferable to use a thin polarizer with a thickness of 3 μm or more and 15 μm or less as the iodine-based polarizer. It is particularly preferable that the thickness be 12 μm or less, even more preferably 10 μm or less, and especially preferably 8 μm or less. Such thin polarizers have less thickness variation, excellent visibility, and excellent resistance to thermal shock due to minimal dimensional change.

[0026] Iodine-based polarizers, made by dyeing a polyvinyl alcohol-based film with iodine and uniaxially stretching it, can be produced, for example, by dyeing the polyvinyl alcohol by immersing it in an aqueous solution of iodine and stretching it to 3 to 7 times its original length. Boric acid, zinc sulfate, zinc chloride, etc., may be included as needed, or the film may be immersed in an aqueous solution of potassium iodide, etc. Furthermore, if necessary, the polyvinyl alcohol-based film may be immersed in water and washed before dyeing. Washing the polyvinyl alcohol-based film with water cleans away dirt and anti-blocking agents from the film surface, and also prevents uneven dyeing by swelling the film. Stretching may be performed after dyeing with iodine, while dyeing, or after stretching. Stretching can also be performed in aqueous solutions of boric acid or potassium iodide, or even in a water bath.

[0027] Typical examples of thin iodine-based polarizers include: Patent No. 4751486 specification, Patent No. 4751481 specification, Patent No. 4815544 specification, Patent No. 5048120 specification, International Publication No. 2014 / 077599 pamphlet, International Publication No. 2014 / 077636 pamphlet, Examples include thin polarizers described in the text or thin polarizers obtained from the manufacturing methods described therein.

[0028] As for the thin polarizers, among manufacturing methods that include a step of stretching in a laminated state and a step of dyeing, those obtained by a manufacturing method that includes a step of stretching in a boric acid aqueous solution, as described in Japanese Patent No. 4751486, Japanese Patent No. 4751481, and Japanese Patent No. 4815544, are preferred because they can be stretched to a high magnification and their polarization performance can be improved. In particular, those obtained by a manufacturing method that includes a step of auxiliary air stretching before stretching in a boric acid aqueous solution, as described in Japanese Patent No. 4751481 and Japanese Patent No. 4815544, are preferred. These thin polarizers can be obtained by a manufacturing method that includes a step of stretching a polyvinyl alcohol-based resin (hereinafter also referred to as PVA-based resin) layer and a stretching resin substrate in a laminated state and a step of dyeing. With this manufacturing method, even if the PVA-based resin layer is thin, it is possible to stretch it without problems such as breakage due to stretching because it is supported by the stretching resin substrate.

[0029] The functional layer side of the iodine-based polarizer may be subjected to surface modification treatment before the formation of the functional layer. Examples of surface modification treatments include corona treatment, plasma treatment, and itro treatment, with corona treatment being particularly preferred. Corona treatment generates reactive functional groups such as carbonyl groups and amino groups on the polarizer surface, improving adhesion to the adhesive layer. In addition, the ashing effect removes foreign matter from the surface and reduces surface irregularities, making it possible to manufacture a laminated optical film with excellent appearance characteristics.

[0030] Furthermore, the functional layer side of the iodine-based polarizer may be coated with an easy-adhesion composition before the functional layer is formed to form an easy-adhesion layer. Examples of easy-adhesion compositions include compounds that can also be incorporated into radical polymerizable curable compositions, such as aqueous solutions containing a monofunctional radical polymerizable compound represented by general formula (2), which will be described later.

[0031] In the laminated optical film according to the present invention, the optical film laminated with the iodine-based polarizer is preferably a phase difference film. However, the phase difference film may be, for example, a phase difference film having an easy-adhesion layer on the adhesive layer side, or a phase difference film having a surface modification treatment such as corona treatment on the adhesive layer side. The easy-adhesion layer and surface modification treatment may be the same as those for the polarizer. Alternatively, the phase difference film may have an acrylic film, polycarbonate film, triacetylcellulose (TAC) film, cycloolefin polymer film, etc., laminated on the adhesive layer side. The phase difference film will be described below.

[0032] <Phase difference film> Examples of phase difference films include birefringent films made by uniaxial or biaxial stretching of polymer materials, liquid crystal polymer orientation films, and films in which a liquid crystal polymer orientation layer is supported by a film. The thickness of the film constituting the phase difference film is not particularly limited, but it is generally around 1 to 150 μm.

[0033] As for the phase difference film, the following formulas (1) to (3): 0.70 <Re

[0450] / Re

[0550] <0.97···(1) 1.5 × 10 -3 <Δn<6×10 -3 ...(2) 1.13 <NZ<1.50···(3) A reverse wavelength-dispersive phase difference film that satisfies the following equation may also be used: (In the formula, Re

[0450] and Re

[0550] are the in-plane phase difference values ​​of the phase difference film measured with light of wavelengths 450 nm and 550 nm at 23°C, respectively; Δn is the in-plane birefringence nx-ny when the refractive indices in the slow axis direction and the fast axis direction of the phase difference film are nx and ny, respectively; and NZ is the ratio of the thickness-direction birefringence nx-nz to the in-plane birefringence nx-ny when nz is the refractive index in the thickness direction of the phase difference film).

[0034] When the laminated optical film according to the present invention includes a phase difference film as the second optical film, a liquid crystal phase difference film is preferred. Liquid crystal phase difference films are generally thin, for example, 5 μm or less in thickness. However, as mentioned above, even when the laminated optical film is exposed to high temperature and high humidity, the iodine contained in the iodine-based polarizer remains within the polarizer due to the barrier function of the adhesive layer. Therefore, even a thin liquid crystal phase difference film can sufficiently prevent corrosion of the panel or sensor of the image display device. When forming a liquid crystal phase difference film, a liquid crystalline compound is preferably used, and a solvent containing the liquid crystalline compound can be applied to the substrate using, for example, a wire bar, gap coater, comma coater, gravure coater, or slot die. In this case, the applied liquid crystalline solution may be air-dried or heat-dried. It is preferable that the liquid crystalline solution be applied at a concentration lower than the isotropic phase-liquid crystal phase transition concentration, i.e., in an isotropic phase state. In this case, it can be stably oriented by methods such as rubbing or photo-alignment.

[0035] <Transparent protective film> In the present invention, the material used to constitute the transparent protective film, which can be used as an optical film for laminating a functional layer, or which can constitute a laminated optical film when used in combination with an iodine-based polarizer, is, for example, a thermoplastic resin that is excellent in transparency, mechanical strength, thermal stability, moisture barrier properties, isotropy, etc. Specific examples of such thermoplastic resins include cellulose resins such as triacetylcellulose, polyester resins, polyethersulfone resins, polysulfone resins, polycarbonate resins, polyamide resins, polyimide resins, polyolefin resins, (meth)acrylic resins, cyclic polyolefin resins (norbornene-based resins), polyarylate resins, polystyrene resins, polyvinyl alcohol resins, and mixtures thereof. The transparent protective film may contain one or more suitable additives. Examples of additives include ultraviolet absorbers, antioxidants, lubricants, plasticizers, mold release agents, color inhibitors, flame retardants, nucleating agents, antistatic agents, pigments, and colorants. The content of the thermoplastic resin in the transparent protective film is preferably 50 to 100% by weight, more preferably 50 to 99% by weight, even more preferably 60 to 98% by weight, and particularly preferably 70 to 97% by weight. If the content of the thermoplastic resin in the transparent protective film is 50% by weight or less, the high transparency and other properties inherent to the thermoplastic resin may not be fully realized.

