Patent Application
20100236713
The present invention relates to a film for a display, a polarizing plate and a manufacturing method thereof, and a liquid crystal display.
In recent years development of a thinner and lighter-weighted note type personal computer having a larger image plane and a higher definition is in progress. Accordingly, a protective film for varieties of displays, specifically, a protective film for a liquid crystal display is also more and more intensively required to be thinner and wider, and to have higher quality. Generally, as polarizing plate protective film, a cellulose ester film is widely utilized. Cellulose ester film is generally wound around a core to form a film master roll, which is stored and transported.
Heretofore, this cellulose ester film has been primarily manufactured by a solution casting method. In a solution casting method, cellulose ester dissolved in a solvent is cast on a support to form a film, followed by evaporating the solvent to dry the film, and thus a film is obtained. Since the film obtained by a solution casting method has excellent flatness, a liquid crystal display exhibiting a high image quality without unevenness can be obtained by using the cellulose ester film.
However, a solution casting method requires a large amount of an organic solvent, which has been a problem in view of the large environmental load. Since cellulose ester film is cast by use of a halogen-containing solvent because of the excellent solubility characteristics, decrease of the using amount of a solvent is particularly required. Accordingly, it has become difficult to produce a larger amount of cellulose ester film by a solution casting method.
Further, since it is necessary to remove a solvent remaining in the film interior, facility investment to the manufacturing line such as a drying line, a drying energy and apparatuses for recover and regeneration of an evaporated solvent; and a manufacturing cost have been enormous, and reduction thereof is also an important subject.
On the other hand, disclosed has been a technology to improve spectral characteristics and mechanical characteristics of the cellulose ester film by adding a hindered phenol antioxidant, a hindered amine photo-stabilizer or an acid scavenger at a certain addition ratio (for example, refer to Patent Document 1). A technology to utilize a polyalcohol ester plasticizer (for example, refer to Patent Document 2) and a technology in which the polyalcohol ester plasticizer is further focused onto a specified structure (for example, refer to Patent Document 3) have also been disclosed.
Further, as a technology to prevent degradation of an organic material, a variety of stabilizers and a stabilizer composition containing a phosphate ester have been disclosed (for example, refer to Patent Document 4).
However, in any case, with respect to a cellulose ester film for an optical use, problems have not fully been overcome, for example, there still exist problems of a production load and a facility load as well as not fully sufficient optical property and mechanical property.
In recent years, an attempt has been made to melt cast a cellulose ester film for the application in silver salt photography or in polarizing plate protective film, however, since cellulose ester is a polymer which exhibits a rather high viscosity of the melt, and a high glass transition temperature, it has been known that the leveling of the film is difficult when cellulose ester is melt and extruded through a dies to cast on a cooling drum or on a cooling belt to form a film and that the optical property and the mechanical property of thus obtained film is inferior to those of a solution cast film (for example, refer to Patent Documents 5 and 6).
Therefore, it has been proved that, when a melt cast film is stored for a long period in a state of being wound on a core, there is a problem of easy generation of horseback defects, and defects called as a “core set” and wrinkles in the film at the start of winding of a film master roll.
A horseback defect is a defect in which film master roll deforms in a U-shape like a horseback to generate belt-form convex parts at approximately 2-3 cm pitches in the vicinity of the central portion, and the surface looks distorted when film is made into a polarizing plate because the deformation remains on film Heretofore, generation of a horseback defect has been restrained by decreasing a dynamic friction coefficient between bases or by adjusting a height of a knurling treatment provided on the both sides.
Further, a core set is a film deformation defect generated by roughness of a core and a film When there is such film deformation, it is problematic because the surface looks distorted when the film is made into a polarizing plate.
Further, when a cellulose ester film is used on the outermost surface of a liquid crystal display, a clear hard coat processing, an anti-glare processing or an anti-reflection processing is carried out on the cellulose ester film. When these processes are performed, deformation of the film surface may cause uneven coating or uneven vacuum deposition, which may significantly deteriorate the product yield.
These defects have not been significant problems in the film prepared by a conventional solution casting method, however, it has been found that these defects become significant problems due to the poor flatness of the melt cast film.
Particularly, in recent years, a film master roll is desired to have a wider width and a longer length of film in accordance with the popularization of a larger image screen. Therefore, there is a tendency that the width of a film master roll becomes wider and the weight of a film master roll becomes heavier, and this situation easily causes the above defects. Accordingly, an improvement is strongly desired.
Patent Document 1 JP-A No. 2003-192920 (hereinafter, JP-A refers to Japanese Patent Application Publication)
Patent Document 2 JP-A No. 2003-12823
Patent Document 3 JP-A No. 2003-96236
Patent Document 4 JP-A No. 11-222493
Patent Document 5 Japanese Translation of PCT International Application Publication No. 6-501040
Patent Document 6 JP-A No. 2000-352620
An object of the present invention is to provide a film for a display which causes no deformation defects of a film master roll such as a horseback defect or a convex defect even after a long term storage, specifically to provide a polarizing plate protective film utilizing a cellulose ester film, a polarizing plate, a manufacturing method thereof, and a liquid crystal display utilizing said polarizing plate.
One of the aspects of the present invention to achieve the above object is a film for a display comprising a cellulose ester and a compound represented by Formula (I) or (Ia).
b) is a cross-sectional view of the primary portion of a casting die.
a)-8(c) are drawings to show a storing state of a film master roll for a display.
The above object of the present invention is achieved by the following structures.
(1) A film for a display comprising a cellulose ester and a compound represented by Formula (I) or (Ia):
wherein R2 to R5 each independently represent a hydrogen atom or a substituent; R2 and R3, R3 and R4, and R4 and R5 may be combined to form a ring; R6 represents a hydrogen atom or a substituent; n represents an integer of 1-4; when n equals to 1, R1 represents a substituent; and when n is 2-4, R1 represents a di- to tetra-valent linkage group,
wherein n represents an integer of 2 to 4; m represents an integer of 1-3: R1a and R6a each independently represent a hydrogen atom or a substituent; Rta represents a hydrogen atom or a substituent; a plurality of Rta may be combined to form a ring; and Rka represents a di- to tetra-valent linkage group.
(2) The film for a display of Item (1), wherein
R1 in Formula (I) is a conjugated substituent when n is 1; or R1a in Formula (Ia) is a conjugated substituent when n is 1.
(3) The film for a display of Item (1) or (2), wherein the compound represented by Formula (I) is a compound represented by Formula (I-1):
wherein R2 to R5 each independently represent a hydrogen atom or a substituent; R7 to R11 each independently represent a hydrogen atom, an alkyl group having 1 to 18 carbon atoms or an alkoxy group having 1 to 18 carbon atoms.
(4) The film for a display of any one of Items (1) to (3), wherein a sum of Hammett's σp values of R7 to R11 is 0 or less.
(5) The film for a display of any one of Items (1) to (4), wherein the compound represented by Formula (I) is a compound represented by Formula (I-2):
wherein R2 to R5 each independently represent a hydrogen atom or a substituent.
(6) The film for a display of any one of Items (1) to (5), wherein R5 in Formula (I) is a hydrogen atom.
