# Patent

## Title
Optical film, and polarizing plate and liquid crystal display device employing same

## Abstract

The invention is an optical film at least containing cellulose acylate and a compound having a structure denoted by General Formula (I) described below, and a polarizing plate and a liquid crystal display device employing the optical film.




R1 and R3 represent a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group, and R5a and R5b represent an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, an aryl group, or a heterocyclic group. R1, R3, R5a, and R5b may have a substituent group.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of PCT International Application No. PCT/JP2014/068357 filed on Jul. 9, 2014, which was published under PCT Article 21(2) in Japanese, which claims priority under 35 U.S.C. §119 (a) to Japanese Patent Application No. 2013-143707 filed in Japan on Jul. 9, 2013. The above applications are hereby expressly incorporated by reference, in their entirety, into the present application.


BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical film, and a polarizing plate and a liquid crystal display device employing the same.
2. Description of the Related Art
An optical film such as a cellulose acylate film has been used in various liquid crystal display devices as an optical member of the liquid crystal display device, for example, a support of an optical compensation film, a protective film of a polarizing plate, and the like,
The liquid crystal display device has been used in indoor such as in a TV and for example, has been increasingly used in outdoor mainly for a portable device. For this reason, a liquid crystal display device capable of withstanding hygrothermal conditions has been required to be developed from the related art.
In addition, a demand for the liquid crystal display device to be resistant to severe usage conditions in extensively various purposes has been increased, and annually, durability has been required to be at a higher level than that of the related art.
In addition, recently, the liquid crystal display device has been enlarged and thinned mainly for a TV, and according to this, the optical film which is a configuration member is required to be thin. From the related art, it has been important for the optical film to have suitable hardness and excellent cutting properties from a viewpoint of workability, and the thinned optical film is further required to have improved hardness and cutting properties.
In the optical film using the cellulose acylate film, it has been known that a specific compound is contained in the optical film in order to solve various problems in further improving performance, in properties as the optical film, or in manufacturing.
For example, in order to suppress a variation in retardation of the optical film due to environment humidity, a barbituric acid compound (refer to JP2011-118135A) has been proposed in which one of a 5-position is a hydrogen atom and the other is a group having a specific Hammett σm or σp value. In addition, in order to enhance durability of a polarizer, a barbituric acid compound (refer to JP2011-126968A) has been proposed in which one of a 5-position is a hydrogen atom and the other is an aryl group. Both of these compounds have a hydrogen atom in the 5-position, and are compounds which physically and chemically function as an acid. In order to enhance peel property from the support body in solution casting method and to enhance durability of the polarizer by further developing these compounds, it has been also proposed that a specific organic acid is contained in the optical film (refer to JP2012-72348A).
SUMMARY OF THE INVENTION
As a result of intensive studies of the present inventors, it has been found that, in the thinned cellulose acylate film, in order to maintain the same level of workability as that of a film having a sufficient thickness as in the related art, it is necessary to make brittleness and surface hardness compatible. In the study of the present inventors, it has been found that an effect of increasing hardness of the optical film is exhibited in a compound of a part of derivatives of the barbituric acid functioning as an acid. However, as a result of examination of durability in various conditions in addition to the enhancement in the hardness of the optical film, it has been obvious that a new problem occurs in which the optical film is colored in specific conditions.
For this reason, an object of the present invention is to provide an optical film in which hardness and light resistance of the optical film are able to be improved, and in particular, coloration of the optical film in optical durability is able to be suppressed, and a polarizing plate and a liquid crystal display device in which these optical properties are maintained by using the optical film, and durability including display unevenness is enhanced.
The present inventors have variously studied a barbituric acid compound, and as a result thereof, it has been found that a barbituric acid compound which does not function as an acid is effective for attaining the object described above, and thus the present invention has been completed.
That is, the object described above is attained by the following means.
<1> An optical film containing cellulose acylate and at least one type of a compound denoted by General Formula (I) described below.




In General Formula (I), R1 and R3 each independently represent a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group, and R5a and R5b each independently represent an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, an aryl group, or a heterocyclic group.
<2> The optical film according to <1>, in which the total number of ring structures existing in R1, R3, R5a, and R5b described above is greater than or equal to 2.
<3> The optical film according to <1> or <2>, in which at least one of R1 and R3 described above is an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group.
<4> The optical film according to any one of <1> to <3>, in which at least one of R5a and R5b described above does not have a ring structure.
<5> The optical film according to any one of <1> to <4> in which at least one of R5a and R5b described above is a substituent group having carbon atoms of less than or equal to 4.
<6> The optical film according to any one of <1> to <5>, in which at least one of R5a and R5b described above is a substituent group having carbon atoms of less than or equal to 4, and the other is a substituent group having a ring structure.
<7> The optical film according to any one of <1> to <6>, in which at least one of R1 and R3 described above is an alkyl group or an aryl group having an aryl group as a substituent group.
<8> The optical film according to any one of <1> to <7>, in which the cellulose acylate is cellulose acylate in which a total degree of acyl substitution A satisfies the following expression.

1.5≦A≦3.0

<9> The optical film according to any one of <1> to <8>, in which the cellulose acylate is cellulose acylate in which an acyl group is an acetyl group, and a total degree of acetyl substitution B satisfies the following expression.

2.0≦B≦3.0

<10> The optical film according to any one of <1> to <9>, wherein the optical film comprises at least two layers, in which a hard coat layer is laminated on a layer containing the cellulose acylate and at least one type of the compound denoted by General Formula (I) described above.
<11> A polarizing plate including a polarizer; and the optical film according to any one of <1> to <10> on at least one surface of the polarizer.
<12> A liquid crystal display device, at least including the polarizing plate according to <11>; and a liquid crystal cell.
Herein, a numerical range denoted by using “to” indicates a range including numerical values described before and after “to” as a lower limit value and an upper limit value.
Here, herein, unless otherwise stated, a group capable of having a substituent group (for example, a group having an alkyl site, an aryl site, and a hetero ring site) may have a substituent group. For example, the alkyl group is an alkyl group which may have a substituent group, and the aryl group or the aromatic group is an aryl group or an aromatic group which may have a substituent group.
In addition, when at least two substituent groups are included in the same atom, and when the adjacent bonded atoms respectively have the substituent groups, these substituent groups may form a ring by being bonded to each other.
Further, when a plurality of groups having the same code exist or when a plurality of groups having the same code exist due to a plurality of repetitions, these groups may be identical to each other or different from each other.
Herein, when a plurality of substituent groups or connecting groups (hereinafter, referred to as a substituent group and the like) are concurrently or selectively defined, the respective substituent groups and the like may be identical to each other or different from each other.
According to the present invention, it is possible to provide an optical film in which hardness and light resistance of the optical film are able to be improved, and in particular, coloration of the optical film in optical durability is able to be suppressed, and a polarizing plate and a liquid crystal display device in which these optical properties are maintained by using the optical film, and durability including display unevenness is enhanced.
The above-described and other characteristics, and advantages of the present invention will be obvious from the following description with suitable reference to the drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example schematically illustrating an inner structure of a liquid crystal display device of the present invention.
FIG. 2 is an example schematically illustrating an inner structure of another liquid crystal display device of the present invention.



DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described in detail with reference to embodiments.
[Optical Film]
An optical film of the present invention is formed of at least one layer of a cellulose acylate film containing cellulose acylate and at least one type of a compound denoted by General Formula (I). In addition, the cellulose acylate film may be configured of a plurality of layers, and the compound denoted by General Formula (I) may be contained in any one of the layers or in all layers.
Here, a cellulose acylate film or a cellulose acylate layer indicates that cellulose acylate is contained in a resin component configuring the film or the layer in the amount of greater than or equal to 50 mass %. Here, the content of the cellulose acylate in the resin component is preferably greater than or equal to 60 mass %, is more preferably greater than or equal to 70 mass %, is even more preferably greater than or equal to 80 mass %, and is particularly preferably greater than or equal to 85 mass %. Furthermore, the upper limit of the content of the cellulose acylate is not particularly limited.
On the other hand, in addition to the layer containing the cellulose acylate as described above in the amount of greater than or equal to 50 mass %, the optical film of the present invention may form a multi-layered configuration along with another layer in which the cellulose acylate is not contained as the resin component, or even when the cellulose acylate is contained, the content of the cellulose acylate is less than 50 mass % of the total resin component. Examples of such a layer include various functional layers specialized for a specific function, and examples of the functional layer include a hard coat layer and the like.
The optical film of the present invention is useful for various purposes such as a polarizing plate protective film and a surface protective film arranged on an image display surface.
<<Cellulose Acrylate Film>>
In the present invention, as described above, the cellulose acylate film is formed of a film in which a ratio of cellulose acylate in a resin constituent is greater than or equal to 50 mass %, and is the optical film of the present invention in the narrow sense.
The cellulose acylate film may be a single layer, or a laminated body of two or more layers. However, the layer herein indicates a layer which does not include the functional layer as described above, but contains cellulose acylate in the amount of greater than or equal to 50 mass % with respect to the total resin component. When the cellulose acylate film is a laminated body of two or more layers, it is preferable that the cellulose acylate film has a two-layer structure or a three-layer structure, and it is more preferable that the cellulose acylate film has the three-layer structure. When the cellulose acylate film has the three-layer structure, it is preferable that the cellulose acylate film includes a core layer of one layer (that is, the thickest layer, and hereinafter, referred to as a base layer), and a skin layer A and a skin layer B interposing the core layer therebetween. That is, it is preferable that the cellulose acylate film of the present invention has a three-layer structure of the skin layer B/the core layer/the skin layer A. Such a laminated body is able to be manufactured by various casting methods such as cocasting described below. The skin layer B is a layer which is in contact with a metal support body described below at the time of manufacturing the cellulose acylate film by using solution film formation, and the skin layer A is an air interface layer on a side opposite to the metal support body side. Furthermore, the skin layer A and the skin layer B are collectively referred to as a skin layer (or a surface layer).
In the present invention, the cellulose acylate film contains cellulose acylate and at least one type of a compound denoted by General Formula (I) described below.
<Compound Denoted by General Formula (I)>