[0036] Furthermore, the material used to form the transparent protective film is preferably one that is excellent in terms of transparency, mechanical strength, thermal stability, moisture barrier properties, and isotropy, and is particularly good if it has a moisture permeability of 150 g / m². 2 It is more preferable that the amount is 24 hours or less, and 140 g / m² 2 Products with a shelf life of 24 hours or less are particularly preferred, and the density is 120 g / m². 2 Even better are those with a shelf life of 24 hours or less.

[0037] The transparent protective film may be provided with functional layers such as a hard coat layer, an anti-reflective layer, an anti-sticking layer, a diffusion layer, or an anti-glare layer. These functional layers, such as the hard coat layer, anti-reflective layer, anti-sticking layer, diffusion layer, and anti-glare layer, can be provided on the transparent protective film itself, or they can be provided separately from the transparent protective film.

[0038] The thickness of the transparent protective film can be determined as appropriate, but generally it is about 1 to 500 μm, preferably 1 to 300 μm, and more preferably 5 to 200 μm, considering factors such as strength, workability, and thinness. Furthermore, 10 to 200 μm is preferred, and 20 to 80 μm is preferred.

[0039] The present invention relates to a method for manufacturing an optical film with a functional layer, wherein an optical film has a functional layer laminated on it, and comprises a coating step of coating the optical film with a radical polymerizable curable composition, and an irradiation step of curing at least a portion of the radical polymerizable curable composition by irradiating the coated surface of the optical film with active energy rays, wherein the irradiation step is performed in an atmosphere with an oxygen concentration of 5% or more, the radical polymerizable curable composition contains at least one selected from the group consisting of amino-based photopolymerization initiators and thiol compounds, and the thickness of the functional layer is less than 5 μm. The following describes each step.

[0040] (Coating process) In the coating process, a radically polymerizable curable composition capable of imparting various functions is coated onto the optical film. The method for coating the optical film with the radically polymerizable curable composition is appropriately selected depending on the viscosity of the composition and the desired thickness. Examples include reverse coaters, gravure coaters (direct, reverse, and offset), bar reverse coaters, roll coaters, die coaters, bar coaters, and rod coaters. The viscosity of the radically polymerizable curable composition is preferably 0.5 to 100 mPa·s. If the viscosity of the radically polymerizable curable composition is high, the surface smoothness after coating is poor, resulting in an undesirable appearance. Therefore, each composition can be heated or cooled to adjust its viscosity to a preferred range before application.

[0041] (irradiation process) In the irradiation process, at least a portion of the radical polymerizable curable composition is cured by irradiating the coated surface of the optical film with active energy rays. The irradiation direction of the active energy rays (electron beam, ultraviolet light, visible light, etc.) can be any appropriate direction.

[0042] In the irradiation process, it is preferable to irradiate the coated surface of the optical film with the radical polymerizable curable composition using a UV-LED light source having a maximum emission wavelength in the 280-420 nm wavelength range as the active energy ray, because this reduces the thermal impact on the optical film during irradiation. In addition, the degree of curing of the radical polymerizable curable composition can be easily controlled while reducing thermal damage to the optical film during the irradiation process. For example, when an adhesive layer is formed on the functional layer side of the optical film with a cured adhesive layer, at least a portion of the unreacted radical polymerizable curable composition may become compatible with the coated adhesive composition, improving the adhesion at the interface. Therefore, the adhesion between the optical film with the functional layer and other optical films may be improved.

[0043] In the method for manufacturing an optical film with a functional layer according to the present invention, the irradiation step involves irradiating the film with the active energy rays in an atmosphere with an oxygen concentration of 5% or higher. This allows a thin functional layer, specifically a functional layer with a thickness of less than 5 μm, to be laminated onto the optical film in an atmosphere with an oxygen concentration of 5% or higher, rather than, for example, an inert gas atmosphere. In other words, it offers excellent productivity. To enable this irradiation step, the method for manufacturing an optical film with a functional layer according to the present invention uses a radical polymerizable curable composition containing at least one selected from the group consisting of amino-based photopolymerization initiators and thiol compounds to form the functional layer on the optical film. The radical polymerizable curable composition is described below.

[0044] <Radical polymerizable curable composition> The radically polymerizable curable composition contains at least one selected from the group consisting of amino-based photopolymerization initiators and thiol compounds.

[0045] Amino-based photopolymerization initiators are photopolymerization initiators having at least an amino group. Examples of amino-based photopolymerization initiators include 2-methyl-1-[4-(methylthio)phenyl]-2-morpholinopropan-1-one, 2-benzyl-2-(dimethylamino)-4'-morpholinobtyrophenone, 2-dimethylamino-2-(4-methyl-benzyl)-1-(4-morpholin-4-yl-phenyl)-butan-1-one, piperazine-based polymer initiators of α-aminoketones, 4,4'-bis(diethylamino)benzophenone, ethyl-4-(dimethylamino) benzoate, 2-ethylhexyl-4-dimethylaminobenzoate, poly(ethylene glycol)bis(p-dimethylaminobenzoate), N-methyl-N-phenyl, 1,1', 1'' triesters with 2-ethyl-2-(hydroxymethyl)-1,3-propanediol, and polyfunctional amines. In order to maintain sufficient reactivity of the curable components in the radical polymerizable curable composition even in an atmosphere with an oxygen concentration of 5% or higher, the present invention preferably uses a compound containing a tertiary amino group among the above-mentioned amino-based photopolymerization initiators, and more preferably uses a benzophenone-based photopolymerization initiator or an acetophenone-based photopolymerization initiator.

[0046] In order to maintain sufficient reactivity of the curable components in the radical polymerizable curable composition even in an atmosphere with an oxygen concentration of 5% or more, in the present invention, it is preferable that the composition contains 1 to 10 parts by mass of an amino-based photopolymerization initiator, and more preferably 2 to 5 parts by mass, when the total amount of curable components is 100 parts by mass.

[0047] Thiol compounds are compounds having a mercapto group (thiol group) called an -SH group. In order to sufficiently maintain the reactivity of the curable component in the radical polymerizable curable composition even in an atmosphere with an oxygen concentration of 5% or more, it is particularly preferable in the present invention to use a compound having at least two or more secondary mercapto groups as the thiol compound. Examples of compounds having two or more secondary mercapto groups include 1,4-bis(3-mercaptobutyryloxy)butane, 2,3-butanedithiol, and meso-2,3-dimercaptosuccinic acid. Examples of compounds having three secondary mercapto groups include trimethylolpropane tris(3-mercaptobutyrate) and 1,3,5-tris(2-(3-sulfanylbutanoyloxy)ethyl)-1,3,5-triazinan-2,4,6-trione. Examples of compounds having four secondary mercapto groups include pentaerythritol tetrakis(3-mercaptobutyrate).

[0048] In order to maintain sufficient reactivity of the curable components in the radical polymerizable curable composition even in an atmosphere with an oxygen concentration of 5% or more, in the present invention, it is preferable that the curable composition contains 1 to 30 parts by mass of thiol compounds, and more preferably 1.5 to 15 parts by mass, when the total amount of curable components is 100 parts by mass.