(7) The film for a display of Item (1), wherein the compound represented by Formula (Ia) is a compound represented by Formula (I-3):
wherein R1, R2, R3, R5 and R6 each independently represent a hydrogen atom or a substituent; R2 and R3 may be combined to form a ring; and X represents a divalent linkage group.
(8) The film for a display of any one of Items (1) to (7) further comprising a compound represented by Formula (A):
wherein R11 to R16 each independently represent a hydrogen atom or a substituent.
(9) The film for a display of any one of Items (1) to (8) further comprising a phosphonite compound.
(10) The film for a display of any one of Items (1) to (9), wherein a transmittance of the film for a light flux having a wavelength of 450 nm is 90% or more.
(11) The film for a display of any one of Items (1) to (10), wherein the cellulose ester is a mixed fatty acids ester.
(12) The film for a display of any one of Items (1) to (11), wherein a total number of carbon atoms contained in acyl groups in one glucose unit of the cellulose ester is 6.1 to 7.5, wherein the total number of carbon atoms represents a sum of each product of a number of carbon atoms of each acyl group multiplied by a substitution degree of the acyl group, wherein the substitution degree represents an average number of 3 hydroxyl groups replaced with an acyl group in one glucose unit of the cellulose ester.
(13) The film for a display of any one of Items (1) to (12), wherein the film is a long length film wound in a roll.
(14) A polarizing plate protective film for a liquid crystal display comprising the film for a display of claim 1.
(15) The polarizing plate protective film of Item (14), wherein the polarizing plate protective film is a long length film wound in a roll.
(16) A polarizing plate comprising the polarizing plate protective film of Item (14) or (15) provided on at least one surface of a polarizer film
(17) A method to produce the polarizing plate of Item (16) comprising the steps of:
wherein R2 to R5 each independently represent a hydrogen atom or a substituent; R2 and R3, R3 and R4, and R4 and R5, may be combined to form a ring; R6 represents a hydrogen atom or a substituent; n represents an integer of 1-4; when n equals to 1, R1 represents a substituent; and when n is 2-4, R1 represents a di- to tetra-valent linkage group,
wherein n represents an integer of 2 to 4; m represents an integer of 1-3; R1a and R6a each independently represent a hydrogen atom or a substituent; Rta represents a hydrogen atom or a substituent; a plurality of Rta may be combined to form a ring; and Rka represents a di- to tetra-valent linkage group,
wherein R2 to R5 each independently represent a hydrogen atom or a substituent; R1 to R11 each independently represent a hydrogen atom, an alkyl group having 1 to 18 carbon atoms or an alcokyl group having 1 to 18 carbon atoms,
wherein R2 to R3 each independently represent a hydrogen atom or a substituent,
wherein R1, R2, R3, R5 and R6 each independently represent a hydrogen atom or a substituent R2 and R3 may be combined to form a ring; and X represents a divalent linkage group.
(19) A liquid crystal display comprising the polarizing plate of Item (16) provided on at least one surface of a liquid crystal cell.
(20) A liquid crystal display comprising a polarizing plate produced by the method of Item (17) or (18) provided on at least one surface of a liquid crystal cell.
The present invention can provide a film for a display which generates no deformation defects of a master roll such as a horseback defect and a convex defect even after a long term storage, in particular, a polarizing plate protective film utilizing cellulose ester film, a polarizing plate, a manufacturing method thereof, and a liquid crystal display utilizing said polarizing plate.
In the following, the most preferred embodiment to practice the present invention will be detailed; however, the present invention is not limited thereto.
In the present invention, the film for a display is characterized by containing cellulose ester and a compound represented by the aforesaid Formula (I) or (Ia).
The film for a display refers to various types of film which is utilized in such as a liquid crystal display, a plasma display panel and an organic EL display. For example, various types of film such as a polarizing plate protective film, a non-oriented film, a retardation film, a luminance enhancing film, an antireflection film or an anti-glare film is included in the film for a display. It is specifically preferable that the film of the present invention is utilized in polarizing plate protective film of a liquid crystal display.
The film for a display includes a film having a size of a liquid crystal display, which is utilized as a polarizing plate protective film utilized in a liquid crystal display, and a long length film. Long length film is preferably has a length of not less than 100 m and not more than 10,000 m. Specifically, the effect of the present invention is more significantly exhibited in the case of handling long length film as a roll form.
It is preferable that the film for a display of the present invention contains a cellulose ester film and said cellulose ester film contains a compound represented by Formula (I) or (Ia). Herein, the film for a display may contain only a cellulose ester film or a cellulose ester film accumulated with one or more other layers.
Next, compounds represented by Formula (I) will be explained.
In above-described Formula (I), R2-R5 each independently is a hydrogen atom or a substituent. R2 and R3, R3 and R1, or R4 and R5 may form a ring by bonding to each other. R6 is a hydrogen atom or a substituent, n is an integer of 1-4, and R1 is a substituent when n is 1, while R1 is a 2-4 valent connecting group when n is 2-4.
Substituents represented by R1-R6 are not specifically limited, however, include an alkyl group (such as a methyl group, an ethyl group, a propyl group, an isopropyl group, a t-butyl group, a pentyl group, a hexyl group, an octyl group, a dodecyl group and trifluoromethyl group), a cycloalkyl group (such as a cyclopentyl group and a cyclohexyl group), an aryl group (such as a phenyl group and a naphthyl group), an acylamino group (such as an acetylamino group and a benzoylamino group), an alkylthio group (such as a methylthio group and an ethylthio group), an arylthio group (such as a phenylthio group and a naphthylthio group), an alkenyl group (such as a vinyl group, a 2-propenyl group, a 3-butenyl group, a 1-methyl-3-propenyl group, a 3-pentenyl group, a 1-methyl-3-butenyl group, a 4-hexenyl group and a cyclohexenyl group), a halogen atom (such as a fluorine atom, a chlorine atom, a bromine atom and an iodine atom), an alkynyl group (such as a propalgyl group), a heterocyclic group (such as a pyridyl group, a thiazolyl group, an oxazolyl group and an imidazolyl group), an alkylsulfonyl group (such as a methylsulfonyl group and an ethylsulfonyl group), an arylsulfonyl group (such as a phenylsulfonyl group and a naphthylsulfonyl group), an alkylsulfinyl group (such as a methylsulfinyl group), an arylsulfinyl group (such as a phenylsulfinyl group), a phosphono group, an acy group (such as an acetyl group, a pivaloyl group and a benzoyl group), a carbamoyl group (such as an aminocarbonyl group, a methylaminocarbonyl group, a dimethylaminocarbonyl group, a butylaminocarbonyl group, a cyclohexylaminocarbonyl group, a phenylaminocarbonyl group and a 2-pyridylaminocarbonyl group), a sulfamoyl group (such as an aminosulfonyl group, a methylaminosulfonyl group, a dimethylaminosulfonyl group, a butylaminosulfonyl group, a hexylaminosulfonyl group, a cyclohexylaminosulfonyl group, an octylaminosulfonyl group, a dodecylaminosulfonyl group, a phenylaminosulfonyl group, a naphthylaminosulfonyl group and a 2-pyridylaminosulfonyl group), a sulfonamide group (such as a methanesulfonamide group and a benzenesulfonamido group), a cyano group, an alkoxy group (such as a methoxy group, an ethoxy group and a propoxy group), an aryloxy group (such as a phenoxy group and a naphthyloxy group), a heterocyclicoxy group, a siloxy group, an acyloxy group (such as an acetyloxy group and a benzoyloxy group), a sulfonic acid group, a salt of sulfonic acid, an aminocarbonyloxy group, an amino group (such as an amino group, an ethylamino group, a dimethylamino group, a butylamino group, a cyclopentylamino group, a 2-ethylhexylamino group and a dodecylamino group), an anilino group (such as a phenylamino group, a chlorophenylamino group, a toluidino group, an anisidino group, a naphthylamino group and a 2-pyridylamino group), an imido group, an ureido group (such as a methylureido group, an ethylureido group, a pentylureido group, a cyclohexlureido group, an octylureido group, a dodecylureido group, a phenylureido group, a naphthylureido group and a 2-pyridylureido group), an alkoxycarbonylamino group (such as a methyoxycarbonylamino group and a phenoxycarbonylamino group), an aryloxycarbonylamino group (such as a phenoxycarbonylamino group), a heterocyclicthio group, a thioureido group, a carboxyl group, a salt of carboxylic acid, a hydroxyl group, a mercapto group and a nitro group. These groups may be further substituted by a similar substituent.