In General Formula (I), R1 and R3 each independently represent a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group, and R5a and R5b each independently represent an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, an aryl group, or a heterocyclic group. These R1, R3, R5a, and R5b may have a substituent group.
A mechanism in which the compound denoted by General Formula (I)contributes to the effect of the present invention is uncertain, and is estimated as follows.
The compound denoted by General Formula (I) generates a mutual interaction due to hydrogen bonding with respect to cellulose acylate, and is able to exist in the vicinity of a main chain of the cellulose acylate. As a result thereof, it is considered that a free volume in cellulose acylate of the film is reduced, and thus the compound contributes to improvement or maintenance of hardness.
In addition, in the compound denoted by General Formula (I), a 5-position is not substituted with a hydrogen atom, and thus enol is not generated. According to such a structure, it is considered that the absorption wavelength of the compound denoted by General Formula (I) becomes a short wavelength, and light absorption in a long wavelength ultraviolet region is able to be suppressed, and thus the coloration of the optical film is able to be suppressed under an environment exposure light, and the compound contributes to provision of a liquid crystal display device having excellent display performance.
In General Formula (I), the number of carbon atoms of the alkyl group of R1, R3, R5a, and R5b is preferably 1 to 20, is more preferably 1 to 10, and is even more preferably 1 to 5.
Examples of the alkyl group include methyl, ethyl, isopropyl, t-butyl, 2-ethyl hexyl, n-octyl, n-decyl, n-octadecyl, and isooctadecyl.
In addition, the alkyl group may have a substituent group, and examples of such a substituent group include a substituent group S described below.
[Substituent Group S]
Examples of the substituent group S include an alkyl group (preferably an alkyl group having 1 to 20 carbon atoms, for example, methyl, ethyl, isopropyl, t-butyl, pentyl, heptyl, 1-ethyl pentyl, 2-ethyl hexyl, benzyl, and the like), an alkenyl group (preferably an alkenyl group having 2 to 20 carbon atoms, for example, vinyl, allyl, oleyl, and the like), an alkynyl group (preferably an alkynyl group having 2 to 20 carbon atoms, for example, ethynyl, 2-butynyl, phenyl ethynyl, and the like), a cycloalkyl group (preferably a cycloalkyl group having 3 to 20 carbon atoms, for example, cyclopropyl, cyclopentyl, cyclohexyl, 4-methyl cyclohexyl, and the like), an aryl group (preferably an aryl group having 6 to 20 carbon atoms, for example, phenyl, 1-naphthyl, 4-methoxy phenyl, 2-chlorophenyl, 3-methyl phenyl, and the like), a heterocyclic group (preferably a heterocyclic group having 0 to 20 carbon atoms, an oxygen atom, a nitrogen atom, and a sulfur atom are preferable as a ring configuring hetero atom, a ring may be condensed with a benzene ring or a hetero ring in a 5-membered ring or 6-membered ring, or a ring may be a saturated ring, an unsaturated ring, and an aromatic ring, for example, 2-pyridyl, 4-pyridyl, 2-imidazolyl, 2-benzimidazolyl, 2-thiazolyl, 2-oxazolyl, and the like), an alkoxy group (preferably an alkoxy group having 1 to 20 carbon atoms, for example, methoxy, ethoxy, isopropyl oxy, benzyl oxy, and the like), an aryl oxy group (preferably an aryl oxy group having 6 to 20 carbon atoms, for example, phenoxy, 1-naphthyl oxy 3-methyl phenoxy, 4-methoxy phenoxy, and the like),
an alkylthio group (preferably an alkylthio group having 1 to 20 carbon atoms, for example, methylthio, ethylthio, isopropylthio, benzylthio, and the like), an arylthio group (preferably an arylthio group having 6 to 20 carbon atoms, for example, phenylthio, 1-naphthylthio, 3-methyl phenylthio, 4-methoxy phenylthio, and the like), an acyl group (including an alkyl carbonyl group, an alkenyl carbonyl group, an aryl carbonyl group, and a heterocyclic carbonyl group, preferably an acyl group having carbon atoms of less than or equal to 20, for example, acetyl pivaloyl, acryloyl, methacryloyl, benzoyl, nicotinoyl, and the like), an alkoxy carbonyl group (preferably an alkoxy carbonyl group having 2 to 20 carbon atoms, for example, ethoxy carbonyl, 2-ethyl hexyl oxy carbonyl, and the like), an aryl oxy carbonyl group (preferably an aryl oxy carbonyl group having 7 to 20 carbon atoms, for example, phenyl oxy carbonyl, naphthyl oxy carbonyl, and the like), an amino group (including an amino group, an alkyl amino group, an aryl amino group, and a heterocyclic amino group, preferably an amino group having 0 to 20 carbon atoms, for example, amino, N,N-dimethyl amino, N,N-diethyl amino, N-ethyl amino, anilino, 1-pyrrolidinyl, piperidino, morphonyl, and the like), a sulfone amide group of alkyl or aryl (preferably a sulfone amide group having 0 to 20 carbon atoms, for example, N,N-dimethyl sulfone amide, N-phenyl sulfone amide, and the like) a sulfamoyl group of alkyl or aryl (preferably a sulfamoyl group having 0 to 20 carbon atoms, for example, N,N-dimethyl sulfamoyl, N-phenyl sulfamoyl, and the like), an acyl oxy group (preferably an acyl oxy group having 1 to 20 carbon atoms, for example, acetyl oxy, benzoyl oxy, and the like), a carbamoyl group of alkyl or aryl (preferably a carbamoyl group having 1 to 20 carbon atoms, for example, N,N-dimethyl carbamoyl, N-phenyl carbamoyl, and the like), an acyl amino group (preferably an acyl amino group having 1 to 20 carbon atoms, for example, acetyl amino, acryloyl amino, benzoyl amino, nicotine amide, and the like), a cyano group, a hydroxy group, a mercapto group, a carboxyl group, or a halogen atom (for example, a fluorine atom, a chlorine atom, a bromine atom, an iodine atom, and the like).
These substituent groups may further substituted with a substituent group, and examples of such a substituent group include the substituent groups S described above.
For example, an aralkyl group in which an alkyl group is substituted with an aryl group, a group in which an alkyl group is substituted with an alkoxy carbonyl group or a cyano group, and the like are exemplified.
An aryl group, an alkoxy carbonyl group, and a cyano group are preferable as the substituent group included in the alkyl group of R1, R3, R5a, and R5b.
Examples of such a substituted alkyl group include an aralkyl group (preferably a benzyl group) and an alkyl group in which a 2-position or a 3-position is substituted with an alkoxy carbonyl group or a cyano group [preferably a 1-alkoxy carbonyl methyl group, a 2-(alkoxy carbonyl)ethyl group, and a 2-cyanoethyl group].
The number of carbon atoms of the alkenyl group of R1, R3, R5a, and R5b in General Formula (I) is preferably 2 to 20, is more preferably 2 to 10, and is even more preferably 2 to 5.
Examples of the alkenyl group include vinyl, allyl, isopropenyl, 2-pentenyl, and oleyl.
In addition, the alkenyl group may have a substituent group, and examples of such a substituent group include the substituent groups S described above,
The number of carbon atoms of the cycloalkyl group of R1, R3, R5a, and R5b in General Formula (I) is preferably 3 to 20, is more preferably 3 to 10, and is even more preferably 3 to 6.
Examples of the cycloalkyl group include cyclopropyl, cyclopentyl, and cyclohexyl.
In addition, the cycloalkyl group may have a substituent group, and examples of such a substituent group include the substituent groups S described above.
The number of carbon atoms of the cycloalkenyl group of R1, R3, R5a, and R5b in General Formula (I) is preferably 5 to 20, is more preferably 5 to 10, and is even more preferably 5 or 6.
Examples of the cycloalkenyl group include cyclopentenyl and cyclohexenyl.
In addition, the cycloalkenyl group may have a substituent group, and examples of such a substituent group include the substituent groups S described above.
The number of carbon atoms of the aryl group of R1, R3, R5a, and R5b in General Formula (1) is preferably 6 to 20, is more preferably 6 to 10, and is even more preferably 6 to 8.
Examples of the aryl group include phenyl and naphthyl.
In addition, the aryl group may have a substituent group, and examples of such a substituent group include the substituent groups S described above.
The number of carbon atoms of the heterocyclic group of R5a, and R5b in General Formula (1) is preferably 0 to 20, is more preferably 1 to 10, is even more preferably 2 to 10, and is particularly preferably 2 to 5.
A hetero ring of a 5-membered ring or a 6-membered ring is preferable as a hetero ring of the heterocyclic group, and the hetero ring may be substituted with a substituent group, or may be a ring condensed with a benzene ring, an aliphatic ring, or a hetero ring. Here, examples of the substituent group include the substituent groups S described above.
Examples of a hetero atom configuring the hetero ring of the heterocyclic group include a nitrogen atom, an oxygen atom, or a sulfur atom, and the hetero ring may be a heteroaromatic ring or may be a hetero ring which is not an aromatic ring.
Examples of the hetero ring of the heterocyclic group include a thiophene ring, a furan ring, a pyrrole ring, a pyrazole ring, an imidazole ring, a thiazole ring, an oxazole ring, a triazole ring, a tetrazole ring, a pyridine ring, a pyrazine ring, a pyrrolidine ring, a pyrroline ring, a pyrazolidine ring, a piperidine ring, a piperazine ring, a morpholine ring, a thiomorpholine ring, and a benzene condensed ring thereof (for example, an indole ring, a benzimidazole ring, and the like).
In the present invention, in R1 and R3, it is preferable that at least one of R1 and R3 is an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group. In addition, it is also preferable that at least one of R1 and R3 is an alkyl group or an aryl group having an aryl group as a substituent group.
On the other hand, in R5a and R5b, it is preferable that at least one of R5a and R5b does not have a ring structure. In addition, it is more preferable that at least one of R5a and R5b is a substituent group having carbon atoms of less than or equal to 4, and it is even more preferable that at least one of R5a and R5b is a substituent group having carbon atoms of less than or equal to 4, and the other is a substituent group having a ring structure,
In General Formula (I), a preferred compound is the following compound.
(1) A compound in which at least one of R1 and R3 is an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group.
Among them, a case where the other is a hydrogen atom is more preferable.
(2) A compound in which at least one of R1 and R3 is a substituted alkyl group, and a substituent group of the substituted alkyl group is an aryl group, an alkoxy carbonyl group, or a cyano group.
(3) A compound in which at least one of R1, R3, R5a, and R5b has an aromatic ring.
(4) A compound in which at least one of R1, R3, R5a, and R5b has a cycloalkyl group or a cycloalkenyl group.
(5) A compound in which R1, R3, R5a, and R5b have two or more ring structures in total.
At this time, it is more preferable that a ring of the ring structure is a ring structure selected from an aromatic ring, a cycloalkyl ring, or a cycloalkenyl ring. In addition, the total number of ring structures is preferably 2 to 4, and is more preferably 2 or 3.
(6) A compound in which R5a or R5b is a substituted alkyl group, and a substituent group of the substituted alkyl group is an aryl group, an alkoxy carbonyl group, or a cyano group.
(7) A compound in which R5a or R5b is a group selected from a benzyl group, an alkyl group, and an aryl group.
In particular, a compound in which R5a or R5b is a group selected from a benzyl group, a phenyl group, and a non-substituted alkyl group having 1 to 4 carbon atoms (preferably methyl) is included.
(8) A compound in which at least one of R5a and R5b does not have a ring structure.
Hereinafter, a specific example of the compound denoted by General Formula (I) of the present invention will be described, but the present invention is not limited thereto.



