[0049] In order to maintain sufficient reactivity of the curable components in the radical polymerizable curable composition even in an atmosphere with an oxygen concentration of 5% or more, it is also preferable in the present invention for the radical polymerizable curable composition to contain both an amino-based photopolymerization initiator and a thiol compound. In that case, when the total amount of curable components is 100 parts by mass, it is preferable that the composition contains 1 to 5 parts by mass of the amino-based photopolymerization initiator and 1 to 10 parts by mass of the thiol compound.

[0050] In the present invention, in addition to either or both of an amino-based photopolymerization initiator and a thiol compound, a compound represented by the following general formula (1) is included as a photopolymerization initiator in the radically polymerizable curable composition;

[0051] [Chemical formula] (In the formula, R 1 and R 2 represent -H, -CH2CH3, -iPr or Cl, and R 1 and R 2 may be the same or different) is preferably blended. Among the compounds represented by the general formula (1), diethylthioxanthone in which R 1 and R 2 are -CH2CH3 is particularly preferred. The blending ratio of the compound represented by the general formula (1) in the radical-polymerizable curable composition is preferably 0.5 to 5 parts by mass, more preferably 1 to 3.5 parts by mass, based on 100 parts by mass of the total amount of the curable components.

[0052] Examples of the polymerizable components that can be blended in the radical-polymerizable curable composition include electron beam-curable, ultraviolet-curable, and visible light-curable radical-polymerizable compounds. In the present invention, active energy rays in the wavelength range of 10 nm to less than 380 nm are referred to as ultraviolet rays, and active energy rays in the wavelength range of 380 nm to 800 nm are referred to as visible light.

[0053] In the method for producing an optical film with a functional layer according to the present invention, when the optical film is an iodine-based polarizer, for example, a barrier function can be imparted to suppress the elution and diffusion of iodine from the iodine-based polarizer. When imparting a barrier function to the iodine-based polarizer, it is preferable to blend a (meth)acrylate (A) having a cyclic hydrocarbon skeleton in the molecule as a curable component in the radical-polymerizable curable composition.

[0054] (Meth)acrylate (A) having a cyclic hydrocarbon skeleton is, for example, a (meth)acrylate having an alicyclic skeleton, and due to having a cyclic hydrocarbon skeleton, it can form a barrier functional layer with low mobility and low ion permeability. Therefore, by incorporating (meth)acrylate (A) having a cyclic hydrocarbon skeleton in its molecule as a curable component in a radical polymerizable curable composition, the movement of iodine from an iodine-based polarizer can be retained in the barrier functional layer. As a result, even when an image display device incorporating an iodine-based polarizer is used under high temperature and high humidity conditions, corrosion of the panel or sensor of the image display device by iodine can be sufficiently prevented. As for (meth)acrylate (A), a compound having 5 to 12 carbon atoms constituting the cyclic hydrocarbon skeleton in its molecule is preferable because it can more reliably retain the movement of iodine from an iodine-based polarizer in the barrier functional layer.

[0055] When a (meth)acrylate (A) having a cyclic hydrocarbon skeleton is used, it is preferable because the movement of iodine from the iodine-based polarizer can be more reliably retained in the barrier functional layer. Examples of (meth)acrylates with two or more functions include the compound described in formula (A1) below, which will be described later.

[0056] (A) is a (meth)acrylate (A) having a cyclic hydrocarbon skeleton, as shown in the following formulas (A1) to (A5); [ka] It is preferable to use at least one compound selected from the group consisting of the compounds described in JPEG2026115625000004.jpg105156, because this allows for more reliable retention of iodine transfer from the iodine-based polarizer within the barrier functional layer.

[0057] In order to effectively exert the barrier function against iodine in the barrier functional layer, it is preferable that the radical polymerizable curable composition contains 70 parts by mass or more of (meth)acrylate (A) having a cyclic hydrocarbon skeleton in its molecule, when the total amount of curable components in the radical polymerizable curable composition is 100 parts by mass. More preferably, it is 80 parts by mass or more, and even more preferably 85 parts by mass or more.

[0058] When forming a barrier functional layer on an iodine-based polarizer, it is preferable that the radical polymerizable curable composition contains, as a polymerizable component, (meth)acrylate (A) having a cyclic hydrocarbon skeleton in its molecule, and further contains (meth)acrylate (B) containing a hydroxyl group. The (meth)acrylate (B) containing a hydroxyl group has the effect of enhancing the adhesion function of the barrier functional layer to the iodine-based polarizer. However, in order to achieve both the barrier function of the iodine-based polarizer and the adhesion function to the iodine-based polarizer, it is preferable that, when the total amount of curable components in the radical polymerizable curable composition is 100 parts by mass, the amount of (meth)acrylate (A) having a cyclic hydrocarbon skeleton in its molecule is 70 parts by mass or more, and furthermore, the content of (meth)acrylate (A) relative to (meth)acrylate (B) is designed to be within the range of 2 to 6 times. To achieve a better balance between the barrier function of iodine-based polarizers and the adhesion function with iodine-based polarizers, it is more preferable to use 5 to 25 parts by mass of (meth)acrylate (B) when the total amount of (meth)acrylate compound is 100 parts by mass.

[0059] Examples of hydroxyl group-containing (meth)acrylates (B) include hydroxyalkyl (meth)acrylates such as 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 3-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, 4-hydroxybutyl (meth)acrylate, 6-hydroxyhexyl (meth)acrylate, 8-hydroxyoctyl (meth)acrylate, 10-hydroxydecyl (meth)acrylate, and 12-hydroxylauryl (meth)acrylate; hydroxyl group-containing (meth)acrylates such as [4-(hydroxymethyl)cyclohexyl]methyl acrylate, cyclohexanedimethanol mono(meth)acrylate, and 2-hydroxy-3-phenoxypropyl (meth)acrylate; and N-hydroxyalkyl group-containing (meth)acrylamide derivatives such as N-methylol (meth)acrylamide, N-hydroxyethyl (meth)acrylamide, and N-methylol-N-propane (meth)acrylamide.

[0060] In the method for producing an optical film with a functional layer according to the present invention, when the optical film is an iodine-based polarizer, or when it is another optical film, such as a phase difference film, a liquid crystal phase difference film, or a transparent protective film, the radical polymerizable curable composition may further contain the radical polymerizable compounds shown below as curable components.

[0061] Radical polymerizable compounds include compounds having a radically polymerizable functional group of a carbon-carbon double bond, such as a (meth)acrylic group or a vinyl group. These monomer components can be either monofunctional radical polymerizable compounds or polyfunctional radical polymerizable compounds having two or more polymerizable functional groups. Furthermore, these radical polymerizable compounds can be used individually or in combination of two or more. Among these radical polymerizable compounds, compounds having a (meth)acrylic group are preferred, for example.

[0062] Examples of monofunctional radical polymerizable compounds include (meth)acrylic acid derivatives. Examples of (meth)acrylic acid derivatives include alkoxy group or phenoxy group-containing (meth)acrylates such as 2-methoxyethyl (meth)acrylate, 2-ethoxyethyl (meth)acrylate, 2-methoxymethoxyethyl (meth)acrylate, 3-methoxybutyl (meth)acrylate, ethyl carbitol (meth)acrylate, phenoxyethyl (meth)acrylate, alkylphenoxy polyethylene glycol (meth)acrylate; cyclohexyl (meth)acrylate, 4-tert-butylcyclohexyl acrylate, and cyclopentyl Examples include cycloalkyl(meth)acrylates such as (meth)acrylate; aralkyl(meth)acrylates such as benzyl(meth)acrylate; polycyclic(meth)acrylates such as 2-isobornyl(meth)acrylate, 2-norbornylmethyl(meth)acrylate, 5-norbornen-2-ylmethyl(meth)acrylate, 3-methyl-2-norbornylmethyl(meth)acrylate, dicyclopentenyl(meth)acrylate, dicyclopentenyloxyethyl(meth)acrylate, and dicyclopentanyl(meth)acrylate.