In aforesaid Formula (I), R2-R5 is preferably a hydrogen atom or an alkyl group.
In aforesaid Formula (I), R6 is a hydrogen atom or a substituent, and a substituent represented by R6 includes substituents similar to substituents represented by R2-R5. R5 may be a substituent, however, is preferably a hydrogen atom. Particularly R6 is preferably a hydrogen atom.
In aforesaid Formula (I), n is an integer of 1-4, and R1 is a substituent when n is 1, as explained above, while R1 each is corresponding 2-4 valent connecting group when n is an integer of 2-4.
Herein, R1 is preferably a substituent of a conjugate type when n is 1. Examples of a substituent of a conjugate type include ethylene, acetylene, butadiene; aromatic hydrocarbon and a heterocyclic ring such as pyridine, anthrathene, pyrene, furan, benzene and naphtharene and preferably aromatic hydrocarbon such as benzene and naphthalene.
When R1 is a 2-4 valent connecting group, a divalent connecting group includes, for example, a divalent alkylene group which may be provided with a substituent, a divalent arylene group which may be provided with a substituent, an oxygen atom, a nitrogen atom, a sulfur atom or combinations of these connecting groups.
A trivalent connecting group includes, for example, a trivalent alkylene group which may be provided with a substituent, a trivalent arylene group which may be provided with a substituent, a nitrogen atom or combinations of these connecting groups. A tetravalent connecting group includes, for example, a tetravalent alkylene group which may be provided with a substituent, a tetralent arylene group which may be provided with a substituent or combinations of these connecting groups.
In aforesaid Formula (I), n is preferably 1 and R1 is preferably a phenyl group which may be substituted or unsubstituted. More specifically, it is preferably aforesaid Formula (I-1). In aforesaid Formula I-1), R2-R5 each independently are a hydrogen atom or a substituent. R7-R11 each independently are a hydrogen atom, an alkyl group having a carbon number of 1-18, or an alkoxy group having a carbon number of 1-18.
In aforesaid Formula (I-1), the total sum of Hammett's σp value of R7-R11 is preferably not more than 0. Herein, σp value described in this patent publication will be explained. Hammett's rule is an empirical rule proposed by L. P. Hammett in 1935 to discuss the influence of a substituent on a reaction or equilibrium of a benzene derivative, and is widely recognized to be valid nowadays. The coefficient of a substituent determined by Hammett's rule includes σp value and am value, which can be referred to general literatures and are detailed in “Lange's Handbook of Chemistry” the 12th edition, edited by J. A. Dean (1979) (McGraw-Hill) and “Kagaku No Ryoiki”, Special No. 122, pp. 96-103 (1979) (Nankodo). In the present invention, each substituent will be limited or explained based on Hammett's coefficient of substituent σp value, however, this does not necessarily mean to be limited to substituents, the values of which are already known in literatures, but naturally includes substituent the value of which supposed to be in the range when measured based on Hammett's rule. In this patent, σp value represents this meaning.
An example of aforesaid Formula (I-1) includes compounds of aforesaid Formula (I-2). In aforesaid Formula (I-2), R2-R5 each independently are a hydrogen atom or a substituent.
Next, compounds of Formula (Ia) of the present invention will be explained.
In aforesaid Formula (Ia), n is an integer of 2-4 and m is an integer of 1-3. R1a and R6a each independently are a hydrogen atom or a substituent. Rta is a hydrogen atom or a substituent. Herein, Rta may bond to each other to form a ring. Rka is a 2-4 valent connecting group.
As specific examples of R1a and R6a, the explanations of R1 and R6 described above can be applied. Herein, R1a is preferably a substituent of a conjugate type when n is 1. Examples of a conjugated substituent include ethylene, acetylene and butadiene; an aromatic hydrocarbon and a heterocyclic ring such as pyridine, anthrathene, pyrene, furan, benzene and naphthalene. Among them, aromatic hydrocarbon such as benzene and naphthalene are preferable.
An example of aforesaid Formula (Ia) includes a compound of aforesaid Formula (I-3). In Formula (I-3), R1, R2, R3, R5 and R6 each independently are a hydrogen atom or a substituent. Herein, R2 and R5 may bond to each other to form a ring. X is a divalent connecting group.
Next, Formula (I) will be detailed from another view point.
n is preferably 1 or 2; when n is 1, R1 is a naphthyl group, a phenathryl group, an anthryl group, a 5,6,7,8-tetrahydro-2-naphthyl group, a 5,6,7,8-tetrahydro-1-naphthyl group, a thienyl group, a benzo[b]thienyl group, a naphtho[2,3-b]thienyl group, a thianthrenyl group, a dibenzofuryl, a chromenyl group, a xanthenyl group, a phenoxanthinyl group, a pyrrolyl group, an imidazolyl group, a pyrazolyl group, a pyradinyl group, a pyrimidinyl group, a pyridazinyl group, an indolizinyl group, an isoindolyl group, an indolyl group, an indazolyl group, a purinyl group, a quinolizinyl group, an isoquinolyl group, a quinolyl group, a phthalazinyl group, a naphthylizinyl group, a quinoxalinyl group, a quinazolinyl group, a cinnolyl group, a pteridinyl group, a carbazolyl group, a β-carbonylyl group, a phenanthiridinyl group, an acridinyl group, a perimidinyl group, a phenanthrolinyl group, a phenazinyl group, an isothiazolyl group, a phenothiazinyl group, an isoxazolyl group, a furazanyl group, a biphenyl group, a teruphenyl group, a fluorenyl group or a phenoxazinyl group, which are unsubstituted or substituted by an alkyl group having a carbon number of 1-4, an alkoxy group having a carbon number of 1-4, an alkylthio group having a carbon number of 1-4, a hydroxyl group, a halogen atom, an amino group, an alkylamino group having a carbon number of 1-4, a phenylamino group or di(alkyl having a carbon number of 1-4)-amino group, or R1 is a group represented by formula (II) described below;
and R1 is a phenylene group or a naphthylene group, which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4 or a hydroxyl group; or —R12—XR13— (wherein, X is a direct bond, an oxygen atom, a sulfur atom or —NR31— when n is 2.