It has been known that the compound denoted by General Formula (1) described above is able to be synthesized by using a synthesis method of a barbituric acid in which a urea derivative and a malonic acid derivative are condensed. The barbituric acid having two substituent groups on N is obtained by heating N,N′-disubstituted urea and malonic acid chloride, or by mixing and heating N,N′-disubstituted urea and an activation agent such as a malonic acid and an acetic anhydride. For example, methods disclosed in Journal of the American Chemical Society, Vol. 61, P. 1015 (1939), Journal of Medicinal Chemistry, Vol. 54, P. 2409 (2011), Tetrahedron Letters, Vol. 40, P. 8029 (1999), WO2007/150011A, and the like are able to be preferably used.
Here, the malonic acid used in the condensation may be a non-substituted malonic acid or may have a substituent group, and when a malonic acid having substituent groups corresponding to R5a and R5b is used, the compound denoted by General Formula (I) of the present invention is able to be synthesized by constituting a barbituric acid. In addition, a nucleophilic substitution reaction, a Michael addition reaction, or the like is performed with respect to a barbituric acid having a non-substituted 5-position which is obtained by condensing a non-substituted malonic acid and a urea derivative, and thus the compound denoted by General Formula (I) of the present invention is able to be synthesized.
Furthermore, the synthesis method of the compound denoted by General Formula (I) of the present invention is not limited the above description.
The content of the compound denoted by General Formula (I) in the cellulose acylate film is not particularly limited. However, the content of the compound denoted by General Formula (I) in the cellulose acylate film is preferably 0.1 parts by mass to 50 parts by mass, is more preferably 0.2 parts by mass to 30 parts by mass, is even more preferably 0.3 parts by mass to 15 parts by mass, and is particularly preferably 0.3 parts by mass to 10 parts by mass, with respect to 100 parts by mass of cellulose acylate. According to such a content, hardness and suppression of coloration of the optical film which are the effects of the present invention are sufficiently expressed, and transparency of the film is also maintained.
In addition, even when two or more types of compounds denoted by General Formula (I) are contained in the cellulose acylate film, it is preferable that the total amount is in the range described above.
<Cellulose Acylate>
In the present invention, one type of cellulose acylate which is a main component of the cellulose acylate film may be used, or two or more types thereof may be used. For example, the cellulose acylate may be cellulose acetate formed only of an acetyl group as an acyl substituent group, may be cellulose acylate having a plurality of different acyl substituent groups, or may be a mixture of different cellulose acylates.
Examples of cellulose which is a raw material of the cellulose acylate used in the present invention include cotton linter, wood pulp (broad leaf wood pulp and conifer wood pulp), and the like, cellulose obtained from any raw material cellulose is also able to be used, and according to a case, cellulose may be used by being mixed. For example, celluloses disclosed in Lecture of Plastic Materials (17) Cellulose-Based Resin (by MARUSAWA and UDA, The Nikkan Kogyo Shimbun, Ltd., Published in 1970) or Japan Institute of Invention and Innovation Disclosure 2001-1745 (Pages 7 to 8) are able to be used as the raw material cellulose.
In the present invention, the acyl group of the cellulose acylate may be only one type acyl group, or two or more types of acyl groups may be used. It is preferable that the cellulose acylate used in the present invention has an acyl group having carbon atoms of greater than or equal to 2 as a substituent group. The acyl group having carbon atoms of greater than or equal to 2 may be an aliphatic acyl group or an aromatic acyl group, but is not particularly limited. These acyl groups, for example, are an alkyl carbonyl group, an alkenyl carbonyl group or an aromatic carbonyl group, an aromatic alkyl carbonyl group, and the like of cellulose, and each further have a substituent group. Preferred examples of the acyl group include acetyl, propionyl, butanoyl, heptanoyl, hexanoyl, octanoyl, decanoyl, dodecanoyl, tridecanoyl, tetradecanoyl, hexadecanoyl, octadecanoyl, isobutanoyl, t-butanoyl, cyclohexane carbonyl, oleoyl, benzoyl, naphthyl carbonyl, cinnamoyl, and the like. Among them, the acetyl, the propionyl, the butanoyl the dodecanoyl, the octadecanoyl, the t-butanoyl, the oleoyl, the benzoyl, the naphthyl carbonyl, the cinnamoyl and the like are more preferable, the acetyl, the propionyl, and the butanoyl are even more preferable.
It is preferable that the cellulose acylate used in the present invention has an acyl group having 2 to 4 carbon atoms as a substituent group. When two or more types of acyl groups are used, it is preferable that, among them, one type is an acetyl group, and a propionyl group or a butyryl group is preferable as the acyl group having 2 to 4 carbon atoms used in the other. By using such cellulose acylate, a solution having preferred solubility is able to be prepared, and in particular, in a non-chlorine-based organic solvent (for example, alcohols such as methanol and ethanol), an excellent solution is able to be prepared. Further, a solution having low viscosity and excellent filtration properties is able to be prepared.
In the present invention, in particular, it is preferable that the acyl group of the cellulose acylate is one type of acetyl group from a viewpoint of an excellent hardness enhancement effect of the compound denoted by General Formula (I).
The cellulose acylate preferably used in the present invention will be described in detail.
A β-1,4 bonding glucose unit configuring the cellulose has a free hydroxy group in a 2-position, in a 3-position, and in a 6-position. The cellulose acylate is a polymer in which a part of all of these hydroxy groups is acylated by the acyl group.
An degree of acyl substitution indicates a degree of acylation of the hydroxy group in the cellulose, which is positioned in the 2-position, in the 3-position, and in the 6-position, and when all of the hydroxy groups in the 2-position, in the 3-position, and in the 6-position in all glucose units are acylated, the total degree of acyl substitution is 3, and for example, when all of the hydroxy groups only in the 6-position are acylated in all of the glucose units, the total degree of acyl substitution is 1. Similarly, in all of the hydroxy groups in all of the glucose units, even when all of the hydroxy groups in any one of the 6-position and the 2-position are acylated in each of the glucose units, the total degree of acyl substitution is 1.
That is, the degree of acylation is denoted by a case where all of the hydroxy groups in glucose molecules are acylated to 3.
The details of a measurement method of the degree of acyl substitution are based on a method disclosed in Carbohydrate. Res. by TEZUKA et al. 273, 83-91 (1995) or a method defined in ASTM-D817-96.
The total degree of acyl substitution A of the cellulose acylate used in the present invention is preferably greater than or equal to 1.5 and less than or equal to 3.0 (1.5≦A≦3.0), is more preferably 2.00 to 2.97, is even more preferably greater than or equal to 2.50 and less than 2.97, and is particularly preferably 2.70 to 2.95.
In addition, in cellulose acetate using only the acetyl group as the acyl group of the cellulose acylate, the total degree of acetyl substitution (B) is preferably greater than or equal to 2.0 and less than or equal to 3.0 (2.0≦B≦3.0), is more preferably 2.0 to 2.97, is even more preferably greater than or equal to 2.5 and less than 2.97, and is still more preferably greater than or equal to 2.55 and less than 2.97, is particularly preferably 2.60 to 2.96 and is most preferably 2.70 to 2.95.
Furthermore, in the compound denoted by General Formula (I) of the present invention, the effect is particularly expressed with respect to cellulose acylate in which the total degree of acetyl substitution B is greater than 2.50.
When the cellulose acylate film of the optical film of the present invention is a laminated body (a multi-layered configuration), in the cellulose acylate film, the total degrees of acyl group substitution A of cellulose acylates in each of the layers may be identical to each other or different from each other, and a plurality of cellulose acylates may be mixed in one layer.
In the acylation of cellulose, when an acid anhydride or an acid chloride is used as an acylation agent, methylene chloride or an organic acid such as an acetic acid is used as an organic solvent which is a reaction solvent.
When the acylation agent is the acid anhydride, a protonic catalyst such as a sulfuric acid is preferably used as a catalyst, and when the acylation agent is the acid chloride (for example, CH3C2COCl), a basic compound is used as a catalyst.
An industrial synthesize method of mixed fatty acid ester which is the most general cellulose is a method in which cellulose is acylated by a fatty acid an acetic acid, a propionic acid, a valeric acid, and the like) corresponding to an acetyl group and other acyl groups or a mixed organic acid component including acid anhydrides thereof.
The cellulose acylate, for example, is able to be synthesized by using a method disclosed in JP1998-45804A (JP-H10-45804A).
The film of the present invention, in particular, the cellulose acylate film used in the present invention, preferably contains the cellulose acylate in the amount of 5 mass % to 99 mass %, more preferably contains the cellulose acylate in the amount of 20 mass % to 99 mass %, and particularly preferably contains the cellulose acylate in the amount of 50 mass % to 95 mass % in the total solid content, from a viewpoint of moisture permeability.
<Other Additives>
In the optical film of the present invention, in particular, in the cellulose acylate additives such as a retardation adjusting agent (a retardation expression agent and a retardation reduction agent), a plasticizer such as a polycondensed ester compound (a polymer), polyvalent ester of polyvalent alcohol, phthalic acid ester, and phosphoric acid ester, an ultraviolet absorbent, an antioxidant, and a matting agent are able to be added.
Furthermore, herein, a compound group is described, for example, by using “-based” such as a phosphoric acid ester-based compound. In this case, the “phosphoric acid ester-based compound” has the same meaning as that of a phosphoric acid ester compound.
(Retardation Reduction Agent)
In the present invention, a phosphoric acid ester-based compound or compounds other than a non-phosphoric acid ester-based compound which has been known as the additive of the cellulose acylate film are able to be widely adopted as the retardation reduction agent.
A high molecular retardation reduction agent is selected from a phosphoric acid polyester-based polymer, a styrene-based polymer, an acrylic polymer, and a copolymer thereof, and the acrylic polymer and the styrene-based polymer are preferable. In addition, it is preferable that at least one type of polymers having negative intrinsic birefringence such as the styrene-based polymer and the acrylic polymer is included.
Examples of a low molecular weight retardation reduction agent which is the compound other than the non-phosphoric acid ester-based compound are able to include the followings. The low molecular weight retardation reduction agent may be a solid or an oily substance. That is, the melting point or the boiling point thereof is not particularly limited. For example, ultraviolet absorbing materials having a melting point of lower than or equal to 20° C. and a melting point of higher than or equal to 20° C. are mixed, or similarly, deterioration preventive agents having a melting point of lower than or equal to 20° C. and a melting point of higher than or equal to 20° C. are mixed. In addition, examples of an infrared absorbing dye are able to include infrared absorbing dyes disclosed in JP2001-194522A. In addition, as the time of adding the materials, the materials may be added in any preparing step of a cellulose acylate solution (dope), or the addition of the materials may be performed by adding a step of adding and preparing the additive to the final preparing step of a dope preparing step. In addition, the added amount of each of the materials is not particularly limited insofar as the function is expressed.
The low molecular weight retardation reduction agent which is the compound other than the non-phosphoric acid ester-based compound is not particularly limited. Furthermore, the details thereof are disclosed in paragraphs 0066 to 0085 of JP2007-272177A.
As disclosed in JP2007-272177A, a compound denoted by General Formula (1) disclosed in paragraphs 0066 to 0085 of JP2007-272177A, is able to be obtained by a condensation reaction between a sulfonyl chloride derivative and an amine derivative.
A compound denoted by General Formula (2) disclosed in JP2007-272177A is able to be obtained by a dehydrative condensation reaction between carboxylic acids and amines using a condensation agent (for example, dicyclohexyl carbodiimide (DCC) and the like), a substitution reaction between a carboxylic acid chloride derivative and an amine derivative, and the like.
It is more preferable that retardation reduction agent is a Rth reduction agent from a viewpoint of realizing a preferred Nz factor. Here, Rth indicates retardation of the cellulose acylate film in a film thickness direction. Among the retardation reduction agents, examples of the Rth reduction agent are able to include an acrylic polymer and a styrene-based polymer, low molecular compounds denoted by General Formulas (3) to (7) disclosed in JP2007-272177A, and among them, the acrylic polymer and the styrene-based polymer are preferable, and the acrylic polymer is more preferable.
The added amount of the retardation reduction agent is preferably 0.01 parts by mass to 30 parts by mass, is more preferably 0.1 parts by mass to 20 parts by mass, and is particularly preferably 0.1 parts by mass to 10 parts by mass, with respect to 100 parts by mass of cellulose acylate. By setting the added amount to be less than or equal to 30 parts by mass, it is possible to improve compatibility with respect to a cellulose-based resin, and it is possible to prepare a film having excellent transparency. When two or more types of retardation reduction agents are used, it is preferable that the total amount is in the range described above.
(Retardation Expression Agent)
In order to express a retardation value, the optical film of the present invention may contain at least one type of retardation expression agent.
The retardation expression agent is not particularly limited, and examples of the retardation expression agent include a retardation expression agent formed of a rod-like compound or a disk-like compound, or a compound exhibiting retardation expression properties among the non-phosphoric acid ester-based compounds. As the rod-like compound or the disk-like compound, a compound having at least two aromatic rings is able to be preferably used as the retardation expression agent.
The added amount of the retardation expression agent formed of the rod-like compound is preferably 0.1 parts by mass to 30 parts by mass, and is more preferably 0.5 parts by mass to 20 parts by mass, with respect to 100 parts by mass of cellulose acylate.
The disk-like compound has more excellent Rth retardation expression properties than the rod-like compound, and thus when particularly large Rth retardation is required, the disk-like compound is preferably used. Two or more types of retardation expression agents may be used together.
It is preferable that the retardation expression agent has the maximum absorption wavelength in a wavelength region of 250 nm to 400 nm, and it is preferable that the retardation expression agent does not substantially have absorption in a visible region.
The details of the retardation expression agent are disclosed in Page 49 of Journal of Technical Disclosure 2001-1745.
The added amount of the retardation expression agent formed of the disk-like compound is preferably 0.1 parts by mass to 30 parts by mass, and is more preferably 0.5 parts by mass to 20 parts by mass, with respect to 100 parts by mass of cellulose acylate.
The added amount of the disk-like compound contained in the retardation expression agent is preferably less than 3 parts by mass, is more preferably less than 2 parts by mass, and is particularly preferably less than 1 part by mass, with respect to 100 parts by mass of cellulose acylate.
[Plasticizer (Hydrophobizing Agent)]
In the optical film, in particular, in the cellulose acylate film, a plasticizer is contained in the cellulose acylate film, moisture content or moisture permeability of the cellulose acylate film decreases, and a hydrolysis reaction of the cellulose acylate due to moisture in the cellulose acylate film is suppressed. Further, the plasticizer suppresses diffusion of the additives from the cellulose acylate film to a polarizer layer under hygrothermal conditions, and thus it is possible to reduce deterioration of polarizer performance.
The compound denoted by General Formula (I) of the present invention is contained in the optical film, in particular, in the cellulose acylate film, and thus is able to be used as the plasticizer. That is, an effect of enhancing durability including control of a glass transition temperature and a reduction in the moisture content and the moisture permeability as described above is able to be obtained, and hardness of the cellulose acylate film is also able to be high. Further, even when the compound denoted by General Formula (I) of the present invention is used together with other general-purpose plasticizers, the hardness improvement effect is able to be obtained, and thus a plurality of plasticizers may be contained together in the optical film and in the cellulose acylate film.
In the present invention, among the plasticizers used together, a multi-ester-based plasticizer is preferable in which ester groups are positionally close to each other and clogged with each other in molecules. Specifically, examples of the multi-ester-based plasticizer include a polycondensed ester compound (hereinafter, referred to as a polycondensed ester-based plasticizer), a polyvalent ester compound of polyvalent alcohol (hereinafter, referred to as a polyvalent alcohol ester-based plasticizer), and a carbohydrate compound (hereinafter, referred to as a carbohydrate derivative-based plasticizer). In the present invention, these compounds are excellent for expressing the plasticizer effect as described above.
Hereinafter, the plasticizer used in the present invention will be described.
(Polycondensed Ester-Based Plasticizer)
The polycondensed ester-based plasticizer is obtained by polycondensing a bivalent carboxylic acid compound and a diol compound.
It is preferable that the polycondensed ester-based plasticizer is obtained by polycondensing at least one type of dicarboxylic acid denoted by General Formula (a) described below and at least one type of diol denoted by General Formula (b) described below.




In General Formulas (a) and (b), X represents a bivalent aliphatic group having 2 to 18 carbon atoms, a bivalent aromatic group having 6 to 18 carbon atoms, or a bivalent hetero ring having 2 to 18 carbon atoms, and Z represents a bivalent aliphatic group having 2 to 8 carbon atoms. Here, the bivalent aliphatic group having 2 to 8 carbon atoms may be a straight-chain bivalent aliphatic group or a branched bivalent aliphatic group.
Examples of the bivalent carboxylic acid compound denoted by General Formula (a) include, as described above, an aliphatic carboxylic acid and an aromatic carboxylic acid or a heterocyclic carboxylic acid, and the aliphatic carboxylic acid or the aromatic carboxylic acid is preferable.
On the other hand, examples of the diol compound also include an aromatic compound or a heterocyclic compound in addition to the aliphatic compound denoted by General Formula (b) described above.
Among them, a polycondensed ester-based plasticizer formed of at least one type of dicarboxylic acid having aromatic ring (also referred to as an aromatic dicarboxylic acid) and at least one type of aliphatic diol in which the average number of carbon atoms is 2.5 to 8.0 is preferable. In addition, a polycondensed ester-based plasticizer formed of a mixture of an aromatic dicarboxylic acid and at least one type of aliphatic dicarboxylic acid, and at least one type of aliphatic diol in which the average number of carbon atoms is 2.5 to 8.0 is also preferable.
The number average molecular weight of the polycondensed ester-based plasticizer is preferably 500 to 2000, is more preferably 600 to 1500, and is even more preferably 700 to 1200. When the number average molecular weight of the polycondensed ester-based plasticizer is greater than or equal to 500, and is preferably greater than or equal to 600, volatility decreases, and a defect in film or step contamination due to volatilization under high temperature conditions at the time of stretching the cellulose acylate film is excellently suppressed.
In addition, when the number average molecular weight of the polycondensed ester-based plasticizer is less than or equal to 2000, compatibility with respect to the cellulose acylate increases, and bleed out at the time of film formation and at the time of heating and stretching is excellently suppressed.
When a mixture of an aromatic dicarboxylic acid and an aliphatic dicarboxylic acid is used as a dicarboxylic acid component, the average number of carbon atoms in the dicarboxylic acid component is preferably 5.5 to 10.0, and is more preferably 5.6 to 8.0.
When the average number of carbon atoms is greater than or equal to 5.5, a polarizing plate having excellent durability is able to be obtained. When the average number of carbon atoms is less than or equal to 10.0, the compatibility with respect to the cellulose acylate becomes excellent, and bleed out during the film formation of the cellulose acylate film is excellently suppressed.
Examples of the aromatic dicarboxylic acid which is able to be used for synthesizing the polycondensed ester-based plasticizer are able to include a phthalic acid, a terephthalic acid, an isophthalic acid, a 1,5-naphthalene dicarboxylic acid, a 1,4-naphthalene dicarboxylic acid, a 1,8-naphthalene dicarboxylic acid, a 2,8-naphthalene dicarboxylic acid, a 2,6-naphthalene dicarboxylic acid, and the like. Among them, the phthalic acid, the terephthalic acid, and the 2,6-naphthalene dicarboxylic acid are preferable, the phthalic acid and the terephthalic acid are more preferable, and the terephthalic acid is even more preferable.
The polycondensed ester-based plasticizer obtained from the diol compound and the dicarboxylic acid including the aliphatic dicarboxylic acid contains an aliphatic dicarboxylic acid residue.
Examples of the aliphatic dicarboxylic acid synthesizing the polycondensed ester-based plasticizer include an oxalic acid, a malonic acid, a succinic acid, a maleic acid, a fumaric acid, a glutaric acid, an adipic acid, a pimelic acid, a suberic acid, an azelaic acid, a sebacic acid, a dodecane dicarboxylic acid, a 1,4-cyclohexane dicarboxylic acid, and the like.
Examples of the diol synthesizing the polycondensed ester-based plasticizer include an aromatic diol and an aliphatic diol, and in the present invention, it is preferable that the polycondensed ester-based plasticizer is synthesized by using at least the aliphatic diol.
It is preferable that the polycondensed ester-based plasticizer contains an aliphatic diol residue in which the average number of carbon atoms is 2.5 to 7.0, and it is more preferable that the polycondensed ester-based plasticizer contains an aliphatic diol residue in which the average number of carbon atoms is 2.5 to 4.0.
When the average number of carbon atoms in the aliphatic diol residue is less than 7.0, the compatibility with respect to the cellulose acylate is enhanced, and the bleed out, an increase in heating loss of the compound, and a planar defect which is considered to be caused by the step contamination at the time of performing web drying with respect to the cellulose acylate are excellently suppressed. In addition, when the average number of carbon atoms in the aliphatic diol residue is greater than or equal to 2.5, the synthesis is easily performed.
Alkyl diols or alicyclic diols are preferable as the aliphatic diol used for synthesizing the polycondensed ester-based plasticizer, and for example, ethylene glycol, 1,2-propane diol, and 1,3-propane diol are preferable, and the ethylene glycol and the 1,2-propane diol are more preferable.
The terminal of the polycondensed ester-based plasticizer may be left as diol or a carboxylic acid (that is, a polymer long-chain terminal is —OH or CO2H) without being sealed, and may be subjected to so-called terminal sealing by allowing monocarboxylic acids or monoalcohols to react therewith. Furthermore, by sealing the terminal of the polycondensed ester-based plasticizer, it is possible to obtain a cellulose acylate film in which a state at a normal temperature is rarely turned into a solid state, handling properties become excellent, and humidity stability and durability of a polarizing plate are excellent.
Polycondensed ester-based plasticizers J-1 to J-38 disclosed in paragraphs 0062 to 0064 of JP2012-234159A are preferable as the polycondensed ester-based plasticizer.
(Polyvalent Alcohol Ester-Based Plasticizer)
The polyvalent alcohol ester-based plasticizer used in the present invention is an ester in which an alcohol portion is derived from polyvalent alcohol having two or more hydroxy groups. In addition to the hydroxy group, alcohol in which saturated hydrocarbon which may be separated through an ether bond is substituted with two or more hydroxy groups is preferable as alcohol of the alcohol portion.
The polyvalent alcohol which is the raw material of the polyvalent alcohol ester-based plasticizer is denoted by General Formula (c) described below.