[0063] Other examples of monofunctional radical polymerizable compounds include various (meth)acrylic acid derivatives having a (meth)acryloyloxy group. Specifically, examples include alkyl esters of (meth)acrylic acid (with 1-20 carbon atoms), such as methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, 2-methyl-2-nitropropyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, s-butyl (meth)acrylate, t-butyl (meth)acrylate, n-pentyl (meth)acrylate, t-pentyl (meth)acrylate, 3-pentyl (meth)acrylate, 2,2-dimethylbutyl (meth)acrylate, n-hexyl (meth)acrylate, cetyl (meth)acrylate, n-octyl (meth)acrylate, lauryl (meth)acrylate, 2-ethylhexyl (meth)acrylate, 4-methyl-2-propylpentyl (meth)acrylate, and n-octadecyl (meth)acrylate.

[0064] Other monofunctional radical polymerizable compounds include, for example, (meth)acrylamide derivatives having a (meth)acrylamide group. Specific examples of (meth)acrylamide derivatives include, for example, N-alkyl group-containing (meth)acrylamide derivatives such as N-methyl(meth)acrylamide, N,N-dimethyl(meth)acrylamide, N,N-diethyl(meth)acrylamide, N-isopropyl(meth)acrylamide, N-butyl(meth)acrylamide, and N-hexyl(meth)acrylamide; N-aminoalkyl group-containing (meth)acrylamide derivatives such as aminomethyl(meth)acrylamide and aminoethyl(meth)acrylamide; N-alkoxy group-containing (meth)acrylamide derivatives such as N-methoxymethylacrylamide and N-ethoxymethylacrylamide; and N-mercaptoalkyl group-containing (meth)acrylamide derivatives such as mercaptomethyl(meth)acrylamide and mercaptoethyl(meth)acrylamide. Furthermore, examples of heterocyclic (meth)acrylamide derivatives in which the nitrogen atom of the (meth)acrylamide group forms a heterocycle include N-acryloylmorpholine, N-acryloylpiperidine, N-methacryloylpiperidine, and N-acryloylpyrrolidine.

[0065] Furthermore, monofunctional radical polymerizable compounds include epoxy group-containing (meth)acrylates such as glycidyl (meth)acrylate and 4-hydroxybutyl (meth)acrylate glycidyl ether; halogen-containing (meth)acrylates such as 2,2,2-trifluoroethyl (meth)acrylate, 2,2,2-trifluoroethyl ethyl (meth)acrylate, tetrafluoropropyl (meth)acrylate, hexafluoropropyl (meth)acrylate, octafluoropentyl (meth)acrylate, heptadecafluorodecyl (meth)acrylate, and 3-chloro-2-hydroxypropyl (meth)acrylate; and dimethylaminoethyl (meth)acrylate, etc. Alkylaminoalkyl (meth)acrylates; oxetane group-containing (meth)acrylates such as 3-oxetanylmethyl (meth)acrylate, 3-methyl-oxetanylmethyl (meth)acrylate, 3-ethyl-oxetanylmethyl (meth)acrylate, 3-butyl-oxetanylmethyl (meth)acrylate, and 3-hexyl-oxetanylmethyl (meth)acrylate; heterocyclic (meth)acrylates such as tetrahydrofurfuryl (meth)acrylate and butyrolactone (meth)acrylate; or hydroxypivalate neopentyl glycol (meth)acrylic acid adducts and p-phenylphenol (meth)acrylate may be used.

[0066] Furthermore, as monofunctional radical polymerizable compounds, carboxyl group-containing monomers such as (meth)acrylic acid, carboxyethyl acrylate, carboxypentyl acrylate, itaconic acid, maleic acid, fumaric acid, crotonic acid, and isocrotonic acid may be used.

[0067] Furthermore, as monofunctional radical polymerizable compounds, for example, lactam-based vinyl monomers such as N-vinylpyrrolidone, N-vinyl-ε-caprolactam, and methylvinylpyrrolidone; and vinyl monomers having nitrogen-containing heterocyclic rings such as vinylpyridine, vinylpiperidone, vinylpyrimidine, vinylpiperazine, vinylpyrazine, vinylpyrrole, vinylimidazole, vinyloxazole, and vinylmorpholine may be used.

[0068] Furthermore, as the monofunctional radical polymerizable compound, a radical polymerizable compound having an active methylene group may be used. A radical polymerizable compound having an active methylene group is a compound that has an active double bond group such as a (meth)acrylic group at its terminal or in the molecule, and also has an active methylene group. Examples of active methylene groups include an acetoacetyl group, an alkoxymalonyl group, or a cyanoacetyl group. It is preferable that the active methylene group is an acetoacetyl group. Specific examples of radical polymerizable compounds having an active methylene group include acetoacetoxyalkyl (meth)acrylates such as 2-acetoacetoxyethyl (meth)acrylate, 2-acetoacetoxypropyl (meth)acrylate, and 2-acetoacetoxy-1-methylethyl (meth)acrylate; 2-ethoxymalonyloxyethyl (meth)acrylate, 2-cyanoacetoxyethyl (meth)acrylate, N-(2-cyanoacetoxyethyl)acrylamide, N-(2-propionylacetoxybutyl)acrylamide, N-(4-acetoacetoxymethylbenzyl)acrylamide, and N-(2-acetoacetylaminoethyl)acrylamide. The radical polymerizable compound having an active methylene group is preferably an acetoacetoxyalkyl (meth)acrylate.

[0069] Furthermore, in the present invention, the radical polymerizable curable composition contains the following general formula (2): [ka] A monofunctional radical polymerizable compound represented by (where X is a reactive group, Y is a C1-C12 alkylene group which may have a branched chain, or a phenylene group which may have a substituent, R 1 and R 2 Each of these may independently represent a hydrogen atom, an aliphatic hydrocarbon group which may have substituents, an aryl group which may have substituents, or a heterocyclic group which may have substituents.

[0070] In the monofunctional radical polymerizable compound represented by general formula (2), the aliphatic hydrocarbon group may be a linear or branched alkyl group having 1 to 20 substituents, a cyclic alkyl group having 3 to 20 substituents, or an alkenyl group having 2 to 20 substituents. The aryl group may be a phenyl group having 6 to 20 substituents, a naphthyl group having 10 to 20 substituents, etc. The heterocyclic group may be a 5-membered or 6-membered ring containing at least one heteroatom and having substituents. These may be linked together to form a ring. In general formula (1), R 1 and R 2 Preferably, the member is a hydrogen atom, a linear or branched alkyl group having 1 to 3 carbon atoms, and most preferably a hydrogen atom.