R2, R3, R4 and R5 each independently are a hydrogen atom, a chlorine atom, a hydroxyl group, an alkyl group having a carbon number of 1-25, a phenylalkyl group having a carbon number of 7-9, an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted phenyl group, an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted cycloalkyl group having a carbon number of 5-8, an alkoxy group having a carbon number of 1-18, an alkylthio group having a carbon number of 1-18, an alkylamino group having a carbon number of 1-4, a di(alkyl having a carbon number of 1-4)amino group, an alkanoyloxy group having a carbon number of 1-25, an alkanoylamino group having a carbon number of 1-25, an alkenoyloxy group having a carbon number of 3-25, an alkanoyloxy group having a carbon number of 3-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, a cycloalkylcarbonyloxy group having a carbon number of 6-9, a benzoyloxy group, or an (alkyl having a carbon number of 1-12)-substituted benzoyloxy group; or substituents R2 and R3, R3 and R4, or R4 and R5 may bond to each other to form a ring.
Herein, specific examples of such a ring include the following.
Said ring is preferably a 5-6 membered ring and includes such as a cyclopentene ring, a cyclohexene ring, a benzene ring, a pyridine ring, a dihydropyrane ring, a tetrahydropyridine ring and a naphthalene ring.
R4 further is —(CH2)p—COR15 or —(CH2)qOH (wherein, p is 0, 1 or 2, q is 1, 2, 3, 4, 5 or 6); or when R3, R5 and R6 is a hydrogen atom, R4 further is a group represented by following formula (III)
(wherein, R1 is identical to those defined above in the case of n=1).
R6 is a hydrogen atom or a group represented by following formula (IV)
(wherein, R4 is not a group of formula (III) but is identical to those defined above in the case of n=1).
R7; R8, R9, R10 and R11 each independently are a hydrogen atom, a halogen atom, a hydroxyl group, an alkyl group having a carbon number of 1-25; an alkyl group having a carbon number of 2-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; an alkoxy group having a carbon number of 2-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; an alkylthio group having a carbon number of 1-25, an alkenyl group having a carbon number of 3-25, an alkenyloxy group having a carbon number of 3-25, an alkynyl group having a carbon number of 3-25, an alkynyloxy group having a carbon number of 3-25, a phenylalkyl group having a carbon number of 7-9, a phenylalkoxy group having a carbon number of 7-9; an unsubstituted or an (alkyl baying a carbon number of 1-4)-substituted phenyl group; an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted phenoxy group; an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted cycloalkyl group having a carbon number of 5-8, an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted cycloalkoxy group having a carbon number of 5-8; an alkylamino group having a carbon number of 1-4, a di(alkyl having a carbon number of 1-4)amino group, an alkanoyl group having a carbon number of 1-25; an alkanoyl group having a carbon number of 3-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; an alkanoyloxy group having a carbon number of 1-25; an alkanoyloxy group having a carbon number of 3-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; an alkanoylamino group having a carbon number of 1-25, an alkenoyl group having a carbon number of 3-25, an alkenoyl group having a carbon number of 3-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; an alkenoyloxy group having a carbon number of 3-25; an alkenoyloxy group having a carbon number of 3-25 which; a cycloalkylcarbonyl group having a carbon number of 6-9, a cycloalkylcarbonyloxy group having a carbon number of 6-9, a benzoyl group or an (alkyl having a carbon number of 1-12)-substituted benzoyl group; a benzoyloxy group or an (alkyl having a carbon number of 1-12)-substituted benzoyloxy group;
and further, in formula (II), each pair of substituents R7 and R8, or R8 and R11 may form a benzene ring together with the bonded carbon atoms.
R12 and R13 each independently are an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted phenylene group or naphthalene group; R14 is a hydrogen atom or an alkyl group having a carbon number of 1-8; R15 is a hydroxyl group, the following group
(wherein, M is r-valent metal cation and r is 1, 2 or 3.), an alkoxy group having a carbon number of 1-18 or
R16 and R17 each independently are a hydrogen atom, CF3, an alkyl group having a carbon number of 1-12 or a phenyl group, or R16 and R17 form a cycloalkylidene ring having a carbon number of 5-8, which is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4, together with the bonded carbon atoms; R18 and R19 each independently are a hydrogen atom, an alkyl group having a carbon number of 1-4, or a phenyl group; R20 is a hydrogen atom, an alkyl group having a carbon number of 1-4, R21 is a hydrogen atom, an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted phenyl group, an alkyl group having a carbon number of 1-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; a phenylalkyl group having a carbon number of 7-9 which is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4 at the phenyl portion; a phenylalkyl group having a carbon number of 7-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain and is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4 at the phenyl portion; or R20 and R21 form a cycloalkylene ring having a carbon number of 5-12, which is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4 together with the bonded carbon atoms; R22 is a hydrogen atom or an alkyl group having a carbon number of 1-4; R23 is an alkanoyl group having a carbon number of 1-25, an alkanoyl group having a carbon number of 3-25, an alkanoyl group having a carbon number of 3-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; an alkanoyl group having a carbon number of 2-25 which is substituted by di(alkyl having a carbon number of 1-6)-phosphonate group; a cycloalkylcarbonyl group having a carbon number of 6-9, a thenoyl group, a furoyl group, a benzoyl group or an (alkyl having a carbon number of 1-12)-substituted benzoyl group;
(wherein, s is 1 or 2); R24 and R25 each independently are a hydrogen atom or an alkyl group having a carbon number of 1-18; R26 is a hydrogen atom or an alkyl group having a carbon number of 1-8; R27 is a direct bond or an alkylene group having a carbon number of 1-18; an alkylene group having a carbon number of 2-18 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain; an alkenylene group having a carbon number of 2-18, an alkylidene group having a carbon number of 2-20, a phenylalkylidene group having a carbon number of 7-20, a cycloalkylene group having a carbon number of 5-8, a bicycloalkylene group having a carbon number of 7-8, an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted phenylene group,
R28 is a hydroxyl group,
an alkoxy group having a carbon number of 1-18 or
R29 is an oxygen atom, —NH— or
R30 is an alkyl group having a carbon number of 1-18 or a phenyl group; R31 is a hydrogen atom or an alkyl group having a carbon number of 1-18.