Rα-(OH)m   General Formula (c)

In General Formula (c), Rα represents an m-valent organic group, and m represents a positive integer of greater than or equal to 2.
The number of carbon atoms in the polyvalent alcohol is preferably greater than or equal to 5, and is more preferably 5 to 20.
Examples of such polyvalent alcohol include sugar alcohol or glycols.
Specifically, triethylene glycol, tetraethylene glycol, dipropylene glycol, tripropylene glycol, sorbitol, trimethylol propane, and xylitol are preferable.
An acid portion derived from a monocarboxylic acid is preferable as an acid portion of the polyvalent alcohol ester (an acyl portion of ester). Examples of such an acid include an aliphatic monocarboxylic acid, an alicyclic monocarboxylic acid, and an aromatic monocarboxylic acid, and it is preferable that the alicyclic monocarboxylic acid and the aromatic monocarboxylic acid are used from a viewpoint of improving moisture permeability and retention properties.
The number of carbon atoms in the aliphatic monocarboxylic acid is preferably 1 to 32, is more preferably 1 to 20, and is particularly preferably 1 to 10. It is preferable that an acetic acid is contained from a viewpoint of increasing the compatibility with respect to the cellulose derivative, and it is also preferable that the acetic acid and other monocarboxylic acids are used by being mixed.
Preferred examples of the aliphatic monocarboxylic acid include a saturated fatty acid such as an acetic acid, a propionic acid, a butyric acid, a valeric acid, a caproic acid, an enanthic acid, a caprylic acid, a pelargonic acid, a cupric acid, a 2-ethyl-hexane carboxylic acid, an undecylic acid, a lauric acid, a tridecylic acid, a myristic acid, a pentadecylic acid, a palmitic acid, a heptadecylic acid, a stearic acid, a nonadecanoic acid, an arachic acid, a behenic acid, a lignoceric acid, a cerotic acid, a heptacosanoic acid, a montanic acid, a melissic acid, and a lacceric acid, an unsaturated fatty acid such as an undecylenic acid, an oleic acid, a sorbic acid, a linoleic acid, a linolenic acid, and an arachidonic acid, and the like.
Preferred examples of the alicyclic monocarboxylic acid include a cyclopentane carboxylic acid, a cyclohexane carboxylic acid, a cyclooctane carboxylic acid, or a derivative thereof.
Preferred examples of the aromatic monocarboxylic acid include an aromatic monocarboxylic acid in which an alkyl group is introduced into a benzene ring of a benzoic acid, such as a benzoic acid and a toluic acid, biphenyl carboxylic acid, an aromatic monocarboxylic acid having two or more benzene rings, such as a naphthalene carboxylic acid and a tetralin carboxylic acid, or a derivative thereof, and the benzoic acid is particularly preferable.
The molecular weight of the polyvalent alcohol ester-based plasticizer is not particularly limited, but is preferably 300 to 3000, and is more preferably 350 to 1500. It is preferable that the polyvalent alcohol ester-based plasticizer has a large molecular weight from a viewpoint of excellently suppressing volatilization from the optical film, and it is preferable that the polyvalent alcohol ester-based plasticizer has a small molecular weight from a viewpoint of the moisture permeability and the compatibility with respect to the cellulose derivative.
For example, a compound disclosed in paragraphs 0045 to 0049 of JP2012-234159A is preferable as the polyvalent alcohol ester-based plasticizer, and is preferably incorporated herein as a part.
(Carbohydrate Derivative-Based Plasticizer)
Examples of the carbohydrate derivative-based plasticizer include derivatives of carbohydrate having monosaccharide or 2 to 10 monosaccharide units, and among them, acylated carbohydrate is preferable.
Examples of the carbohydrate having monosaccharide or 2 to 10 monosaccharide units preferably include ribose, arabinose, xylose, lyxose, glucose, fructose, mannose, galactose, trehalose, maltose, cellobiose, lactose, sucrose, sucralose, α-cyclodextrin, β-cyclodextrin, γ-cyclodextrin, δ-cyclodextrin, xylitol, and sorbitol, more preferably include the arabinose, the xylose, the glucose, the fructose, the mannose, the galactose, the maltose, the cellobiose, the sucrose, the β-cyclodextrin, and the γ-cyclodextrin, and particularly preferably include the xylose, the glucose, the fructose, the mannose, the galactose, the maltose, the cellobiose, the sucrose, the xylitol, and the sorbitol.
Preferred examples of the carbohydrate derivative-based plasticizer include maltose octaacetate, cellobiose octaacetate, sucrose octaacetate, xylose tetrapropionate, glucose pentapropionate, fructose pentapropionate, mannose pentapropionate, galactose pentapropionate, maltose octapropionate, cellobiose octapropionate, sucrose octapropionate, xylose tetrabenzoate, glucose pentabenzoate, fructose pentabenzoate, mannose pentabenzoate, galactose pentabenzoate, maltose octabenzoate, cellobiose octabenzoate, sucrose octabenzoate, xylitol pentabenzoate, and sorbitol hexabenzoate.
A carbohydrate derivative-based plasticizer having a pyranose structure or a furanose structure is preferable as the carbohydrate derivative-based plasticizer.
A compound disclosed in paragraphs 0030 to 0039 of JP2012-234159A is preferable as the carbohydrate derivative-based plasticizer.
Furthermore, in the present invention, the contents disclosed in paragraphs 0026 to 0068 of JP2012-234159A are preferably applied to the plasticizer, and the contents disclosed in paragraphs 0026 to 0068 are preferably incorporated herein as a part.
The added amount of the plasticizer is preferably 1 mass % to 20 mass % with respect to the cellulose acylate. When the added amount of the plasticizer is greater than or equal to 1 mass %, a durability enhancement effect of a polarizer is easily obtained, and when the added amount of the plasticizer is less than or equal to 20 mass %, the bleed out hardly occurs. Further, the added amount is preferably 2 mass % to 15 mass %, and is particularly preferably 5 mass % to 15 mass %. Furthermore, two or more types of plasticizers may be added. Even when two or more types of plasticizers are added, a specific example and a preferred range of the added amount are identical to those described above.
A timing of adding the plasticizer to the cellulose acylate film is not particularly limited insofar as the plasticizer is added at the time of forming the film. For example, the plasticizer may be added at the time of synthesizing the cellulose acylate, or the plasticizer may be mixed with the cellulose acylate at the time of preparing a dope.
(Antioxidant)
It is preferable that the optical film of the present invention contains an antioxidant. The antioxidant is able to be added to the cellulose acylate solution. In the present invention, a known antioxidant, for example, a phenol-based antioxidant or a hydroquinone-based antioxidant such as 2,6-di-t-butyl-4-methyl phenol, 4,4′-thiobis-(6-t-butyl-3-methyl phenol), 1,1′-bis(4-hydroxy phenyl)cyclohexane, 2,2′-methylene bis(4-ethyl-6-t-butyl phenol), 2,5-di-t-butyl hydroquinone, and pentaerythrityl-tetrakis[3-(3,5-di-t-butyl-4-hydroxy phenyl)propionate] is able to be added. Further, it is preferable that a phosphorus-based antioxidant such as tris(4-methoxy-3,5-diphenyl)phosphite, tris(nonyl phenyl)phosphite, tris(2,4-di-t-butyl phenyl)phosphite, bis(2,6-di-t-butyl-4-methyl phenyl)pentaerythritol diphosphite, and bis(2,4-di-t-butyl phenyl)pentaerythritol diphosphite is used.
The added amount of the antioxidant is preferably 0.05 parts by mass to 5.0 parts by mass with respect to 100 parts by mass of the cellulose acylate.
(Ultraviolet Absorbent)
The optical film of the present invention may contain an ultraviolet absorbent from a viewpoint of preventing deterioration of a polarizing plate, a liquid crystal, and the like. The ultraviolet absorbent is able to be added to the cellulose acylate solution. In the present invention, an ultraviolet absorbent having low absorbancy in visible light having a wavelength of greater than or equal to 400 nm is preferably used as the ultraviolet absorbent from a viewpoint of excellent absorption capacity in ultraviolet light having a wavelength of less than or equal to 370 nm and excellent liquid crystal display properties. Examples of the ultraviolet absorbent preferably used in the present invention include a hindered phenol-based compound, a hydroxy benzophenone-based compound, a benzotriazole-based compound, a salicylic acid ester-based compound, a benzophenone-based compound, a cyanoacrylate-based compound, a nickel complex salt-based compound, and the like.
Examples of the hindered phenol-based compound include 2,6-di-t-butyl-p-cresol, pentaerythrityl-tetrakis[3-(3,5-di-t-butyl-4-hydroxy phenyl)propionate], N,N′-hexamethylene bis(3,5-di-t-butyl-4-hydroxy-hydrocinnamide), 1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxy benzyl)benzene, tris-(3,5-di-t-butyl-4-hydroxy benzyl)-isocyanurate, and the like.
Examples of the benzotriazole-based compound include 2-(2′-hydroxy-5′-methyl phenyl)benzotriazole, 2,2-methylene bis[4-(1,1,3,3-tetramethyl butyl)-6-(2H-benzotriazol-2-yl)phenol], (2,4-bis-(n-octylthio)-6-(4-hydroxy-3,5-di-t-butyl anilino)-1,3,5-triazine, triethylene glycol-bis[3-(3-t-butyl-5-methyl-4-hydroxy phenyl)propionate], N,N′-hexamethylene bis(3,5-di-t-butyl-4-hydroxy-hydrocinnamide), 1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxy benzyl)benzene, 2-(2′-hydroxy-3′,5′-di-t-butyl phenyl)-5-chlorobenzotriazole, 2-(2′-hydroxy-3′,5′-di-t-amyl phenyl)-5-chlorobenzotriazole, 2,6-d i-t-butyl-p-cresol, pentaerythrityl-tetrakis[3-(3,5-di-t-butyl-4-hydroxy phenyl)propionate], and the like.
The added amount of the ultraviolet absorbent is preferably 1% to 1.0% in a mass ratio in the total solid content of the cellulose acylate film, and is further preferably 10 ppm to 1000 ppm.
(Matting Agent)
The optical film of the present invention may further contain a matting agent from a viewpoint of film slipperiness and stable manufacturing. The matting agent may be a matting agent of an inorganic compound, or may be a matting agent of an organic compound.
An inorganic compound containing silicon (for example, silicon dioxide, calcined calcium silicate, hydrated calcium silicate, aluminum silicate, magnesium silicate, and the like), titanium oxide, zinc oxide, aluminum oxide, barium oxide, zirconium oxide, strontium oxide, antimony oxide, tin oxide, tin-antimony oxide, calcium carbonate, talc, clay, calcined kaolin, calcium phosphate, and the like are preferable as the matting agent of the inorganic compound, and the inorganic compound containing silicon or the zirconium oxide is more preferable. The silicon dioxide is particularly preferable from a viewpoint of capable of reducing turbidity of the cellulose acylate film.
For example, commercial products with product names such as Aerosil R972, Aerosil R974, Aerosil R812, Aerosil 200, Aerosil 300, Aerosil R202, Aerosil OX50, and Aerosil TT600 (all are manufactured by Nippon Aerosil Co., Ltd.) are able to be used as fine particles of the silicon dioxide. For example, commercially available products with product names such as Aerosil R976 and Aerosil R811 (all are manufactured by Nippon Aerosil Co., Ltd.) are able to be used as the fine particles of the zirconium oxide.
For example, a polymer such as a silicone resin, a fluorine resin, and an acrylic resin is preferable as the matting agent of the organic compound, and among them, the silicone resin is preferable. Among the silicone resins, a silicone resin having a three-dimensional mesh-like structure is particularly preferable, and for example, commercially available products with product names such as Tospearl 103, Tospearl 105, Tospearl 108, Tospearl 120, Tospearl 145, Tospearl 3120, and Tospearl 240 (all are manufactured by Momentive Performance Materials Inc.) are able to be used.
When such a matting agent is added to the cellulose acylate solution, a method of adding the matting agent is not particularly limited insofar as a desired cellulose acylate solution is able to be obtained by using any method. For example, the additive may be contained in a step of mixing the cellulose acylate and a solvent, or the additive may be added after preparing a mixed solution of the cellulose acrylate and a solvent.
Further, a so-called adding immediately before casting method may be used in which the additive is added and mixed immediately before casting a dope, and the mixing is performed by disposing screw type kneaders online. Specifically, a static mixer such as an inline mixer is preferable. In addition, a static mixer SWJ (a Toray static in-tube mixer Hi-Mixer) (manufactured by Toray Engineering Co., Ltd.) is preferable as the inline mixer.
Furthermore, in order to eliminate concentration unevenness, aggregation of particles, and the like in the inline adding, a manufacturing method of a cellulose acylate film is disclosed in JP2003-053752A in which a distance L between an adding nozzle tip end mixing a dope of a main raw material with an additive liquid having a different composition and a starting end of an inline mixer is set to he less than or equal to 5 times an inner diameter d of a tube for a main raw material, and thus concentration unevenness, aggregation of matting particles, and the like are eliminated. A more preferred aspect is disclosed in which a distance (L) between a tip opening portion of a supply nozzle for an additive liquid having a composition different from that of a dope of a main raw material and a starting end of an inline mixer is set to be less than or equal to 10 times an inner diameter (d) of the tip opening portion of the supply nozzle, and an inline mixer is a static non-stirring type in-tube mixer or a dynamic stirring type in-tube mixer. More specifically, it is disclosed that a flow ratio of a dope of a main raw material of a cellulose acylate film/an inline additive liquid is 10/1 to 500/1, and is preferably 50/1 to 200/1.
Further, a method of adding an additive is disclosed in JP2003-014933A of which an object is to provide a retardation film in which bleed out of the additive is reduced, a peeling phenomenon between layers is eliminated, and slipperiness and transparency are excellent. Specifically, it is disclosed that the additive may be added into a dissolving vessel, or the additive or a solution in which the additives are dissolved or dispersed may be added into the dope during liquid feeding between the dissolving vessel and a cocasting die, and in the latter case, it is preferable that mixing means such as a static mixer is disposed in order to increase mixing properties.
It is particularly preferable that the matting agent is contained in the cellulose acylate film in the ratio of 0.05 mass % to 1.0 mass %. According to such a value, when haze of the cellulose acylate film does not increase, and the cellulose acylate film is actually used in an LCD, the value described above contributes to suppression of problems such as a decrease in contrast, the occurrence of a bright spot, and the like. In addition, it is possible to realize creaking resistance and scratch resistance. From such a viewpoint, it is particularly preferable that the matting agent is contained in the cellulose acylate film in the ratio of 0.05 mass % to 1.0 mass %.
<Physical Properties of Cellulose Acylate Film>
(Hardness)
As surface hardness, it is preferable that knoop hardness according to a knoop method using a knoop indenter is high, and it is also preferable that pencil hardness is high. The knoop hardness is able to be measured by using a hardness meter including a knoop indenter in an indenter, for example, “Fischer Scope H100Vp type hardness meter” manufactured by Fischer Instruments K. K.
The pencil hardness, for example, is able to be evaluated by using a pencil for a test defined in JIS-S6006 according to a pencil hardness evaluation method defined in JIS-K5400.
The compound denoted by General Formula (I) of the present invention is able to increase hardness of the cellulose acylate film such as knoop hardness. Furthermore, the hardness of the cellulose acylate film is able to be adjusted according to the type or the content of the compound denoted by General Formula (I).
[Modulus of Elasticity (Modulus of Tension Elasticity)]
It is preferable that the cellulose acylate film practically exhibits sufficient modulus of elasticity (modulus of tension elasticity). The range of the modulus of elasticity is not particularly limited. However, the range of the modulus of elasticity is preferably 1.0 GPa to 5.0 GPa, and is more preferably 2.0 GPa to 5.0 GPa from a viewpoint of manufacturing suitability and handling properties. The compound denoted by General Formula (I) of the present invention is added into the cellulose acylate film, and thus the cellulose acylate film is hydrophobized and the modulus of elasticity is improved, and these properties are advantages of the present invention.
(Photoelastic Coefficient)
The absolute value of a photoelastic coefficient of the cellulose acylate film is preferably less than or equal to 8.0×10−12 m2/N, is more preferably less than or equal to 6×10−12 m2/N, and is even more preferably less than or equal to 5×10−12 m2/N. The photoelastic coefficient of the cellulose acylate film decreases, and thus when the optical film of the present invention including the cellulose acylate film is incorporated in a liquid crystal display device as a polarizing plate protective film, it is possible to suppress the occurrence of unevenness under hygrothermal conditions. The photoelastic coefficient, unless otherwise specifically stated, is calculated by being measured according to the following methods.
The lower limit value of modulus of photoelasticity is not particularly limited. Furthermore, it is practical that the lower limit value of modulus of photoelasticity is greater than or equal to 0.1×10−12 m2/N.
The cellulose acylate film is cut to have a size of 3.5 cm ×12 cm, and the photoelastic coefficient is calculated from a slope of a straight line of a change in retardation (Re is measured by using an ellipsometer (M150[product name], manufactured by Jasco Corporation), and Re with respect to stress) at each load of no load, 250 g, 500 g, 1000 g, and 1500 g.
(Moisture Content)
The moisture content of the cellulose acylate film is able to be evaluated by measuring an equilibrium moisture content at constant temperature and humidity. The equilibrium moisture content is calculated by measuring the moisture amount of a sample which reaches equilibrium after being placed for 24 hours at the constant temperature and humidity described above using a Karl Fischer method and by dividing a moisture amount (g) by a sample mass (g).
The moisture content of the cellulose acylate film at a temperature of 25° C. and relative humidity of 80% is preferably less than or equal to 5 mass %, is more preferably less than or equal to 4 mass %, and is even more preferably less than 3 mass %. The moisture content of the cellulose acylate film decreases, and thus when the optical film of the present invention including the cellulose acylate film is incorporated in the liquid crystal display device as the polarizing plate protective film, it is possible to suppress the occurrence of display unevenness of the liquid crystal display device under hygrothermal conditions. The lower limit value of the moisture content is not particularly limited. Furthermore, it is practical that the lower limit value of the moisture content is greater than or equal to 0.1 mass %.
(Moisture Permeability)
The moisture permeability of the cellulose acylate film is able to be evaluated by measuring the mass of water vapor per 24 hours passing through the sample in an atmosphere of a temperature of 40° C. and relative humidity of 90% on the basis of a moisture permeability test (a cup method) of JIS Z0208, and by converting the mass of the water vapor per 24 hours into the mass of the water vapor passing through for 24 hours per a sample area of 1 m2.
The moisture permeability of the cellulose acylate film is preferably 500 g/m2·day to 2000 g/m2·day, is more preferably 900 g/m2·day to 1300 g/m2·day, and is particularly preferably 1000 g/m2·day to 1200 g/m2·day.
(Haze)
The haze of the cellulose acylate film is preferably less than or equal to 1%, is more preferably less than or equal to 0.7%, and is particularly preferably less than or equal to 0.5%. By setting the haze to be less than or equal to the upper limit value described above, advantages such as a further increase in transparency of the cellulose acylate film and ease of use as an optical film are obtained. The haze, unless otherwise specifically stated, is calculated by being measured according to the following methods. The lower limit value of the haze is not particularly limited. Furthermore, it is practical that the lower limit value of the haze is greater than or equal to 0.001%.
The haze of a cellulose acylate film of 40 mm×80 mm is measured under an environment of a temperature of 25° C. and relative humidity of 60% by using a hazemeter (HGM-2DP, manufactured by Suga test Instruments Co., Ltd.) according to JIS K6714.
(Film Thickness)
The average film thickness of the cellulose acylate film is preferably 10 μm to 100 μm, is more preferably 15 μm to 80 μm, and is even more preferably 15 μm to 70 μm. By setting the average film thickness of the cellulose acylate film to be greater than or equal to 15 μm, handling properties at the time of preparing a web-like film are improved, and thus setting the average film thickness of the cellulose acylate film to be greater than or equal to 15 μm is preferable. In addition, by setting the average film thickness of the cellulose acylate film to be less than or equal to 70 μm, it is easy to deal with a humidity change, and it is easy to maintain optical properties.
In addition, when the cellulose acylate film has a laminated structure of three or more layers, the film thickness of the core layer is preferably 3 μm to 70 μm, and is more preferably 5 μm to 60 μm, and the film thickness of the skin layer A and the skin layer B is preferably 0.5 μm to 20 μm, is more preferably 0.5 μm to 10 μm, and is particularly preferably 0.5 μm to 3 μm.
(Width)
The width of the cellulose acylate film is preferably 700 mm to 3000 mm, is more preferably 1000 mm to 2800 mm, and is particularly preferably 1300 mm to 2500 mm.
<Manufacturing Method of Cellulose Acylate Film>
A manufacturing method of the cellulose acylate film of the present invention is not particularly limited. Furthermore, it is preferable that the cellulose acylate film of the present invention is manufactured by using a melting film forming method or a solution film forming method, and it is more preferable that the cellulose acylate film of the present invention is manufactured by using the solution film forming method (a solvent cast method). A manufacturing example of the cellulose acylate film using the solvent cast method is able to refer to the specification of each of U.S. Pat. Nos. 2,336,310B, 2,367,603B, 2,492,078B, 2,492,977B, 2,492,978B, 2,607,704B, 2,739,069B, and 2,739,070B, the specification of each of GB640731B and GB736892B, and the publication of each of JP1970-4554B (JP-S45-4554B), JP1974-5614B (JP-S49-5614B), JP1985-176834A (JP-S60-176834A), JP1985-203430A (JP-S60-203430A), JP-1987-115035A (JP-S62-115035A), and the like. In addition, the cellulose acylate film may be subjected to a stretching treatment. A method and conditions of the stretching treatment, for example, is able to refer to the publication of each of JP1987-115035A (JP-S62-115035A), JP1992-152125A (JP-H04-152125A), JP1992-284211A (JP-H04-284211A). JP1992-298310A (JP-H04-298310A), JP1999-48271A (JP-H11-48271A), and the like.
(Casting Method)
Examples of the solution casting method include a pressure die method in which a prepared dope is homogeneously extruded onto a metal support body from a pressure die, a doctor blade method in which the film thickness of a dope which has been casted on a metal support body is adjusted first by using a blade, a reverse roll coater method in which the film thickness is adjusted by using a reversely rotating roll, and the like, and the pressure die method is preferable. A coat hanger type die, a T die type die, or the like is used as the pressure die, and all of the dies are able to be preferably used. In addition, the solution is able to be casted by using various methods which have been known from the related art in which a cellulose acylate solution is casted and a film is formed in addition to the methods described herein, and each condition is set in consideration of a difference in a boiling point of a solvent to be used, or the like, and thus casting film formation is able to be performed as with a method of the related art.
Cocasting
In the formation of the cellulose acylate film, a lamination casting method such as a cocasting method, a sequentially casting method, and a coating method is preferably used, and a cocasting method is particularly preferably used from a viewpoint of stable manufacturing and a reduction in production costs.
When the cellulose acylate film is manufactured by using the cocasting method and the sequentially casting method, first, the cellulose acetate solution (the dope) for each layer is prepared. The cocasting method (multi-layer concurrently casting) is a casting method in which the dope is extruded from a die for casting concurrently extruding each dope for casting of each of the layers (three layers or three or more layers may be used) from a separate slit or the like onto a support body for casting (a band or a drum), the respective layers are concurrently casted, are peeled off from the support body at a suitable timing, and are dried, and thus a film is molded.
The sequentially casting method is a casting method in which, first, a dope for casting of a first layer is extruded from the die for casting onto the support body for casting, is casted, and is dried or is not dried, and a dope for casting of a second layer is extruded from the die for casting and is casted thereonto, and as necessary, dopes for third or more layers are sequentially casted and laminated, and are peeled off from the support body at a suitable timing and are dried, and thus a cellulose acylate film is molded. In general, the coating method is a method in which a core layer is molded into the shape of a film by using a solution film forming method, a coating liquid applied onto a surface layer is prepared, the coating liquid is applied onto each one surface or is concurrently applied onto both surfaces of the core layer and is dried by using a suitable coating machine, and thus a cellulose acylate film having a laminated structure is molded.
A drum of which the surface is subjected to mirror finishing by chromium plating or a stainless steel belt (may be a band) which is subjected to mirror finishing by surface grinding is used as a metal support body endlessly traveling which is used for manufacturing the cellulose acylate film. One or two or more pressure dies to be used may be disposed in the upper portion of the metal support body The number of pressure dies is preferably 1 or 2. When two or more pressure dies are disposed, a doping amount to be casted may be divided into each of the dies at various ratios, or a dope may be fed into each of the dies from a plurality of precise quantitative gear pumps at each of the ratios. The temperature of the dope (a resin solution) used in the casting is preferably −10° C. to 55° C., and is more preferably 25° C. to 50° C. In this case, the solution temperature may be identical in all of steps, or may be different in each of the steps. When the solution temperature is different in each of the steps, a desired temperature may be set immediately before the casting.
In addition, the material of the metal support body described above is not particularly limited, and SUS (for example, SUS316) is more preferable.
(Peeling)
It is preferable that the manufacturing method of the cellulose acylate film includes a step in which a film formed of the dope described above is peeled from the metal support body. A peeling method in the manufacturing method of the cellulose acylate film is not particularly limited, and when a known method is used, it is possible to enhance peel property.
(Stretching Treatment)
It is preferable that the manufacturing method of the cellulose acylate film includes a step in which the film is stretched after being formed. It is preferable that a stretching direction of the cellulose acylate film is either a cellulose acylate film transport direction (an MD direction) or a direction orthogonal to the transport direction (a TD direction). Furthermore, it is particularly preferable that the cellulose acylate film is stretched in the direction orthogonal to the cellulose acylate film transport direction (the TD direction) from a viewpoint of a machining process of a polarizing plate using the cellulose acylate film, which follows after the stretching.