[0071] X in the monofunctional radical polymerizable compound represented by general formula (2) is a reactive group, a functional group that can react with the curable component in the radical polymerizable curable composition, and examples include hydroxyl group, amino group, aldehyde group, carboxyl group, vinyl group, (meth)acrylic group, styryl group, (meth)acrylamide group, vinyl ether group, epoxy group, oxetane group, α,β-unsaturated carbonyl group, mercapto group, halogen group, etc. It is preferable that the reactive group X is at least one reactive group selected from the group consisting of vinyl group, (meth)acrylic group, styryl group, (meth)acrylamide group, vinyl ether group, epoxy group, oxetane group, and mercapto group. It is more preferable that the reactive group X is at least one reactive group selected from the group consisting of (meth)acrylic group, styryl group, and (meth)acrylamide group, and it is even more preferable when the monofunctional radical polymerizable compound represented by general formula (2) has a (meth)acrylamide group, as this increases the reactivity and the copolymerization rate with the curable component in the functional layer. Furthermore, the high polarity of the (meth)acrylamide group and its excellent adhesive properties make it preferable in that the effects of the present invention can be efficiently obtained.

[0072] Preferred specific examples of monofunctional radical polymerizable compounds represented by general formula (2) include the following compounds (2a) to (2d). Note that R in general formulas (2a) and (2b) 3 This is either a hydrogen atom or a methyl group. [ka]

[0073] Examples of monofunctional radical polymerizable compounds represented by general formula (2) include, in addition to the examples given above, esters of (meth)acrylates and boric acid, such as esters of hydroxyethyl acrylamide and boric acid, methylol acrylamide and boric acid, esters of hydroxyethyl acrylate and boric acid, and esters of hydroxybutyl acrylate and boric acid.

[0074] Examples of polyfunctional radical polymerizable compounds having two or more polymerizable functional groups include tripropylene glycol di(meth)acrylate, tetraethylene glycol di(meth)acrylate, polyethylene glycol diacrylate, 1,6-hexanediol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, 1,10-decanediol diacrylate, 2-ethyl-2-butylpropanediol di(meth)acrylate, bisphenol A di(meth)acrylate, bisphenol A ethylene oxide adduct di(meth)acrylate, bisphenol A propylene oxide adduct di(meth)acrylate, bisphenol A diglycidyl ether di(meth)acrylate, and Examples include esters of (meth)acrylic acid with polyhydric alcohols such as opentyl glycol di(meth)acrylate, tricyclodecane dimethanol di(meth)acrylate, cyclic trimethylolpropane formal(meth)acrylate, dioxane glycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, pentaerythritol tetra(meth)acrylate, dipentaerythritol penta(meth)acrylate, dipentaerythritol hexa(meth)acrylate, and EO-modified diglycerin tetra(meth)acrylate, as well as 9,9-bis[4-(2-(meth)acryloyloxyethoxy)phenyl]fluorene. Specific examples include Light Acrylate 9EG-A (manufactured by Kyoeisha Chemical Co., Ltd.), Aronics M-220 (manufactured by Toagosei Co., Ltd.), Light Acrylate 1,9ND-A (manufactured by Kyoeisha Chemical Co., Ltd.), Light Acrylate DGE-4A (manufactured by Kyoeisha Chemical Co., Ltd.), Light Acrylate DCP-A (manufactured by Kyoeisha Chemical Co., Ltd.), SR-531 (manufactured by Sartomer), CD-536 (manufactured by Sartomer), and others.

[0075] In the present invention, the radical polymerizable curable composition may contain, in addition to the radical polymerizable compound, an acrylic oligomer obtained by polymerizing (meth)acrylic monomer and having no polymerizable groups. By including the acrylic oligomer in the radical polymerizable curable composition, curing shrinkage when the composition is irradiated and cured with active energy rays can be reduced, and interfacial stress between the functional layer and the polarizer and other optical films can be reduced. As a result, a decrease in adhesion between the functional layer and the polarizer and other optical films can be suppressed.

[0076] For radical polymerizable curable compositions, low viscosity is preferable when considering workability and uniformity during coating. Therefore, acrylic oligomers obtained by polymerizing (meth)acrylic monomers and that do not have polymerizable groups are also preferably low viscosity. As acrylic oligomers that are low viscosity and can prevent curing shrinkage of the functional layer, those with a weight-average molecular weight (Mw) of 15,000 or less are preferred, those with a weight-average molecular weight (Mw) of 10,000 or less are more preferred, and those with a weight-average molecular weight (Mw) of 5,000 or less are particularly preferred. On the other hand, in order to sufficiently suppress curing shrinkage of the functional layer, the weight-average molecular weight (Mw) of the acrylic oligomer is preferably 500 or more, more preferably 1,000 or more, and particularly preferred to be 1,500 or more. Examples of (meth)acrylic monomers that constitute acrylic oligomers include, specifically, methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, 2-methyl-2-nitropropyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, S-butyl (meth)acrylate, t-butyl (meth)acrylate, n-pentyl (meth)acrylate, t-pentyl (meth)acrylate, 3-pentyl (meth)acrylate, 2,Alkyl esters of (meth)acrylic acid (C1-C20) such as 2-dimethylbutyl (meth)acrylate, n-hexyl (meth)acrylate, cetyl (meth)acrylate, n-octyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, 4-methyl-2-propylpentyl (meth)acrylate, N-octadecyl (meth)acrylate, and also, for example, cycloalkyl (meth)acrylates (e.g., cyclohexyl (meth)acrylate, cyclopentyl (meth)acrylate, etc.), aralkyl (meth)acrylates (e.g., benzyl (meth)acrylate, etc.), polycyclic (meth)acrylates (e.g., 2-isobornyl (meth)acrylate, 2-norbornylmethyl (meth)acrylate, 5-norbornen-2-yl-methyl (meth)acrylate, 3-methyl-2-norbornylmethyl ( (meth)acrylates, etc.), hydroxyl group-containing (meth)acrylic acid esters (e.g., hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 2,3-dihydroxypropylmethyl-butyl (meth)methacrylate, etc.), alkoxy group- or phenoxy group-containing (meth)acrylic acid esters (2-methoxyethyl (meth)acrylate, 2-ethoxyethyl (meth)acrylate, 2-methoxymethoxyethyl (meth)acrylate, 3-methoxybutyl (meth)acrylate, ethyl carbitol (meth)acrylate, phenoxyethyl (meth)acrylate, etc.), epoxy group-containing (meth)acrylic acid esters (e.g., glycidyl (meth)acrylate, etc.), halogen-containing (meth)acrylic acid esters (e.g., 2,2,2-trifluoroethyl (meth)acrylate, 2,2Examples include 2-trifluoroethylethyl (meth)acrylate, tetrafluoropropyl (meth)acrylate, hexafluoropropyl (meth)acrylate, octafluoropentyl (meth)acrylate, heptadecafluorodecyl (meth)acrylate, etc., and alkylaminoalkyl (meth)acrylates (e.g., dimethylaminoethyl (meth)acrylate). These (meth)acrylates can be used alone or in combination of two or more types. Specific examples of acrylic oligomers (E) include "ARUFON" from Toagosei Co., Ltd., "Actflow" from Soken Chemical Co., Ltd., and "JONCRYL" from BASF Japan.