When n is 1, R1 is preferably a group represented by aforesaid formula (II); a naphthyl group, a phenanthryl group, an anthoryl group, a 5,6,7,8-tetrahydro-2-naphthyl group, a 5,6,7,8-tetrahydro-1-naphthyl group, a thienyl group, a benzo[b]thienyl group, a naphtho[2,3-b]thienyl group, a thianthrenyl group, a dibenzofuryl group, a chromenyl group, a xanthenyl group, a phenoxanthinyl group, a pyrrolyl group, an imidazolyl group, a pyrazolyl group, a pyradinyl group, a pyridinyl group, a pyridazinyl group, an indolydinyl group, an isoindolyl group, an indolyl group, an indazolyl group, a purinyl group, a quinolizinyl group, an isoquinolyl group, a quinolyl group, a phthalazinyl group, a naphthylizinyl group, a quinoxalinyl group, a quinazolinyl group, a cinnolyl group, a butedinyl group, a carbazolyl group, a β-carbolinyl group, a phenanthyridinyl group, an acridinyl group, a perimidinyl group, a phenanthrolinyl group, a phenaziyl group, an isothiazolyl group, a phenothiazinyl, an isoxazolyl group, a furazanyl group, a biphenyl group, a terphenyl group, a fluorenyl group or a phenoxazinyl group, each of which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4, an alkoxy group having a carbon number of 1-4, an alkylthio group having a carbon number of 1-4, a hydroxyl group, a halogen atom, an amino group, an alkylamino group having a carbon number of 1-4 or di(alkyl having a carbon number of 1-4)-amino group; typically, a 1-naphtyl group, a 2-naphthyl group, a 1-phenylamino-4-naphthyl group, a 1-methylnaphthyl group, a 2-methylnaphthyl group, a 1-methoxy-2-naphthyl group, a 2-methoxy-1-naphthyl group, a 1-dimethylamino-2-naphthyl group, a 1,2-dimethyl-4-naphthyl group, a 1,2-dimethyl-6-naphthiyl group, a 1,2-dimethyl-7-naphthiyl group, a 1,3-dimethyl-6-naphthiyl group, a 1,4-dimethyl-6-naphthiyl group, a 1,5-dimethyl-2-naphthiyl group, a 1,6-dimethyl-2-naphthiyl group, a 1-hydroxy-2-naphthyl group, a 2-hydroxy-1-naphthyl group, a 1,4-dihydroxy-2-naphthyl group, a 7-phenanthryl group, a 1-anthryl group, a 2-anthryl group, a 9-anthryl group, a 3-benzo[b]thienyl group, a 5-benzo[b]thienyl group, a 2-benzo[b]thienyl group, a 4-dibenzofuryl group, a 4,7-dibenzofuryl group, a 4-methyl-7-benzofuryl group, a 2-xanthenyl group, a 8-methyl-2-xanthenyl group, a 3-xanthenyl group, a 2-phenoxanthinyl group, a 2,7-phenoxanthinyl group, a 2-pyrrolyl group, a 3-pyrrolyl group, a 5-methyl-3-pyrrolyl group, a 2-imidazolyl group, a 4-imidazolyl group, a 5-imidazolyl group, a 2-methyl-4-imidazolyl group, a 2-ethyl-4-imidazolyl group, a 2-ethyl-5-imidazolyl group, a 3-pyrazolyl group, a 1-methyl-3-pyrazolyl group, a 1-propyl-4-pyrazolyl group, a 2-pyrazinyl group, a 5,6-dimethyl-2-pyrazinyl, a 2-indolizinyl group, a 2-methyl-3-isoindolyl group, a 2-methyl-1-isoindolyl group, a 1-methyl-2-indolyl group, a 1-methyl-3-indolyl group, a 1,5-dimethyl-2-indolyl group, a 1-methyl-3-indazolyl group, a 2,7-dimethyl-8-purinyl group, a 2-methoxy-7-methyl-8-purinyl group, a 2-quinolizinyl group, a 3-isoquinolyl group, a 6-isoquinolyl group, a 7-isoquinolyl group, an isoquinolyl group, a 3-methoxy-6-isoquinolyl group, a 2-quinolyl group, a 6-quinolyl group, a 7-quinolyl group, a 2-methoxy-3-quinolyl group, a 2-methoxy-6-quinolyl group, a 6-phthalazinyl, a 7-phthalazinyl group, a 1-methoxy-6-phthalazinyl group, a 1,4-dimethoxy-6-phthalazinyl group, 1,8-naphthylizini-2-yl group, a 2-quinoxalinyl group, a 6-quinoxalinyl group, a 2,3-dimethyl-6-quinoxalinyl group, a 2,3-dimethoxy-6-quinoxalinyl group, a 2-quinazolinyl group, a 7-quinazolinyl group, a 2-dimethylamino-6-quinazolinyl group, a 3-cinnolinyl group, a 6-cinnolinyl group, a 7-cinnolinyl group, a 3-methoxy-7-cinnolinyl group, a 2-pteridinyl group, a 6-pteridinyl group, a 7-pteridinyl group, a 6,7-dimethoxy-2-pteridinyl group, a 2-carbazolyl group, a 9-methyl-2-carbazolyl group, a 9-methyl-3-carbazolyl group, a β-carbolini-3-yl group, a 1-methyl-β-carbolini-3-yl group, a 1-methyl-β-carbolini-6-yl group, a 3-phenyanthrizinyl group, a 2-acridinyl group, a 3-acridinyl group, a 2-perimidinyl group, a 1-methyl-5-perimidinyl group, a 5-phenanthrolinyl group, a 6-phenanthrolinyl group, a 1-phenazinyl group, a 2-phenazinyl group, a 3-isothiazolyl group, a 4-isothiazolyl group, a 5-isothiazolyl group, a 2-phenothiazinyl group, a 3-phenothiazinyl group, a 10-methyl-3-phenothiazinyl group, a 3-isoxazolyl group, a 4-isoxazolyl group, a 5-isoxazolyl group, a 4-methyl-3-furazanyl group, a 2-phenoxazinyl group or a 10-methyl-2-phenoxazinyl group.
Specifically preferable as the above-described substituents are, a group represented by aforesaid formula (II); a naphthyl group, a phenanthryl group, an anthryl group, a 5,6,7,8-tetrahydro-2-naphthyl group, a 5,6,7,8-tetrahydro-1-naphthyl group, a thienyl group, a benzo[b]thienyl group, a naphtho[2,3-b]thienyl group, a thianthrenyl group, a dibenzofuryl group, a chromenyl group, a xanthenyl group, a phenoxanthinyl group, a pyrrolyl group, an isoindolyl group, an indolyl group, a phenothiazinyl, a biphenyl group, a terphenyl group, a fluorenyl group or a phenoxazinyl group, each of which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4, an alkoxy group having a carbon n ember of 1-4, an alkylthio group having a carbon number of 1-4, a hydroxyl group, a phenylamino group or di(alkyl having a carbon number of 1-4)amino group; typically, a 1-naphtyl group, a 2-naphthyl group, a 1-phenylamino-4-naphthyl group, a 1-methylnaphthyl group, a 2-methylnaphthyl group, a 1-methoxy-2-naphthyl group, a 2-methoxyl-naphthyl group, a 1-dimethylamino-2-naphthyl group, a 1,2-dimethyl-4-naphthyl group, a 1,2-dimethyl-6-naphthiyl group, a 1,2-dimethyl-7-naphthiyl group, a 1,3-dimethyl-6-naphthiyl group, a 1,4-dimethyl-6-naphthyl group, a 1,5-dimethyl-2-naphthyl group, a 1,6-dimethyl-2-naphthyl group, a 1-hydroxy-2-naphthyl group, a 2-hydroxy-1-naphthyl group, a 1,4-dihydroxy-2-naphthyl group, a 7-phenanthryl group, a 1-anthryl group, a 2-anthryl group, a 9-anthryl group, a 3-benzo[b]thienyl group, a 5-benzo[b]thienyl group, a 2-benzo[b]thienyl group, a 4-dibenzofuryl group, a 4,7-dibenzofuryl group, a 4-methyl-7-dibenzofuryl group, a 2-xanthenyl group, a 8-methyl-2-xanthenyl group, a 3-xanthenyl group, a 2-phenoxanthinyl group, a 2,7-phenoxanthinyl group, a 2-pyrrolyl group, a 3-pyrrolyl group, a 2-phenothiazinyl group, a 3-phenothiazinyl group and a 10-methyl-3-phenothiazinyl group.