A method of stretching the film in the TD direction, for example, is disclosed in each of JP1987-115035A (JP-S62-115035A), JP1992-152125A (JP-H04-152125A), JP1992-284211A (JP-H04-284211A), JP1992-298310A (JP-H04-298310A), JP1999-48271A (JP-H11-48271A), and the like. When the film is stretched in the MD direction, for example, the speed of a transport roller of the cellulose acylate film is adjusted, and the winding speed of the cellulose acylate film is faster than the peeling speed of the cellulose acylate film, and thus the cellulose acylate film is stretched. When the film is stretched in the TD direction, the cellulose acylate film is able to be stretched also by transporting the cellulose acylate film while holding the width of the cellulose acylate film with a tenter, and by gradually widening the width of the tenter. It is also possible to stretch the cellulose acylate film by using a stretching machine (preferably monoaxial stretching using a long stretching machine) after drying the cellulose acylate film.
When the cellulose acylate film is used as a protective film of a polarizer, a light leakage is suppressed when a polarizing plate is obliquely viewed, and thus it is necessary that a transmission axis of the polarizer and an in-plane slow axis of the cellulose acylate film are arranged to be parallel to each other. In general, a transmission axis of a roll film-like polarizer which is continuously manufactured is parallel to a width direction of the roll and thus in order to continuously bond the protective film which is formed of the roll film-like polarizer described above and a roll film-like cellulose acylate film, it is necessary that an in-plane slow axis of the roll film-like protective film is parallel to a width direction of the cellulose acylate film. Accordingly, it is preferable that further stretching is performed in the TD direction. In addition, the stretching treatment may be performed during a film forming step, or a raw fabric which is formed and is wound may be subjected to the stretching treatment.
The stretching in the TD direction is preferably stretching of 5% to 100%, is more preferably stretching of 5% to 80%, and is particularly preferably stretching of 5% to 40%. Furthermore, unstretching indicates that the stretching is 0%. The stretching treatment may be performed during the film forming step, or a raw fabric which is formed and is wound may be subjected to the stretching treatment. In the former case, the stretching may be performed in a state of including a residual solvent, and the stretching is able to be preferably performed when Amount of Residual Solvent=(Residual Volatile Component Mass/Film Mass after Heating Treatment)×100% is 0.05% to 50%. It is particularly preferable that stretching of 5% to 80% is performed in a state where the amount of residual solvent is 0.05% to 5%.
(Drying)
It is preferable that a step of drying the cellulose acylate film and a step of stretching the cellulose acylate film after being dried at a temperature of higher than or equal to a glass transition temperature (Tg) −10° C. are included in the manufacturing method of the cellulose acylate film from a viewpoint of retardation expression properties.
In the manufacturing of the cellulose acylate film, the dope on the metal support body is dried, in general, by using a method of applying hot air from the surface side of the metal support body (the drum or the belt), that is, from the surface of the web on the metal support body, a method of applying hot air from the back surface of the drum or the belt, a back surface liquid heat transmitting method in which a temperature controlled liquid is in contact with the back surface of the belt or the drum on a side opposite to the surface on which the dope is casted, the drum or the belt is heated by heat transmission, and the surface temperature is controlled, and the like, and among them, the back surface liquid heat transmitting method is preferable. The surface temperature of the metal support body before being casted is not limited insofar as the surface temperature of the metal support body before being casted is lower than or equal to the boiling point of the solvent which is used in the dope. However, in order to accelerate the drying and in order to eliminate fluidity on the metal support body, it is preferable that the surface temperature of the metal support body before being casted in the solvent to be used is set to a temperature 1° C. to 10° C. lower than the boiling point of the solvent having the lowest boiling point. Furthermore, when the casted dope is peeled off without being cooled and dried, the surface temperature of the metal support body before being casted is not limited thereto.
The thickness of the cellulose acylate film may be adjusted to have a desired thickness by adjusting the concentration of solid contents contained in the dope, a slit gap of a base in the die, an extrusion pressure from the die, the speed of the metal support body, and the like.
The length of the cellulose acylate film obtained as described above is preferably wound in 100 m to 10000 m per one roll, is more preferably wound in 500 m to 7000 m, and is even more preferably wound in 1000 m to 6000 m. At the time of winding the cellulose acylate film, it is preferable that a knurling is applied to at least one end, the width of the knurling is preferably 3 mm to 50 mm, and is more preferably 5 mm to 30 mm, and the height of the knurling is preferably 0.5 μm to 500 μm, and is more preferably 1 μm to 200 μm. The cellulose acylate film may be pressed on one side, or may be pressed on both sides.
When the optical film of the present invention is used as an optical compensation film for a large-screen liquid crystal display device, for example, it is preferable that the film is molded such that the width thereof is greater than or equal to 1470 mm. In addition, when the optical film of the present invention is used as a polarizing plate protective film, not only an optical film having an aspect of a film piece which is cut to have a size capable of being directly incorporated in a liquid crystal display device, but also an optical film having an aspect in which the film is prepared in the shape of a long film by continuous production, and is wound into the shape of a roll are included. The optical film having the latter aspect is kept and transported in this state, and is used by being cut to have a desired size when the optical film is practically incorporated in the liquid crystal display device or when the optical film is bonded to the polarizer or the like. In addition, when the optical film is bonded to a polarizer formed of a polyvinyl alcohol film which is similarly prepared in the shape of a long film in a long shape, and then is practically incorporated in the liquid crystal display device, the optical film is used by being cut to have a desired size. One aspect of the optical compensation film or the polarizing plate protective film which is wound in the shape of a roll includes an aspect in which the film is wound in the shape of a roll having a roll length of greater than or equal to 2500 m.
<<Functional Layer>>
In the polarizing plate protective film of the present invention, a functional layer is able to be disposed on the polarizing plate protective film according to the purpose, as desired. Examples of the functional layer include a hard coat layer, an antireflection layer, a light scattering layer, an antifouling layer, an antistatic layer, and the like, and these layers may have a plurality of functions in one layer.
Hereinafter, the hard coat layer will be described as an example.
<<Hard Coat Layer>>
The hard coat layer which is disposed on the cellulose acylate film as desired is a layer for applying hardness or scratch resistance to the optical film of the present invention. For example, a coating composition for forming the hard coat layer is applied onto the cellulose acylate film and is cured, and thus the hard coat layer having high adhesiveness with respect to the cellulose acylate film with the compound denoted by General Formula (I) of the present invention is able to be formed. A filler or an additive is added into the hard coat layer, and thus mechanical performance, electrical performance, optical performance, physical performance, or chemical performance such as water repellency and oil repellency is able to be applied to the hard coat layer itself. The thickness of the hard coat layer is preferably 0.1 μm to 6 μm, and is more preferably 3 μm to 6 μm. By including a thin hard coat layer having a thickness in such a range, an optical film including the hard coat layer is obtained in which physical properties such as suppression of brittleness or curling are enhanced, and a reduction in weight and a reduction in manufacturing costs are realized.
It is preferable that the hard coat layer is formed by curing a curable composition for forming the hard coat layer. It is preferable that the curable composition is prepared as a liquid-like coating composition. An example of such a coating composition contains a monomer or an oligomer for a matrix forming binder, polymers, and an organic solvent. This coating composition is cured after being applied, and thus the hard coat layer is able to be formed. In the curing, a cross-linking reaction or a polymerization reaction is able to be used.
(Monomer or Oligomer for Matrix Forming Binder)
Examples of the monomer or the oligomer for a matrix forming binder which is able to be used include an ionizing radiation curable multifunctional monomer and an ionizing radiation curable multifunctional oligomer. It is preferable that the multifunctional monomer or the multifunctional oligomer is a monomer which is able to be subjected to a cross-linking reaction or a polymerization reaction. A photopolymerizable functional group, an electron beam polymerizable functional group, and a radiation polymerizable functional group are preferable as the functional group of the ionizing radiation curable multifunctional monomer or the ionizing radiation curable multifunctional oligomer, and among them, the photopolymerizable functional group is preferable.
Examples of the photopolymerizable functional group include an unsaturated polymerizable functional group such as a (meth)acryloyl group, a vinyl group, a styryl group, and an allyl group, and a ring opening polymerization type polymerizable functional group such as an epoxy-based compound, and among them, the (meth)acryloyl group is preferable.
Specific examples of the photopolymerizable multifunctional monomer having a photopolymerizable functional group include (meth)acrylic diesters of alkylene glycol such as neopentyl glycol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, and propylene glycol di(meth)acrylate; (meth)acrylate diesters of polyoxy alkylene glycol such as triethylene glycol di(meth)acrylate, dipropylene glycol di(meth)acrylate, polyethylene glycol di(meth)acrylate, and polypropylene glycol di(meth)acrylate; (meth)acrylate diesters of polyvalent alcohol such as pentaerythritol di(meth)acrylate; (meth)acrylate diesters of an adduct of ethylene oxide or propylene oxide such as 2,2-bis-{4-(acryloxy-diethoxy)phenyl}propane, and 2,2-bis{4-(acryloxy.polypropoxy)phenyl} propane; and the like.
Further, urethane(meth)acrylates, polyester(meth)acrylates, isocyanuric acid(meth)acrylates, and epoxy(meth)acrylates are also preferably used as the photopolymerizable multifunctional monomer.
Among them, esters of polyvalent alcohol and (meth)acrylate are preferable, and a multifunctional monomer having three or more (meth)acryloyl groups in one molecule is more preferable.
Specifically, (di)pentaerythritol tri(meth)acryl ate, (di)pentaerythritol tetra(meth)acrylate, (di)pentaerythritol penta(meth)acrylate, (di)pentaerythritol hexa(meth)acrylate, tripentaerythritol tri(meth)acrylate, tripentaerythritol hexa(meth)acrylate, trimethylol propane tri(meth)acrylate, trimethylol ethane tri(meth)acrylate, ditrimethylol propane tetra(meth)acrylate, EO-modified trimethylol propane tri(meth)acrylate, PO-modified trimethylol propane tri(meth)acrylate, EO-modified phosphoric acid tri(meth)acrylate, 1,2,4-cyclohexane tetra(meth)acrylate, pentaglycerol tri(meth)acrylate, 1,2,3-cyclohexane tetra(meth)acrylate, polyester polyacrylate, caprolactone-modified tris((meth)acryloxy ethyl)isocyanurate, and the like are included.
Herein, “(meth)acrylate”, “(meth)acrylic acid”, and “(meth)acryloyl” respectively indicate “acrylate or methacrylate”, “acrylic acid or methacrylic acid”, and “acryloyl or methacryloyl”.
Further, examples of a resin having three or more (meth)acryloyl groups include a polyester resin, a polyether resin, an acrylic resin, an epoxy resin, a urethane resin, an alkyd resin, a spiroacetal resin, a polybutadiene resin, and a polythiol polyene resin which have a comparatively low molecular weight, an oligomer or a prepolymer of a multifunctional compound or the like such as polyvalent alcohol, and the like.
A specific compound of the multifunctional acrylate-based compounds having three or more (meth)acryloyl groups is able to refer to compounds disclosed in paragraph 0096 of JP2007-256844A and the like.
Examples of the urethane(meth)acrylates are able to include a urethane(meth)acrylate-based compound which is obtained by allowing hydroxy group-containing compounds such as alcohol, polyol, and/or a hydroxy group-containing (meth)acrylate to react with isocyanates, or as necessary, by esterifying a polyurethane compound obtained by this reaction with (meth)acrylate.
A specific example of the specific compound is able to refer to examples disclosed in paragraph 0017 of JP2007-256844A and the like.
It is preferable that the isocyanuric acid (meth)acrylates are used from a viewpoint of capable of reducing the curling. Examples of such isocyanuric acid (meth)acrylates include isocyanuric acid diacrylates and isocyanuric acid triacrylates, and an example of a specific compound is able to refer to examples disclosed in paragraphs 0018 to 0021 of JP2007-256844A and the like.
An epoxy-based compound is able to be used in the hard coat layer in order to further reduce contraction due to the curing. A monomer having two or more epoxy groups in one molecule is used as such an epoxy-based compound (monomers having an epoxy group), and examples of the monomer having two or more epoxy groups in one molecule include epoxy-based monomers disclosed in each of JP2004-264563A, JP2004-264564A, JP2005-37737A, JP2005-37738A, JP2005-140862A, JP2005-140862A, JP2005-140863A, JP2002-322430A, and the like. In addition, a compound having both functional groups of an epoxy-based functional group and an acrylic functional group, such as glycidyl(meth)acrylate, is also preferably used.
(High Molecular Compound)
The hard coat layer may contain a high molecular compound. By adding the high molecular compound, it is possible to decrease curing contraction, it is possible to more preferentially adjust viscosity of the coating liquid relevant to dispersion stability of resin particles (aggregation properties), and it is possible to change aggregation behavior of the resin particles by controlling the polarity of a solidified material during the drying or to reduce drying unevenness during the drying, and thus adding the high molecular compound is preferable.
Here, the high molecular compound is a compound which forms a polymer in advance at the time of being added into the coating liquid. Resins such as cellulose esters (for example, cellulose triacetate, cellulose diacetate, cellulose propionate, cellulose acetate propionate, cellulose acetate butyrate, cellulose nitrate, and the like), urethanes, polyesters, (meth)acrylic esters (for example, a methyl methacrylate/methyl(meth)acrylate copolymer, a methyl methacrylate/ethyl(meth)acrylate copolymer, a methyl methacrylate/butyl(meth)acrylate copolymer, a methyl methacrylate/styrene copolymer, a methyl methacrylate/(meth)acrylate copolymer, polymethyl methacrylate, and the like), and polystyrene are preferably used as such a high molecular compound.
(Curable Composition)
An example of a curable composition which is able to be used for forming the hard coat layer is a curable composition including a (meth)acrylate-based compound. It is preferable that the curable composition contains a photoradical polymerization initiator or a thermal radical polymerization initiator along with the (meth)acrylate-based compound, and as necessary, may further contain a filler, a coating auxiliary agent, and other additives. The curable composition is able to be cured by performing a polymerization reaction due to irradiation or heating of ionizing radiation in the presence of the photoradical polymerization initiator or the thermal radical polymerization initiator. In addition, both of ionizing radiation curing and thermal curing are able to be performed. A commercially available compound is able to be used as an optical polymerization initiator and/or a thermal polymerization initiator. The optical polymerization initiator and/or the thermal polymerization initiator is disclosed in “Newest UV Curing Technology” (p. 159, Publisher; Kazuhiro TAKAUSU, Publishing Office; published by Technical Information Institute Co., Ltd., in 1991) or in a catalog of BASF SE.
Another example of the curable composition which is able to be used for forming the hard coat layer is a curable composition containing an epoxy-based compound. It is preferable that the curable composition contains a photoacid generator generating cations due to the action of light along with the epoxy-based compound, and as necessary, may further contain a filler, a coating auxiliary agent, and other additives. The curable composition is able to be cured by performing a polymerization reaction due to light irradiation in the presence of the photoacid generator. Examples of the photoacid generator include an ionic compound such as a triaryl sulfonium salt and a diaryl iodonium salt, a nonionic compound such as nitrobenzyl ester of a sulfonic acid, and the like. In addition, various known photoacid generators such as compounds disclosed in The Japanese Research Association for Organic Electronics Materials, “Organic Material for Imaging”, published by Bunshin Design Printing Publishing And Digital Communications (1997), and the like are able to be used.
In addition, the (meth)acrylate-based compound and the epoxy-based compound may be used together, and in this case, it is preferable that an initiator such as a photoradical polymerization initiator or a thermal radical polymerization initiator, and a photocationic polymerization initiator are used together.
The curable composition which is particularly preferable for forming the hard coat layer is a composition containing a (meth)acrylate-based compound to be used in examples described below.
It is preferable that the curable composition is prepared as a coating liquid. The coating liquid is able to be prepared by dissolving and/or dispersing the components described above in an organic solvent.
(Properties of Hard Coat Layer)
The hard coat layer formed on the cellulose acylate film of the optical film of the present invention has high adhesiveness with respect to the cellulose acylate film. In particular, in the hard coat layer formed of the preferred curable composition described above on the cellulose acylate film containing the compound denoted by General Formula (I), the curable composition is formed with higher adhesiveness with respect to the cellulose acylate film along with the compound denoted by General Formula (I). Accordingly, the optical film of the present invention including such a cellulose acylate film and a hard coat layer maintains adhesiveness between the cellulose acylate film and the hard coat layer even when light irradiation or the like is performed, and has excellent optical durability.
It is preferable that the hard coat layer has excellent scratch resistance. Specifically, when a pencil hardness test (JIS-S6006) which is an index of scratch resistance is performed, it is preferable that hardness of greater than or equal to 3H is attained.
[Polarizing Plate]
A polarizing plate of the present invention includes a polarizer and the optical film of the present invention on at least one surface of the polarizer. It is preferable that the polarizing plate of the present invention includes the polarizer, and the optical film of the present invention on one surface or both surfaces of the polarizer. The polarizer is an iodine-based polarizer, a dye-based polarizer using a dichromatic dye, or a polyene-based polarizer. The iodine-based polarizer and the dye-based polarizer are generally manufactured by using a polyvinyl alcohol-based film. When the optical film of the present invention is used as a polarizer protective film, a preparing method of the polarizing plate is not particularly limited, and the polarizing plate is able to be prepared by using a general method. For example, the general method is a method in which the cellulose acylate film of the optical film of the present invention is subjected to an alkali treatment, and the cellulose acylate film is bonded to both surfaces of the polarizer prepared by dipping and stretching a polyvinyl alcohol film in an iodine solution by using an aqueous solution of fully saponified polyvinyl alcohol. Instead of the alkali treatment, easy adhesion processing as disclosed in JP1994-94915A (JP-H06-94915A) and JP1994-118232A (JP-H06-118232A) may be performed. Examples of an adhesive agent used for bonding a treatment surface of the cellulose acylate film to the polarizer include a polyvinyl alcohol-based adhesive agent such as polyvinyl alcohol and polyvinyl butyral, vinyl-based latex such as butyl acrylate, and the like.
It is preferable that the optical film of present invention is bonded to the polarizer such that a transmission axis of the polarizer and a slow axis of the optical film of the present invention are substantially orthogonal to each other, parallel to each other, or at an angle of 45°. In a liquid crystal display device of the present invention, it is preferable that the transmission axis of the polarizer and the slow axis of the optical film of the present invention are substantially orthogonal to each other. Here, the expression “substantially parallel or orthogonal” includes a range of an error which is allowable in the art to which the present invention belongs. For example, the expression “substantially parallel or orthogonal” indicates a range of less than ±10° from an exact angle relevant to parallel and orthogonal, and an error from the exact angle is preferably less than or equal to 5°, and is more preferably less than or equal to 3°.
The transmission axis of the polarizer and the slow axis of the polarizing plate protective film being parallel to each other indicates that an angle between the direction of the main refractive index nx of the polarizing plate protective film and the direction of the transmission axis of the polarizer is in a range of ±10°. The range of such an angle is preferably ±5°, is more preferably ±3°, is even more preferably ±1°, and is particularly preferably ±0.5°. Furthermore, when the angle is 0°, the direction of the main refractive index nx of the polarizing plate protective film and the direction of the transmission axis of the polarizer are completely parallel to each other without intersecting with each other.
In addition, the transmission axis of the polarizer and the slow axis of the polarizing plate protective film being orthogonal to each other indicates that the direction of the main refractive index nx of the polarizing plate protective film and the direction of the transmission axis of the polarizer intersect with each other at an angle of 90°±10°. The angle is preferably 90°±5°, is more preferably 90°±3°, is even more preferably 90°±1°, and is particularly preferably 90°±0.5°.
By setting the range described above, a light leakage is able to be further reduced under a polarizing plate crossed nicol. The slow axis is able to be measured by various known methods, and for example, is able to be measured by using a birefringence meter (KOBRA DH manufactured by Oji Scientific Instruments).
The polarizing plate of the present invention includes not only a polarizing plate having a shape of a film piece which is cut to have a size capable of being directly incorporated in the liquid crystal display device, but also a polarizing plate having a shape in which a film is prepared in the shape of a long film due to continuous production, and is wound into the shape of a roll (for example, a shape in which a roll length is greater than or equal to 2500 m or greater than or equal to 3900 m). In order to use the polarizing plate of the present invention for a large-screen liquid crystal display device, it is preferable that the width of the polarizing plate is greater than or equal to 1470 mm. A specific configuration of the polarizing plate of the present invention is not particularly limited, and is able to adopt a known configuration. For example, a configuration disclosed in FIG. 6 of JP2008-262161A is able to be adopted.
[Liquid Crystal Display Device]
The liquid crystal display device of the present invention includes at least a liquid crystal cell, and the polarizing plate of the present invention. A liquid crystal display device in a mode of IPS, OCB, or VA in which a polarizing plate is the polarizing plate of the present invention is preferable as the liquid crystal display device of the present invention. In addition, when a first polarizing plate and a second polarizing plate are included, a liquid crystal display device in a mode of IPS, OCB, or VA in which at least one polarizing plate is the polarizing plate of the present invention is preferable as the liquid crystal display device of the present invention.
It is preferable that the liquid crystal display device of the present invention includes a liquid crystal cell, and polarizing plates which are laminated on both sides of the liquid crystal cell and are provided with an optical films on a surface on a side opposite to the liquid crystal cell side. That is, it is preferable that the liquid crystal display device of the present invention includes the first polarizing plate, the liquid crystal cell, and the second polarizing plate, and includes the optical film of the present invention on a surface on a side opposite to the polarizing plate surface side interposed between each of the polarizing plates and the liquid crystal cell. In the liquid crystal display device having such a configuration, display unevenness is excellently suppressed, and high display performance is exhibited.
In addition, it is preferable that the liquid crystal display device of the present invention includes the optical film in which the polarizing plate arranged on a visible side includes the hard coat layer on the surface of the optical film on the visible side, and in particular, includes the cellulose acylate film. In the liquid crystal display device having such a configuration, excellent scratch resistance and excellent optical durability are exhibited in addition to high display performance which is excellent for suppressing display unevenness.
An inner configuration of a typical liquid crystal display device which is the liquid crystal display device of the present invention are illustrated in FIG. 1 and FIG. 2. In FIG. 1, a liquid crystal display device is illustrated in which optical films 31a and 31b of the present invention which are formed of the cellulose acylate film include polarizing plates 21A and 21B arranged on both surfaces of a polarizer 32. In addition, in FIG. 2, a liquid crystal display device provided with an optical film 31a′ in which the polarizing plate 21B arranged on the visible side includes a hard coat layer 311b on the surface of the polarizer 32 on the visible side through a cellulose acylate film 311a is illustrated.
Furthermore, FIG. 1 and FIG. 2 illustrate a configuration of an example of the liquid crystal display device of the present invention, and a specific configuration of the liquid crystal display device of the present invention is not particularly limited, but a known configuration is able to be adopted. In addition, a configuration disclosed in FIG. 2 of JP2008-262161A is also able to be preferably adopted.
EXAMPLES
Hereinafter, the present invention will he described in more detail with reference to examples, but the present invention is not limitedly interpreted by the examples.
Synthesis Examples
Exemplificative compounds (1), (2), (3), (8), (9), (11) to (13), (16), (21), (22), and (26) described below were synthesized.