[0077] In the present invention, the radical polymerizable curable composition may contain cationic polymerizable compounds in addition to radical polymerizable compounds. Cationic polymerizable compounds are classified into monofunctional cationic polymerizable compounds having one cationic polymerizable functional group in the molecule, and polyfunctional cationic polymerizable compounds having two or more cationic polymerizable functional groups in the molecule. Monofunctional cationic polymerizable compounds have relatively low liquid viscosity, so including them in a composition can reduce the liquid viscosity of the composition. Furthermore, monofunctional cationic polymerizable compounds often have functional groups that exhibit various functions, and including them in a radical polymerizable curable composition can allow the cured product to exhibit various functions. Polyfunctional cationic polymerizable compounds can cause three-dimensional crosslinking of the cured product of the radical polymerizable curable composition.

[0078] Cationic polymerizable functional groups include epoxy groups, oxetanyl groups, and vinyl ether groups. Compounds containing epoxy groups include aliphatic epoxy compounds, alicyclic epoxy compounds, and aromatic epoxy compounds. Examples of alicyclic epoxy compounds include 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, caprolactone-modified, trimethylcaprolactone-modified, and valerolactone-modified 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, and specifically, Celoxide 2021, Celoxide 2021A, Celoxide 2021P, Celoxide 2081, Celoxide 2083, Celoxide 2085 (all manufactured by Daicel Chemical Industries, Ltd.), and Cyracure UVR-6105, Cyracure UVR-6107, Cyracure 30, R-6110 (all manufactured by Dow Chemical Japan Ltd.). Compounds containing an oxetanyl group have the effect of improving the curability of radical polymerizable curable compositions and reducing the liquid viscosity of said compositions, therefore, they contain It is preferable to include them. Examples of compounds having an oxetanyl group include 3-ethyl-3-hydroxymethyloxetane, 1,4-bis[(3-ethyl-3-oxetanyl)methoxymethyl]benzene, 3-ethyl-3-(phenoxymethyl)oxetane, di[(3-ethyl-3-oxetanyl)methyl]ether, 3-ethyl-3-(2-ethylhexyloxymethyl)oxetane, and phenol novolac oxetane. Aronoxetane OXT-101, Aronoxetane OXT-121, Aronoxetane OXT-211, Aronoxetane OXT-221, Aronoxetane OXT-212 (all manufactured by Toagosei Co., Ltd.) are commercially available. Compounds having a vinyl ether group are preferable to include because they have the effect of improving the curability of the cationic polymerizable adhesive composition and reducing the liquid viscosity of the composition.Compounds having a vinyl ether group include 2-hydroxyethyl vinyl ether, diethylene glycol monovinyl ether, 4-hydroxybutyl vinyl ether, diethylene glycol monovinyl ether, triethylene glycol divinyl ether, cyclohexanedimethanol divinyl ether, cyclohexanedimethanol monovinyl ether, tricyclodecane vinyl ether, cyclohexyl vinyl ether, methoxyethyl vinyl ether, ethoxyethyl vinyl ether, and pentaerythritol-type tetravinyl ether.

[0079] In this invention, a laminated optical film can be manufactured using a functional layer optical film produced by a method for manufacturing a functional layer optical film. Furthermore, by incorporating this laminated optical film, an image display device and even an organic EL display device can be created.

[0080] In the method for manufacturing a laminated optical film according to the present invention, when the optical film is an iodine-based polarizer, and further when the optical film is an iodine-based polarizer and the second optical film is a phase difference film, when the laminated optical film is incorporated into an image display device, the barrier function layer exhibits a barrier function that significantly inhibits the movement of iodine. As a result, iodine does not reach the panel or sensor of the image display device and remains inside the polarizer. Consequently, even when an image display device incorporating an iodine-based polarizer with a barrier function layer is used under high temperature and high humidity conditions, corrosion of the panel or sensor of the image display device by iodine can be sufficiently prevented.

[0081] Figure 1 shows an example of an embodiment, illustrating an image display device equipped with an iodine-based polarizer with a barrier functional layer, manufactured by the method for manufacturing an optical film with a functional layer according to the present invention. In the embodiment shown in Figure 1, the image display device A is an organic EL image display device equipped with an organic light-emitting diode panel 8, and includes an iodine-based polarizer 1 (iodine-based polarizer 1+2 with barrier functional layer) equipped with a barrier layer 2. An adhesive layer 3 is provided on the barrier layer 2 side of the iodine-based polarizer 1 equipped with the barrier layer 2, and the laminated optical film 10 is formed by laminating the iodine-based polarizer 1+2 with barrier functional layer and a phase difference film 4 via the adhesive layer 3. In this invention, the laminated optical film may consist of three or more optical films, provided that it comprises at least an iodine-based polarizer 1 → barrier layer 2 → adhesive layer 3 → phase difference film 4 from the outer surface (visible surface) toward the inner surface. In the embodiment shown in Figure 1, the image display device A comprises, in order from the outermost surface toward the organic light-emitting diode panel 8, a transparent protective film 7 → second adhesive layer 6 → iodine-based polarizer 1 → barrier layer 2 → adhesive layer 3 → phase difference film 4 → adhesive layer 5 → organic light-emitting diode panel 8. As described above, even when the laminated optical film 10 manufactured in this embodiment is exposed to high temperature and high humidity, the iodine contained in the iodine-based polarizer 1+2 remains within the barrier layer 2 due to the barrier function of the barrier layer 2, thereby preventing iodine from penetrating the phase difference film 4 and adhesive layer 5, and furthermore, the organic light-emitting diode panel 8 or touch sensor (not shown), and thus sufficiently preventing corrosion of the panel or sensor of the image display device.

[0082] <Adhesive layer> The adhesive layer may be formed by a cured layer of a radically polymerizable curable composition used to constitute the functional layer described above. However, the curable components such as radically polymerizable compounds and photopolymerization initiators may be appropriately changed depending on the type of optical film and the second optical film. From the viewpoint of thinning, the thickness of the adhesive layer is preferably 0.1 to 5 μm.

[0083] <Second adhesive layer> The second adhesive layer may also be formed from a cured layer of a radically polymerizable curable composition used to constitute the functional layer described above. However, the curable components such as radical polymerizable compounds and photopolymerization initiators may be appropriately changed depending on the type of optical film and the second optical film. Alternatively, it may be formed from a radically polymerizable adhesive composition, a cationic polymerizable adhesive composition, or an aqueous adhesive composition known to those skilled in the art. As the aqueous adhesive composition, aqueous solutions (for example, solid content concentration of 0.5 to 60% by weight) of aqueous adhesives such as isocyanate adhesives, polyvinyl alcohol adhesives, gelatin adhesives, vinyl latex adhesives, and aqueous polyester adhesives are preferably used. From the viewpoint of thinning, the thickness of the second adhesive layer is preferably 0.1 to 5 μm.

[0084] The laminated optical film produced by the method for manufacturing a laminated optical film according to the present invention is bonded to an organic light-emitting diode panel or a touch sensor by providing an adhesive layer on the second optical film side (the phase difference film side in the embodiment shown in Figure 1).

[0085] <Adhesive layer> The adhesive forming the adhesive layer is not particularly limited, but for example, adhesives based on polymers such as acrylic polymers, silicone polymers, polyesters, polyurethanes, polyamides, polyethers, fluorine-based or rubber-based polymers can be appropriately selected and used. In particular, adhesives that have excellent optical transparency, exhibit appropriate wettability, cohesiveness and adhesion properties, and have excellent weather resistance and heat resistance, such as acrylic adhesives, are preferably used.