A halogen substituent is preferably a chlorine substituent, a bromine substituent or an iodine substituent, and more preferably a chlorine substituent.
An alkanoyl group having a carbon number of up to 25 is a branched or un-branched group, and is, for example, a formyl group, an acetyl group, a propionyl group, a butanoyl group, a pentanoyl group, a hexanoyl group, a heptanoyl group, an octanoyl group, a nonanoyl group, a decanoyl group, an undecanoyl group, a dodecanoyl group, a tridecanoyl group, a tetradecanoyl group, a pentadecanoyl group, a hexadecanoyl group, a heptadecanoyl group, an octadecanoyl group, an eicosanoyl group or a docosanoyl group.
Preferable is an alkanoyl group having a carbon number of 2-18, more preferably of 2-12 and specifically preferably of 2-6. An acetyl group is specifically preferable.
An alkanoyl group having a carbon number of 2-25, which is substituted by di(alkyl having a carbon number of 1-6)phosphonate group, is typically (CH3CH2O)2POCH2CO—, (CH3O)2POCH2CO—, (CH3CH2CH2CH2O)2POCH2CO—, (CH3CH2O)2POCH2CH2CO—, (CH3O)2POCH2CH2CO—, (CH3CH2CH2CH2O)2POCH2CH2CO—, (CH3CH2O)2PO(CH2)4CO—, (CH3CH2O)2PO(CH2)8CO— or (CH3CH2O)2PO(CH2)17O—.
An alkanoyloxy group having a carbon number of up to 25 is a branched or un-branched group, and is, for example, a formyloxy group, an acetoxy group, a propionyloxy group, a butanoyloxy group, a pentanoyloxy group, a hexanoyloxy group, a heptanoyloxy group, an octanoyloxy group, a nonanoyloxy group, a decanoyloxy group, an undecanoyloxy group, a dodecanoyloxy group, a tridecanoyloxy group, a tetradecanoyloxy group, a pentadecanoyloxy group, a hexadecanoyloxy group, a heptadecanoyloxy group, an octadecanoyloxy group, an eicosanoyloxy group or a docosanoyloxy group.
Preferable is an alkanoyloxy group having a carbon number of 2-18, more preferably of 2-12 and for example of 2-6. An acetoxy group is specifically preferred.
An alkenoyl group having a carbon number of 3-25 is a branched or un-branched group, and, for example, includes a propenoyl group, a 2-butenoyl group, a 3-butenoyl group, an isobutenoyl group, an n-2,4-pentadienoyl group, a 3-methyl-2-butenoyl group, an n-2-octenoyl group, an n-2-dodecenoyl group, an iso-dodecenoyl group, an oleoyl group, an n-2-octadecanoyl group or an n-4-octadecanoyl group.
Preferable is an alkenoyl group having a carbon number of 3-18, more preferably of 3-12, for example of 3-6 and specifically preferably of 3-4.
An alkenoyl group having a carbon number of 3-25, which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, is typically CH3OCH2CH2CH═CHCO— or CH3OCH2CH2OCH═CHCO—.
An alkenoyloxy group having a carbon number of 3-25 is a branched or un-branched group, and, for example, includes a propenoyloxy group, a 2-butenoyloxy group, a 3-butenoyloxy group, an isobutenoyloxy group, an n-2,4-pentadiennoyloxy group, a 3-methyl-2-butenoyloxy group, an n-2-octenoyloxy group, an n-2-dodecenoyloxy group, an iso-dodecenoyloxy group, an oleoyloxy group, a n-2-octadecenoyloxy group or an n-4-octadecenoyloxy group.
Preferable is an alkenoyloxy group having a carbon number of 3-18, more preferably 3-12, typically 3-6 and most preferably 3-4.
An alkenoyloxy group having a carbon number of 3-25, which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, is typically CH3OCH2CH2CH═CHCOO— or CH3OCH2CH2OCH═CHCOO—. An alkanoyl group having a carbon number of 3-25, which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, is typically CH3—O—CH2CO—, CH3—S—CH2CO—, CH3—NH—CH2CO—, CH3—N(CH3)—CH2CO—, CH3—O—CH2CH2—OCH2CO—, CH3—(O—CH2CH2)2—O—CH2CO—, CH3—(O—CH2CH2)3O—CH2CO— or CH3—(O—CH2CH2)4O—CH2CO—.
An alkanoyloxy group having a carbon number of 3-25 which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, is typically CH3—O—CH2COO—, CH3—S—CH2COO—, CH3—NH—CH2COO—, CH3—N(CH3)—CH2COO—, CH3—O—CH2CH2—OCH2COO—, CH3—(O—CH2CH2)2O—CH2COO—, CH3—(O—CH2CH2)3O—CH2COO— or CH3—(O—CH2CH2)4—O—CH2COO—.
Examples of a cycloalkylcarbonyl group having a carbon number of 6-9 are preferably a cyclopentylcarbonyl group, a cyclohexylcarbonyl group, a cycloheptylcarbonyl group and a cyclooctylcarbonyl group. And a cyclohexylcarbonyl group is preferred.
Examples of a cycloalkylcarbonyloxy group having a carbon number of 6-9 are preferably a cyclopentylcarbonyloxy group, a cyclohexylcarbonyloxy group, a cycloheptylcarbonyloxy group and a cyclooctylcarbonyloxy group. And a cyclohexylcarbonyloxy group is preferred.
An (alkyl having a carbon number of 1-12)-substituted benzoyl group, which is provided with preferably 1-3 and most preferably 1-2 alkyl groups, is a o-, m- or p-methylbenzoyl group, a 2,3-dimethylbenzoyl group, a 2,4-dimethylbenzoyl group, a 2,5-dimethylbenzoyl group, a 2,6-dimethylbenzoyl group, a 3,4-dimethylbenzoyl group, a 3,5-dimethylbenzoyl group, a 2-methyl-6-ethylbenzoyl group, a 4-tert-butylbenzoyl group, a 2-ethylbenzoyl group, a 2,4,6-trimethylbenzoyl group, a 2,6-dimethyl-4-tert-butylbenzoyl group or a 3,5-di(tert-butyl-benzoyl group.
The preferable substituents are alkyl groups provided with a carbon number of 1-8 and most preferably of 1-4.
An alkyl having a carbon number of 1-12 substituted benzoyloxy group, which is provided with preferably 1-3 and most preferably 1-2 alkyl groups, is a o-, m- or p-methylbenzoyloxy group, a 2,3-dimethylbenzoyloxy group, a 2,4-dimethylbenzoyloxy group, a 2,5-dimethylbenzoyloxy group, a 2,6-dimethylbenzoyloxy group, a 3,4-dimethylbenzoyloxy group, a 3,5-dimethylbenzoyloxy group, a 2-methyl-6-ethylbenzoyloxy group, a 4-tert-butylbenzoyloxy group, a 2-ethylbenzoyloxy group, a 2,4,6-trimethyl-benzoyloxy group, a 2,6-dimethyl-4-tert-butylbenzoyloxy group or a 3,5-di(tert-butyl)benzoyloxy group.