Synthesis Example 1
[Synthesis of Exemplificative Compound (2)]
480 mL of o-dichlorobenzene and 76.9 g of a barbituric acid were put into a three neck flask of 2 L which was attached with a thermometer, a circulation cooling tube, and a stirrer, and 194.4 g of triethyl amine was added while stirring the mixture at room temperature. 189.9 g of benzyl chloride was dropped while heating and stirring the mixture at 85° C., and the mixture was heated and stirred at 90° C. for 5 hours. The obtained reaction solution was cooled to room temperature, and 2 L of ethyl acetate was added thereto, and then a mixture of 1 L of a saline solution of 15 mass % and 100 mL of a concentrated hydrochloric acid was added and was subjected to liquid separation. An organic layer was washed with 400 mL of a saline solution of 15 mass % three times, and then a magnesium sulfate was added thereto and dried. After filtration, a solvent was subjected to vacuum distillation, and was purified with a column chromatography, and thus 50 g of an exemplificative compound (2) was obtained as a white solid (a yield of 21%).
Hereinafter, the data of the synthesized exemplificative compound (2) will be described.
1H-NMR(300 mHz, DMSO-d6)δ: 3.29 to 3.41(m, 4H), 4.60(s, 2H), 6.72 to 6.82(m, 2H), 6.93 to 7.04(m, 4H), 7.12 to 7.29(m, 9H), 11.60(s, 1H)
Synthesis Example 2
[Synthesis of Exemplificative Compound (8)]
160 mL of N,N-dimethyl acetamide, 21.3 g of 1-benzyl-5-phenyl barbiturate (manufactured by Tokyo Chemical Industry Co., Ltd.) and 11.4 g of methyl iodide were put into a three neck flask of 500 mL which was attached with a thermometer, a circulation cooling tube, and a stirrer. 8.1 g of triethyl amine was dropped while stirring the mixture at room temperature, and then the mixture was stirred at room temperature for 5 hours. 200 mL of ethyl acetate and 200 mL of water were added to a reaction mixture, and were subjected to liquid separation. An organic layer was washed with 200 mL of an aqueous solution of sodium disulfite one time and was washed with 200 mL of a saturated saline solution two times, and sodium sulfite was added and dried. After filtration, a solvent was subjected to vacuum distillation, and an obtained solid was added to 100 mL of methanol, and was dispersed and washed, and then was subjected to vacuum filtration and dried, and thus 21.0 g of an exemplificative compound (8) was obtained as a white solid (a yield of 94%).
Hereinafter, the data of the synthesized exemplificative compound (8) will be described.
1H-NMR(300 mHz, DMSO-d6)δ: 1.74(s, 3H), 4.92(s, 2H), 7.14 to 7.22(m, 4H), 7.22 to 7.28(m, 3H), 7.28 to 7.35(m, 3H), 11.82(s, 1H)
Each of exemplificative compounds (1), (3), (9) (11) to (13), (16), (21), (22), and (26) was synthesized by the same method as that of the exemplificative compound (2) or (8) or the same method as that disclosed in the literatures described above.
Example 1
(A) Preparation and Evaluation of Cellulose Acylate Film (Optical Film)—1
(Preparation of Cellulose Acetate)
Cellulose acetate having a total degree of acetyl substitution (B) of 2.87 was prepared. A sulfuric acid (7.8 parts by mass with respect to 100 parts by mass of cellulose) was added as a catalyst, an acetic acid was added, and an acetylation reaction was performed at 40° C. In addition, maturing was performed at 40° C. after the acetylation. Further, a low molecular weight component of the cellulose acetate was washed with acetone and was removed.
(Optical Film: Preparation of Cellulose Acylate Film of Single Layer)
The following compositions were put into a mixing tank and were stirred, and each of the components was dissolved, and thus a cellulose acetate solution was prepared.