[0086] For the exposed surface of the adhesive layer, a separator is temporarily attached and covered to prevent contamination until it is put into practical use. This prevents contact with the adhesive layer under normal handling conditions. As for the separator, except for the thickness conditions mentioned above, suitable thin materials such as plastic film, rubber sheet, paper, cloth, nonwoven fabric, net, foam sheet, metal foil, or laminates thereof can be used, and may be coated with a suitable release agent such as silicone-based, long-chain alkyl-based, fluorine-based, or molybdenum sulfide as needed, in accordance with conventional methods.

[0087] In the present invention, the laminated optical film can be manufactured by the following manufacturing method. A method for manufacturing a laminated optical film in which at least an optical film and a second optical film are laminated with an adhesive layer in between, The optical film is a functional layer optical film manufactured by the method for manufacturing a functional layer optical film according to the present invention, the adhesive layer is a cured layer of the adhesive composition, and the method for manufacturing a laminated optical film includes a second coating step of coating the adhesive composition onto the second optical film, a bonding step of bonding the functional layer surface of the optical film and the coated surface of the adhesive composition of the second optical film together, and an adhesion step of bonding the optical film and the second optical film via an adhesive layer formed by irradiating with active energy rays from the optical film side or the second optical film side to cure at least the adhesive composition.Each step will be described below.The coating step can be carried out by the same method as the coating step described in the method for manufacturing a functional layer optical film.Other steps will be described below.

[0088] (Lamination process) The optical film and the second optical film are laminated together. When laminating the optical film and the second optical film via an adhesive composition, a roll laminator or the like is used.

[0089] (Adhesion process) The iodine-based polarizer and the second optical film (phase difference film) are bonded together via an adhesive layer formed by curing at least the adhesive composition by irradiating the optical film side or the second optical film (phase difference film) side with active energy rays. The irradiation direction of the active energy rays (electron beam, ultraviolet light, visible light, etc.) can be any appropriate direction.

[0090] When irradiating with an electron beam, any suitable irradiation conditions can be adopted, as long as they are conditions that can at least cure the adhesive composition. For example, the acceleration voltage for electron beam irradiation is preferably 5kV to 300kV, and more preferably 10kV to 250kV. If the acceleration voltage is less than 5kV, the electron beam may not reach the adhesive, resulting in insufficient curing. If the acceleration voltage exceeds 300kV, the penetrating force through the sample may be too strong, potentially damaging the iodine-based polarizer and the second optical film (phase difference film). The irradiation dose is 5 to 100kGy, more preferably 10 to 75kGy. If the irradiation dose is less than 5kGy, the adhesive will not cure sufficiently. If it exceeds 100kGy, it will damage the iodine-based polarizer and the second optical film (phase difference film), causing a decrease in mechanical strength and yellowing, making it impossible to obtain the desired optical properties.

[0091] Electron beam irradiation is usually performed in an inert gas environment, but if necessary, it can also be performed in air or under conditions with a small amount of oxygen introduced. Depending on the materials of the optical film and the second optical film, by appropriately introducing oxygen, oxygen inhibition can be intentionally caused on the optical film surface and the second optical film surface that are initially hit by the electron beam, thereby preventing damage to the optical film and the second optical film, and allowing the electron beam to be efficiently directed only at the adhesive.

[0092] In the method for manufacturing a laminated optical film according to the present invention, it is preferable to use an active energy ray that includes visible light in the wavelength range of 380 nm to 450 nm, and more particularly, an active energy ray that has the highest irradiation amount of visible light in the wavelength range of 380 nm to 450 nm. In the method for manufacturing a laminated optical film according to the present invention, as the active energy ray, a gallium-filled metal halide lamp or an LED light source that emits light in the wavelength range of 380 to 440 nm is preferred. Alternatively, a light source containing ultraviolet and visible light such as a low-pressure mercury lamp, medium-pressure mercury lamp, high-pressure mercury lamp, ultra-high-pressure mercury lamp, incandescent bulb, xenon lamp, halogen lamp, carbon arc lamp, metal halide lamp, fluorescent lamp, tungsten lamp, gallium lamp, excimer laser, or sunlight can be used, and ultraviolet light with wavelengths shorter than 380 nm can also be blocked using a bandpass filter. To improve the adhesion performance of the adhesive layer between the optical film and the second optical film while preventing curling of the laminated optical film, it is preferable to use a gallium-filled metal halide lamp and active energy rays obtained through a bandpass filter capable of blocking light with wavelengths shorter than 380 nm, or to use active energy rays with a wavelength of 405 nm obtained using an LED light source.

[0093] When manufacturing the laminated optical film according to the present invention in a continuous line, the line speed depends on the curing time of the adhesive composition, but is preferably 1 to 500 m / min, more preferably 5 to 300 m / min, and even more preferably 10 to 100 m / min. If the line speed is too low, productivity will be poor, or the damage to the optical film and the second optical film will be too great, making it impossible to produce a laminated optical film that can withstand durability tests. If the line speed is too high, the curing of the adhesive composition will be insufficient, and the desired adhesion may not be obtained.

[0094] (Laminated optical film) The laminated optical film produced by the method for manufacturing a laminated optical film according to the present invention can be preferably used for forming various image display devices such as organic EL displays and liquid crystal displays. The formation of organic EL displays and liquid crystal displays can be carried out in accordance with conventional methods. That is, liquid crystal displays are generally formed by assembling components such as liquid crystal cells, polarizing films or optical films, and, if necessary, lighting systems, and incorporating drive circuits. However, the present invention is not particularly limited except for the use of the laminated optical film according to the present invention, and can be carried out in accordance with conventional methods. Any type of liquid crystal cell can be used, such as TN type, STN type, or π type.

[0095] Appropriate liquid crystal display devices can be formed, such as liquid crystal display devices in which optical laminates are arranged on one or both sides of a liquid crystal cell, or in which a backlight or reflector is used in the illumination system. In this case, the optical laminate according to the present invention can be installed on one or both sides of the liquid crystal cell. When optical laminates are provided on both sides, they may be the same or different. Furthermore, when forming a liquid crystal display device, appropriate components such as diffusers, anti-glare layers, anti-reflective films, protective plates, prism arrays, lens array sheets, light diffusers, and backlights can be arranged in appropriate positions in one or more layers. [Examples]

[0096] The following describes some embodiments of the present invention, but the embodiments of the present invention are not limited to these.

[0097] <Iodine-based polarizers> A laminate was formed by air-assisted stretching at a stretching temperature of 130°C from an amorphous PET substrate with a 9 μm thick PVA layer. Next, a colored laminate was formed by dyeing the stretched laminate. Furthermore, an optical film laminate containing a 5 μm thick PVA layer was formed by stretching the colored laminate in boric acid water at a stretching temperature of 65°C, integrally with the amorphous PET substrate, to achieve a total stretching ratio of 5.94 times. Through this two-stage stretching, an optical film laminate containing a 5 μm thick PVA layer (iodine-based polarizer) was obtained, in which the PVA molecules of the PVA layer formed on the amorphous PET substrate were highly oriented, and the iodine adsorbed by dyeing was highly oriented in one direction as a polyiodide ion complex, forming a thin polarizer.