The preferable substituents are alkyl groups provided with a carbon number of 1-8 and most preferably of 1-4.
An alkyl group having a carbon number of up to 25 is a branched or un-branched group, and, for example, a methyl group, an ethyl group, a propyl group, an isopropyl group, a n-butyl group, a secondary butyl group, an isobutyl group, a tertiary butyl group, a 2-ethylbutyl group, a n-pentyl group, an isopentyl group, a 1-methylpentyl group, a 1,3-dimethylbutyl group, a n-hexyl group, a 1-methylhexyl group, a n-heptyl group, an isoheptyl group, a 1,1,3,3-tetramethylbutyl group, a 1-methylheptyl group, a 3-methylheptyl group, an n-octyl group, a 2-ethylhexyl group, a 1,1,3-trimethylhexyl group, a 1,1,3,3-tetramethylpentyl group, a nonyl group, a decyl group, an undecyl group, a 1-methylundecyl group, a dodecyl group, a 1,1,3,3,5,5-hexamethylhexyl group, a tridecyl group, a tetradecyl group, a pentadecyl group, a hexadecyl group, a heptadecyl group, an octadecyl group, an eicosyl group or a docosyl group.
Preferable R2 and R4 are typically an alkyl group having a carbon number of 1-18. Specifically preferable R4 is an alkyl group having a carbon number of 1-4.
An alkenyl group having a carbon number of 3-25 is a branched or un-branched group, and, for example, includes a propenyl group, a 2-butenyl group, a 3-butenyl group, an isobutenyl group, an n-2,4-pentadienyl group, a 3-methyl-2-butenyl group, an n-2-octenyl group, an n-2-dodecenyl group, an iso-dodecenyl group, an oleyl group, an n-2-octadecanyl group or an n-4-octadecanyl group.
Preferable is an alkenyl group having a carbon number of 3-18, more preferably of 3-12, typically of 3-6 and most preferably of 3-4.
An alkenyloxy group having a carbon number of 3-25 is a branched or un-branched group, and, for example, includes a propenyloxy group, a 2-butenyloxy group, a 3-butenyloxy group, an isobutenyloxy group, an n-2,4-pentadienyloxy group, a 3-methyl-2-butenyloxy group, an n-2-octenyloxy group, an n-2-dodecenyloxy group, an iso-dodecenyloxy group, an oleyloxy group, an n-2-octadecanyloxy group or an n-4-octadecanyloxy group.
Preferable is an alkenyloxy group having a carbon number of 3-18, more preferably of 3-12, typically of 3-6 and most preferably of 3-4.
An alkynyl group having a carbon number of 3-25 is an branched or un-branched group, and, for example, includes a propynyl group (—CH2—C≡CH), a 2-butynyl group, a 3-butynyl group, an n-2-octynyl group and an n-2-dodecynyl group.
Preferable is an alkynyl group having a carbon number of 3-18, more preferably of 3-12, typically of 3-6 and most preferably of 3-4.
An alkynyloxy group having a carbon number of 3-25 is a branched or un-branched group, and for example, includes a propynyloxy group (—OCH2—C≡CH), a 2-butynyloxy group, a 3-butynyloxy group, an n-2-octynyloxy group and an n-2-dodecynyloxy group.
Preferable is an alkynyloxy group having a carbon number of 3-18, more preferably of 3-12, typically of 3-6 and most preferably of 3-4.
An alkyl group having a carbon number of 2-25, which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, is typically C3—O—CH2—, CH3—S—CH2—, CH3—NH—CH2—, CH3—N(CH3)—CH2—, CH3—O—CH2CH2—OCH2—, CH3—(O—CH2CH2)2O—CH2—, CH3—(O—CH2CH2)3O—CH2— or CH3—(O—CH2CH2)4—O—CH2—.
A phenylalkyl group having a carbon number of 7-9 is typically a benzyl group, a α-methylbenzyl group, a α, α-dimethylbenzyl group and 2-phenylethyl group. A benzyl group and a α, α-dimethylbenzyl group are preferred.
A phenylalkyl group having a carbon number of 7-9, which is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4 at the phenyl portion, is typically a benzyl group, a α-methylbenzyl group, a α, α-dimethylbenzyl group and 2-phenylethyl group, a 2-methylbenzyl group, a 3-methylbenzyl group, a 4-methylbenzyl group, a 2,4-dimethylbenzyl group, a 2,6-dimethylbenzyl group or a 4-tert-butylbenzyl group. A benzyl group is preferred.
A phenylalkyl group having a carbon number of 7-9, which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, and is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4 at the phenyl portion, is, for example, a branched or un-branched group such as a phenoxymethyl group, a 2-methylphenoxymethyl group, a 3-methylphenoxymethyl group, a 4-methylphenoxymethyl group, a 2,4-methylphenoxymethyl group, a 2,3-methylphenoxymethyl group, a phenylthiomethyl group, a N-methyl-N-phenyl-methyl group, a N-ethyl-N-phenyl-methyl group, a 4-tert-butyl-phenoxymethyl group, a 4-tert-butyl-phenylethoxymethyl group, a 2,4-di-tert-butyl-phenoxymethyl group, a 2,4-di-tert-butyl-phenoxyethoxymethyl group, a phenoxyethoxyethoxyethoxymethyl group, a benzyloxymethyl group, a benzyloxyethoxymethyl group, a N-benzyl-N-ethylmethyl group or an N-benzyl-N-isopropylmethyl group.
A phenylalkoxy group having a carbon number of 7-9 is typically a benzyloxy group, a α-methylbenzyloxy group, a α, α-dimethylbenzyloxy group and 2-phenylethoxy group. A benzyloxy group is preferred.
Examples of a phenyl group, which is substituted by an alkyl group having a carbon number of 1-4 and contains preferably 1-3 and specifically preferably 1 or 2 alkyl groups, are an o-, m- or p-methylphenyl group, a 2,3-dimethylphenyl group, a 2,4-dimethylphenyl group, a 2,5-dimethylphenyl group, a 2,6-dimethylphenyl group, a 3,4-dimethylphenyl group, a 3,5-dimethylphenyl group, a 2-methyl-6-ethylphenyl group, a 4-tert-butylphenyl group, a 2-ethylphenyl group and a 2,6-diethylphenyl group.
Examples of a phenoxy group, which is substituted by preferably 1-3 and specifically preferably 1 or 2 alkyl groups having a carbon number of 1-4, are an o-, m- or p-methylphenoxy group, a 2,3-dimethylphenoxy group, a 2,4-dimethylphenoxy group, a 2,5-dimethylphenoxy group, a 2,6-dimethylphenoxyl group, a 3,4-dimethylphenoxy group, a 3,5-dimethylphenoxy group, a 2-methyl-6-ethylphenoxy group, a 4-tert-butyl-phenoxy group, a 2-ethylphenoxy group and a 2,6-diethylphenoxy group.
Examples of a cycloalkyl group having a carbon number of 5-8, which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4, are a cyclopentyl group, a methylcyclopentyl group, a dimethylcyclopentyl group, a cyclohexyl group, a methylcyclohexyl group, a dimethylcyclohexyl group, a trimethylcyclohexyl group, a tert-butyl-cyclohexyl group, a cycloheptyl group and a cyclooctyl group. A cyclohexyl group and a tert-butyl-cyclohexyl group are preferred.