Composition of Cellulose Acetate Solution
















Cellulose Acetate Having Total Degree of Acetyl
100.0 parts by mass


Substitution (B) of 2.87 and Degree of


Polymerization of 370


Compound Denoted by General Formula (I) Shown
 10.0 parts by mass


in Table 1 Described Below


Methylene Chloride (First Solvent)
402.0 parts by mass


Methanol (Second Solvent)
 60.0 parts by mass









The cellulose acetate solution was casted by using a band casting machine, and was dried at 100° C. until a residual solvent content became 40%, and then a film was peeled off The peeled film was further dried at an atmospheric temperature of 140° C. for 20 minutes. Thus, each of optical films 101 to 105 and c11 to c13 shown in Table 1 described below was prepared. The film thickness of each of the obtained optical films (cellulose acetate films) was 60 μm.
(Measurement of Modulus of Tension Elasticity)
A sample of 150 mm×10 mm was cut from each of the optical films prepared as described above, stress in stretching of 0.1% and stretching of 0.5% at a tensile speed of 10%/minute was measured under an atmosphere of a temperature of 25° C. and relative humidity of 60% by using an universal tensile testing machine “STM T50BP” manufactured by Orientec Co., Ltd., and modulus of elasticity was obtained from the slope. Furthermore, the measurement was performed in two arbitrary directions orthogonal to each other, the geometric mean thereof was obtained, and the obtained value was set to modulus of tension elasticity (unit: GPa).
(Evaluation of Surface Hardness)
Surface hardness of each of the prepared optical films 101 to 105 and c11 to c13 was measured.
A sample surface fixed to a glass substrate was measured in conditions of a loading time of 10 seconds, a creeping time of 5 seconds, an offloading time of 10 seconds, and a maximum load of 50 mN by a knoop indenter in which the direction of a short axis of an indenter was arranged to be parallel to the transport direction (the MD direction; a test direction in a pencil hardness test) at the time of forming the cellulose acylate film using a “Fischer Scope H100Vp type hardness meter” manufactured by Fischer Instruments K. K. The hardness was calculated from a relationship between a contact area of the indenter and the sample and the maximum load which was obtained from an indentation depth, and the average value of five points was set to surface hardness.
In addition, the sample surface fixed to the glass substrate was measured in conditions of a loading time of 10 seconds, a creeping time of 5 seconds, an offloading time of 10 seconds, and an indentation load of 50 mN by using a “Fischer Scope H100Vp type hardness meter” manufactured by Fischer Instruments K. K. on the basis of a method of JIS Z 2251, and the hardness was calculated from the relationship between the contact area of the indenter and the sample and the maximum load which was obtained from the indentation depth. Furthermore, JIS Z 2251 was Japanese Industrial Standards prepared on the basis of ISO4545-1 and ISO4545-4.
Further, in the same indentation position, the knoop indenter was rotated by each 10°, knoop hardness was measured at 18 directions (all directions) in total, and thus the minimum value was obtained. The minimum value was coincident with the surface hardness which was measured by arranging the direction of the short axis of the knoop indenter described above to be parallel to the transport direction (the MD direction; the test direction in the pencil hardness test) at the time of forming the cellulose acylate film. The unit was N/mm2.
A value which was obtained by dividing the value of the knoop hardness at the time of adding the compound denoted by General Formula (1) of the present invention (hereinafter, also referred to as an additive) by the value of knoop hardness at the time of not adding the compound denoted by General Formula (I) of the present invention, was calculated as a hardness improvement effect, and evaluated on the basis of the following criteria.
Furthermore, when the evaluation is greater than or equal to “C”, hardness as the cellulose acetate film is high, and is sufficiently practical from a viewpoint of workability.
Evaluation Criteria of Surface Hardness
A: Greater than or equal to 1.15 times the value of the knoop hardness at the time of not adding the additive
B: Greater than or equal to 1.10 times and less than 1.15 times the value of the knoop hardness at the time of not adding the additive
C: Greater than or equal to 1.03 times and less than 1.10 times the value of the knoop hardness at the time of not adding the additive
D: Less than 1.03 times the value of the knoop hardness at the time of not adding the additive
(Evaluation of Film Coloration)
Light irradiation was performed with respect to each of the optical films of the present invention prepared as described above for 120 hours in conditions of irradiance of 150 W/m2, a black panel temperature of 63° C., and relative humidity of 50% by using a super xenon weather meter (a product name: SX75, manufactured by Suga test Instruments Co., Ltd.). After that, hue b* was measured by using a spectrophotometer UV3150 manufactured by Shimadzu Corporation. When the value of the hue b* is increased on a minus side, a blue color of transmissive light is increased, and when the value of the hue b* is increased on a plus side, a yellow color of the transmissive light is increased. The absolute value of a change in the value of b* before and after the light irradiation was set to Δb*, and this was an index with respect to optical coloration.
The evaluation was performed on the basis of the following criteria.
A: Δb* was less than 0.04
B: Δb* was greater than or equal to 0.04 and less than 0.08
C: Δb* was greater than or equal to 0.08
The results thereof are collectively shown in Table 1 described below.