[0098] The materials constituting the radical polymerizable curable compositions used in Examples 1-7 and Comparative Examples 1-2 are as follows: (curable component) • Tricyclodecanedimethanol diacrylate: Trade name "Light Acrylate DCP-A", manufactured by Kyoeisha Chemical Co., Ltd. (Compound listed in (A1)) • Isobornyl acrylate: Trade name "IB-XA", manufactured by Osaka Organic Chemical Industry Co., Ltd., (compound listed in (A2)) • 4-Hydroxybutyl acrylate: Trade name "4-HBA", manufactured by Osaka Organic Industry Co., Ltd. (Photopolymerization initiator) • 2,4-Diethylthioxanthone: Trade name "DETX-S", manufactured by Nippon Kayaku Co., Ltd. • Bis(2,4,6-trimethylbenzoyl)phenylphosphine oxide: trade name "Omnirad 819", manufactured by IGM Resins BV. • 1-Hydroxycyclohexyl-phenyl ketone: Trade name "Omnirad 184", manufactured by IGM Resins BV. (Amino-based photopolymerization initiator) · 4,4'-Bis(diethylamino)benzophenone: Trade name "Omnirad EMK", manufactured by IGM Resins BV. • Ethyl-4-(dimethylamino) benzoate: Trade name "Omnirad EDB", manufactured by IGM Resins BV. • Polyfunctional amine: Trade name "ESACURE A198", manufactured by IGM Resins BV. (Thiol compounds) • Pentaerythritol tetrakis(3-mercaptobutyrate): Product name "Kalenz MT-PE1", manufactured by Showa Denko Corporation

[0099] <Optical film with functional layer> The PVA layer surface of an optical film laminate containing a PVA layer (iodine-based polarizer) was treated with a corona treatment machine at a processing density of 50 W·min / m². 2 Corona treatment was performed on the corona-treated surface. The radical polymerizable curable compositions used in Examples 1-7 and Comparative Examples 1-2 were coated to a coating thickness of 4 μm using an MCD coater (manufactured by Fuji Machinery Co., Ltd.) (cell shape: honeycomb, gravure roll line count: 250 lines / inch, opening ratio of cells formed on the gravure roll: 40%, rotation speed 120% / line speed) (coating process). The coating thickness was measured using a spectroscopic interferometry film thickness meter (manufactured by Ocean Optics: spectrometer "USB2000+", light source "HL-2000", fiber "OCF-103995").

[0100] In the PVA layer (iodine-based polarizer) of an optical film laminate, a radical polymerizable curable composition coating surface was irradiated with light having a maximum emission wavelength of 365 nm using a UV-LED device (manufactured by Iwasaki Electric Co., Ltd., product name "e-CURE") to cure the radical polymerizable curable compositions used in Examples 1-7 and Comparative Examples 1-2, thereby producing iodine-based polarizers with a barrier functional layer (thickness 4 μm). After the irradiation process, the amorphous PET substrate was peeled off from the PVA layer (iodine-based polarizer).

[0101] The photocurability of the barrier functional layers formed by curing the radical polymerizable curable compositions used in Examples 1-7 and Comparative Examples 1-2 was evaluated by the following method.

[0102] (Radical polymerizable curable composition) Photocurable barrier layer The coated curable composition was irradiated with active energy rays. The surface of the coating was then rubbed with a cloth, and it was judged as follows: × if it was completely liquid, △ if it was not liquid but had many scratches or scratches, ○ if there were almost no scratches on the coating, and ◎ if there were no scratches at all and no tackiness was felt.

[0103] [Table 1]

[0104] The results in Table 1 show that the radical polymerizable curable compositions used in Examples 1-7 reliably cure even in an atmospheric environment with an oxygen concentration of 21%, forming a barrier layer capable of imparting barrier function to iodine-based polarizers. On the other hand, the radical polymerizable curable compositions used in Comparative Examples 1-2 exhibit significantly poor curability, even at a low oxygen concentration of 5%, because they do not contain either an amino-based photopolymerization initiator or a thiol compound. Therefore, it is clear that they cannot form a barrier layer capable of imparting barrier function to iodine-based polarizers. [Explanation of Symbols]

[0105] A. Image display device, 1. Iodine-based polarizer, 2. Barrier layer, 3. Adhesive layer, 4. Phase difference film, 5. Adhesive layer, 6. Second adhesive layer, 7. Transparent protective film, 8. Organic light-emitting diode panel, 10. Laminated optical film

Claims

1. A method for manufacturing an optical film with a functional layer, wherein a functional layer is laminated onto an optical film, A coating step of coating the optical film with a radical polymerizable curable composition, The method comprises an irradiation step of curing at least a portion of the radical polymerizable curable composition by irradiating the coated surface of the optical film with active energy rays, The irradiation step is a step of irradiating with the activated energy ray in an atmosphere with an oxygen concentration of 5% or more. The radical polymerizable curable composition contains at least one selected from the group consisting of amino-based photopolymerization initiators and thiol compounds. A method for manufacturing an optical film with a functional layer, characterized in that the thickness of the functional layer is less than 5 μm.

2. The method for producing an optical film with a functional layer according to claim 1, wherein the amino-based photopolymerization initiator is a compound containing a tertiary amino group.

3. The method for producing an optical film with a functional layer according to claim 1, wherein the amino-based photopolymerization initiator is a benzophenone-based photopolymerization initiator or an acetophenone-based photopolymerization initiator.

4. The method for producing an optical film with a functional layer according to claim 1, wherein the radical polymerizable curable composition contains at least the amino-based photopolymerization initiator, and when the total amount of curable components is 100 parts by mass, it contains 1 to 10 parts by mass of the amino-based photopolymerization initiator.

5. The method for producing an optical film with a functional layer according to claim 1, wherein the thiol compound is a compound having at least two or more secondary mercapto groups.

6. The method for producing an optical film with a functional layer according to claim 1, wherein the radical polymerizable curable composition contains at least the thiol compound, and when the total amount of curable components is 100 parts by mass, it contains 1 to 30 parts by mass of the thiol compound.

7. The method for producing an optical film with a functional layer according to claim 1, wherein the radical polymerizable curable composition contains the amino-based photopolymerization initiator and the thiol compound, and when the total amount of curable components is 100 parts by mass, it contains 1 to 5 parts by mass of the amino-based photopolymerization initiator and 1 to 10 parts by mass of the thiol compound.

8. The method for manufacturing an optical film with a functional layer according to claim 1, wherein the irradiation step is a step of irradiating the coated surface of the optical film with the radical polymerizable curable composition with a UV-LED light source having a maximum emission wavelength in the wavelength range of 280 to 420 nm as the active energy ray.

9. The method for manufacturing an optical film with a functional layer according to claim 1, wherein the optical film is an iodine-based polarizer.

10. A method for manufacturing a laminated optical film in which at least an optical film and a second optical film are laminated with an adhesive layer in between, The optical film is a functional layer optical film manufactured by the method for manufacturing a functional layer optical film described in claim 1. The adhesive layer is a cured layer of the adhesive composition, A second coating step of applying the adhesive composition to the second optical film, A method for manufacturing a laminated optical film, comprising: a bonding step of bonding the functional layer surface of the optical film and the coated surface of the adhesive composition of the second optical film; and an adhesion step of bonding the optical film and the second optical film via an adhesive layer formed by irradiating at least the adhesive composition with active energy rays from the optical film side or the second optical film side.

11. The method for manufacturing a laminated optical film according to claim 10, wherein the optical film is a polarizer.

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