TABLE 1







Added
Modulus of







Amount*
Tension



Compound
(Parts by
Elasticity
Surface
Film


Film No.
Number
Mass)
(GPa)
Hardness
Coloration
Notes







101
(1)
10
4.2
B
A
Present


102
(2)
10
4.0
B
A
Invention


103
(3)
10
3.7
C
A


104
(8)
10
4.3
A
A


105
(9)
10
4.3
A
A


c11
Comparative
10
4.4
A
B
Comparative



Compound 1




Example


c12
Comparative
10
3.6
D
A



Compound 2


c13
None
10
3.7
D
A





*indicates the amount added per 100 parts by mass of cellulose.






Here, a comparative compound 1 is an organic acid A disclosed in JP2011-118135A, and a comparative compound 2 is an oil gelling agent (33) disclosed in JP2002-322294A.




As it is obvious from Table 1, it was found that, in all of the optical films 101 to 105 of the present invention, a coloration suppression effect of the film due to light was excellent, and suitable modulus of tension elasticity and hardness were expressed.
All of the optical films 101 to 105 of the present invention exhibit high surface hardness, compared to an optical film C12 using the comparative compound 2. This is considered that the compound denoted by General Formula (I) of the present invention has a ring structure or a polar group, and thus a mutual interaction with respect to the cellulose acetate becomes stronger.
In addition, in all of the optical films 101 to 105 of the present invention, the coloration of the film due to the light is suppressed, compared to an optical film C11 using the comparative compound 1.
Example 2
(B) Preparation and Evaluation of Cellulose Acylate Optical Film)—2
Optical films 121 to 125 of the present invention were prepared by the same method as that in Example 1 except that the type of the compound denoted by General Formula (I) of the present invention was changed as shown in Table 2 described below. The evaluation of each of the properties was performed by the same method as that in Example 1.












TABLE 2






Compound







Number
Added



Denoted by
Amount*



General
(Parts by
Surface
Film


Film No.
Formula (I)
Mass)
Hardness
Coloration
Notes







121
(11)
10
B
A
Present


122
(12)
10
A
A
Invention


123
(13)
10
A
A


124
(21)
10
B
A


125
(26)
10
B
A





*indicates the amount added per 100 parts by mass of cellulose.






As it is obvious from Table 2, in all of the optical films 121 to 125 of the present invention, the surface hardness was high, and the film coloration due to the light was suppressed. Accordingly, it was found that all of the compounds denoted by General Formula (I) of the present invention contributed to hardness expression properties and suppression of the film coloration.
Example 3
(C) Preparation and Evaluation of Cellulose Acylate (Optical Film)—3
Optical films 131 to 136 of the present invention were prepared by the same method as that in Example 1 except that the degree of cellulose acylate substitution and the type of the compound denoted by General Formula (I) of the present invention were changed as shown in Table 3 described below.
The evaluation of each of the properties was performed by the same method as that in Example 1.











TABLE 3









Cellulose





Acylate
Compound Denoted by



Total
General Formula (I)














Degee of

Added






Acetyl

Amount*
Film
Film Performance















Substitution
Compound
(Parts by
Thickness
Knoop
Film



Film No.
(B)
Number
Mass)
(μm)
Hardness
Coloration
Note





131
2.42
(2)
10
58
B
A
Present









Invention


132
2.42
(8)
10
60
A
A
Present









Invention


133
2.77
(8)
10
61
A
A
Present









Invention


134
2.93
(2)
10
57
B
A
Present









Invention


135
2.93
(8)
19
59
A
A
Present









Invention


136
2.93
(9)
10
60
A
A
Present









Invention





*indicates the amount added per 100 parts by mass of cellulose.






As shown in Table 3, it was found that the compound denoted by General Formula (I) of the present invention had the hardness and the suppression of the film coloration without depending on the degree of cellulose acylate substitution.
Example 4
(D) Preparation and Evaluation of Cellulose Acylate (Optical Film)—4
Each of optical films 141 to 144 and c41 to c43 was prepared by the same method as that in Example 1 except that the type of cellulose acylate, the type of each additive, and the film thickness of the cellulose acylate film were changed as shown in Table 4 described below.
The evaluation of each of the properties was performed by the same method as that in Example 1. However, when the surface hardness was evaluated, as described below, an indentation load was changed according to the film thickness.
(Evaluation of Surface Hardness)
The surface hardness of the cellulose acylate film obtained as described above was measured by the same method as that in Example 1 except that the indentation load was set to 20 mN.
The value of the knoop hardness of each of the films was compared with the value of the knoop hardness of the film which was prepared without adding the additive, and then was evaluated on the basis of the following criteria.
A: Greater than or equal to 1.15 times the value of the knoop hardness at the time of not adding the additive
B: Greater than or equal to 1.10 time and less than 1.15 times the value of the knoop hardness at the time of not adding the additive
C: Greater than or equal to 1.03 time and less than 1.10 times the value of the knoop hardness at the time of not adding the additive
D: Less than 1.03 times the value of the knoop hardness at the time of not adding the additive











TABLE 4









Cellulose





Acylate



Total
Additive














Degee of

Added






Acetyl

Amount
Film
Film Performance















Substitution
Compound
(Parts by
Thickness
Knoop
Film



Film No.
(B)
Number
Mass)
(μm)
Hardness
Coloration
Note

















141
2.86
(1)
10
30
B
A
Present


142
2.86
(2)
12
35
B
A
Invention


143
2.86
(8)
12
25
A
A


144
2.86
(9)
12
26
A
A


c41
2.86
Comparative
12
25
A
B
Comparative




Compound 1




Example


c42
2.86
Comparative
12
27
D
A




Compound 2


c43
2.86
None
0
26
—
A









As shown in Table 4, it was found that, in the optical film containing the compound denoted by General Formula (I) of the present invention, a preferred surface hardness improvement effect and a preferred optical coloration suppression effect were able to be expressed at the time of thinning.
Example 5
(Preparation of Optical Film Attached with Hard Coat Layer)
A hard coat layer solution having the following curable composition was applied onto the surface of each of the optical films of a single layer which was prepared in Example 1, and was cured by ultraviolet irradiation, and thus an optical film attached with a hard coat layer was prepared on which a hard coat layer having a thickness of 6 μm was formed.










Composition of Hard Coat Layer Solution
















Monomer Pentaerythritol Triacrylate/Pentaerythritol
53.5 parts by mass


Tetraacrylate (Mixed Mass Ratio of 3/2)


UV Initiator Irgacure TM 907 (manufactured
 1.5 parts by mass


by BASF SE)


Ethyl Acetate
  45 parts by mass









<Pencil Hardness Evaluation>
The humidity of each of the cellulose acylate films attached with a hard coat layer was adjusted for 2 hours in conditions of a temperature of 25° C. and relative humidity of 60%, and the pencil hardness was measured by using a pencil for a test defined in JIS-S6006 according to a pencil hardness evaluation method defined in JIS-K5400. Specifically, the surface of the hard coat layer was repeatedly scratched 5 times with a pencil with each hardness by using a weight of 500 g, and the hardness was measured until the number of defects became 1.
Here, it is disclosed that a defect defined in JIS-K5400 is a breakage of a coated film and a scratch of the coated film, but concavity of the coated film is not a target. However, in this evaluation, the concavity of the coated film was also determined as a defect. As a result thereof, it was found that all of the optical films 101 to 105 of the present invention had an excellent value of 3H.
Example 6
Evaluation of Performance as Polarizing Plate
(Saponification Treatment of Polarizing Plate Protective Film)
A polarizing plate protective film formed of the optical film 101 of the present invention which was prepared in Example 1 was dipped in 2.3 mol/L of an aqueous solution of sodium hydroxide at 55° C. for 3 minutes. After that, the polarizing plate protective film was washed in a water washing bath at room temperature, and was neutralized at 30° C. by using 0.05 mol/L of a sulfuric acid. The polarizing plate protective film was washed again in the water washing bath at room temperature, and was further dried with hot air at 100° C. Thus, a saponification treatment was performed with respect to the surface of the polarizing plate protective film formed of each of the optical films which were prepared in Examples 1 to 4. Furthermore, a regularly used polarizer as described in the section of [polarizing plate] was used as a polarizer.
(Preparation of Polarizing Plate)
Iodine was adsorbed in a stretched polyvinyl alcohol film, and thus a polarizer was prepared.
A polarizing plate protective film 101 which was prepared in Example 1 and was subjected to the saponification treatment described above was bonded to one side of the polarizer by using a polyvinyl alcohol-based adhesive agent. A commercially available cellulose triacetate film (Fujitac TD80UF (a product name), manufactured by Fujifilm Corporation) was also subjected to the same saponification treatment. The commercially available cellulose triacetate film which had been subjected to the saponification treatment was bonded to the surface of the polarizer on a side opposite to the surface side onto which the polarizing plate protective film 101 subjected to the saponification treatment was bonded by using the polyvinyl alcohol-based adhesive agent.
At this time a transmission axis of the polarizer and a slow axis of the polarizing plate protective film 101 which was prepared in Example 1 and had been subjected to the saponification treatment were arranged to be parallel to each other. In addition, the transmission axis of the polarizer and a slow axis of the commercially available cellulose triacetate film which had been subjected to the saponification treatment were arranged to be orthogonal to each other.
Thus, a polarizing plate 101 of the present invention was prepared.
Each of polarizing plate protective films 102 to 105, 121 to 125, 131 to 136, 141 to 144 and polarizing plate protective films c13 and c43 of a comparative example was subjected to the saponification treatment as described above, and a polarizing plate was prepared, and thus each of polarizing plates 102 to 105, 121 to 125, 131 to 136, and 141 to 144 of the present invention and polarizing plates c13 and c43 of a comparative example was prepared.
The polarizing plate of the present invention reflected the performance of the optical film of the present invention in which the polarizing plate of the present invention was incorporated, and thus excellent performance was exhibited.
As a result thereof, it is possible to prepare a liquid crystal display device having excellent performance as described above by using the optical film of the present invention and the polarizing plate using the optical film.
The present invention is described with reference to the embodiments, but the present invention is not limited thereto unless otherwise specifically stated, and is able to be widely interpreted within the scope and the gist of claims.
Priority is claimed on Japanese Patent Application No. 2013-143707, filed on Jul. 9, 2013, the content of which is incorporated herein as a part by reference.
EXPLANATION OF REFERENCES


    
    
        21A, 21B: polarizing plate
        22: color filter substrate
        23: liquid crystal layer (liquid crystal cell)
        24: array substrate
        25: light guide plate
        26: light source
        31a, 31a′, 31b: optical film (polarizing plate protective film)
        311a: cellulose acylate film
        311b: hard coat layer
        32: polarizer
        R: polarization direction

## Claims

1. An optical film containing at least one layer comprising greater than or equal to 50 mass % of cellulose acylate, and at least one type of a compound denoted by General Formula (I) described below,



wherein in General Formula (I), R1 and R3 each independently represent a hydrogen atom, an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group, and R5a and R5b each independently represent an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group, and
wherein the total number of ring structures existing in R1, R3, R5a, and R5b is greater than or equal to 2, the ring structures being selected from a benzene ring, a cycloalkyl ring and a cycloalkenyl ring.

2. The optical film according to claim 1,
wherein at least one of R1 and R3 described above is an alkyl group, an alkenyl group, a cycloalkyl group, a cycloalkenyl group, or an aryl group.

3. The optical film according to claim 1,
wherein at least one of R5a and R5b described above does not have a ring structure.

4. The optical film according to claim 1,
wherein at least one of R5a and R5b described above is a substituent group having carbon atoms of less than or equal to 4.

5. The optical film according to claim 1,
wherein at least one of R5a and R5b described above is a substituent group having carbon atoms of less than or equal to 4, and the other is a substituent group having a ring structure.

6. The optical film according to claim 1,
wherein at least one of R1 and R3 described above is an alkyl group or an aryl group having an aryl group as a substituent group.

7. The optical film according to claim 1,
wherein the cellulose acylate is cellulose acylate in which a total degree of acyl substitution A satisfies the following expression


1.5≦A≦3.0.

8. The optical film according to claim 1,
wherein the cellulose acylate is cellulose acylate in which an acyl group is an acetyl group, and a total degree of acetyl substitution B satisfies the following expression


2.0≦B≦3.0.

9. The optical film according to claim 1,
wherein the optical film comprises at least two layers, in which a hard coat layer is laminated on a layer containing the cellulose acylate and at least one type of the compound denoted by General Formula (I) described above.

10. A polarizing plate, comprising:
a polarizer; and
the optical film according to claim 1 on at least one surface of the polarizer.

11. A liquid crystal display device, at least comprising:
the polarizing plate according to claim 10; and
a liquid crystal cell.