Examples of a cycloalkoxy group having a carbon number of 5-8, which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4, are a cyclopentoxy group, a methylcyclopentoxy group, a dimethylcyclopentoxy group, a cyclohexoxy group, a methylcyclohexoxy group, a dimethylcyclohexoxy group, a trimethylcyclohexoxy group, a tert-butyl-cyclohexoxy group, a cycloheptoxy group and a cyclooctoxy group. A cyclohexoxy group and a tert-butyl-cyclohexoxy group are preferred.
An alkoxy group having a carbon number of up to 25 is a branched or un-branched group, and for example, is a methoxy group, an ethoxy group, a propoxy group, an isopropoxy group, a n-butoxy group, an isobutoxy group, a pentoxy group, an isopentoxy group, a hexoxy group, a heptoxy group, an octoxy group, a decyloxy group, a tetradecyloxy group, a hexadecyloxy group or an octadecyloxy group. An alkoxy group having a carbon number of 1-12, preferably of 1-8 and for example of 1-6 is preferred.
An alkoxy group having a carbon number of 2-25, which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, is typically CH3—O—CH2CH2O—, CH3SS—CH2CH2O—, CH3—NH—CH2CH2O—, CH3—N(CH3)—CH2CH2O—, CH3—O—CH2CH2—OCH2CH2O—, CH3—(O—CH2CH2)2O—CH2CH2O—, CH3—(O—CH2CH2)3—O—CH2CH2O— or CH3—(O—CH2CH2)4O—CH2CH2O—.
An alkylthio group having a carbon number of up to 25 is a branched or un-branched group, and for example, is a methylthio group, an ethylthio group, a propylthio group, an isopropylthio group, an n-butylthio group, an isobutylthio group, a pentylthio group, an isopentylthio group, a hexylthio group, a heptylthio group, an octylthio group, a decylthioy group, a tetradecylthio group, a hexadecylthio group or an octadecylthio group. An alkythio group having a carbon number of 1-12, preferably of 1-8 and for example of 1-6 is preferred.
An alkylamino group having a carbon number of up to 4 is a branched or unbranched group, and, for example, is a methylamino group, an ethylamino group, a propylamino group, an isopropylamino group, an n-butylamino group, an isobutylamino group or a tert-butylamino group.
A di(alkylamino group having a carbon number of 1-4) group is also a group in which each two portions independent from the other are branched or unbranched, and typically is a dimethylamino group, a methylethylamino group, a diethylamino group, a methyl-n-propylamino group, a methylisopropylamino group, a methyl-n-butylamino group, a methylisobutylamino group, an ethylisopropylamino group, an ethyl-n-butylamino group, an ethylisobutylamino group, an ethyl-tert-butylamino group, a diethylamino group, a diisopropylamino group, an isopropyl-n-butylamino group, an isopropylisobutylamino group, a di-n-butylamino group or a diisobutylamino group.
An alkanoylamino group having a carbon number of up to 25 is a branched or unbranched group, and for example, is a formylamino group, an acetylamino group, a propionylamino group, a butanoylamino group, a pentanoylamino group, a hexanoylamino group, a heptanoylamino group, an octanoylamino group, a nonanoylamino group, a decanoylamino group, an undecanoylamino group, a dodecanoylamino group, a tridecanoylamino group, a tetradecanoylamino group, a pentadecanoylamino group, a hexadecanoylamino group, a heptadecanoylamino group, an octadecanoylamino group, an eicosanoylamino group or a docosanoylamino group.
An alkanoylamino group having a carbon number of 2-18, preferably 2-12 and for example 2-6 is preferred.
An alkylene group having a carbon number of 1-18 is a branched or unbranched group, and for example, is a methylene group, an ethylene group, a propylene group, a trimethylene group, a tetramethylene group, a pentamethylene group, a hexamethylene group, a heptamethylene group, an octamethylene group, a decamethylene group, a dodecamethylene group or an octadecamethylene group.
An alkylene group having a carbon number of 1-12 and specifically of 1-8 is preferable.
An example of a cycloalkylene ring having a carbon number of 5-12, which contains 1 or 2 branched or unbranched groups and is substituted by an alkyl having a carbon number of 1-4, is a cyclopentylene, methylcyclopentylene, dimethylcyclopentylene, cyclohexylene, methylcyclohexylene, dimethylcyclohexylene, trimethylcyclohexylene, tert-butyl-cyclohexylene, cycloheptylene, cyclooctylene or cyclodecylene ring. Cyclohexylene and tert-butyl-cyclohexylene rings are preferred.
Examples of an alkylene group having a carbon number of 2-18, which contains an oxygen atom, a sulfur atom or —N(R14)— in the carbon chain, are —CH2—O—CH2—, —CH2—S—CH2—, —CH2—NH—CH2—, —CH2—N(CH3)—CH2—, —CH2CH2—O—CH2—, —CH2—(O—CH2CH2—)2O—CH2—, —CH2—(O—CH2CH2—)3O—CH2—, —CH2—(O—CH2CH2—)4O—CH2— and —CH2CH2—S—CH2CH2—.
An alkenylene group having a carbon number of 1-18 is typically a vinylene group, a methylvinylene group, an octenylethylene group or a dodecenylethylene group. An alkenylene group having a carbon number of 2-8 is preferred.
Alkylidene groups having a carbon number of 2-20 are typically an ethylidene group, a propylidene group, a butylidene group, a pentylidene group, a 4-methylpentylidene group, a heptylidene group, a nonylidene group, a tridecylidene group, a nonadecylidene group, a 1-methylethylidene group, a 1-ethylpropylidene group and a 1-ethylpentylidene group. An alkylidene group having a carbon number of 2-8 is preferred.
Examples of a phenylalkylidene group having a carbon number of 7-20 are a benzylidene group, a 2-phenylethylidene group and a 1-phenyl-2-hexylidene group. A phenylalkylidene group having a carbon number of 7-9 is preferred.
A cycloalkylene group having a carbon number of 5-8 is an unsaturated hydrocarbon group, which is provided with two free electrons and at least one ring unit, and for example, is a cyclopentylene group, a cyclohexylene group, a cycloheptylene group or a cyclooctylene group. A cyclohexylene group is preferred.
Bicycloalkylene groups having a carbon number of 7-8 are bicycloheptylene group and a bicyclooctylene group.
An example of an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted phenylene group or naphthylene group is a 1,2-, 1,3- or 1,4-phenylene group; a 1,2-, 1,3-, 1,4-, 1,6-, 1,7-, 2,6- or 2,7-naphthylene group. A 1,4-phenylene group is preferred.
Examples of an (alkyl group having a carbon number of 1-4)-substituted cycloalkylidene ring having a carbon number of 5-8, which contains preferably 1-3 and most preferably 1 or 2 branched or unbranched alkyl groups, are cyclopentylidene, methylcyclopentylidene, dimethylcyclopentylidene, cyclohexylidene, methylcyclohexylidene, dimethylcyclohexylidene, trimethylcyclohexylidene, tertiary-butylcyclohexylidene, cycloheptylidene and cyclooctylidene rings. Cyclohexylidene and tertiary-butylcyclohexylidene rings are preferred.
A mono-, di- or tri-valent metal cation is preferably an alkali metal cation, an alkali earth metal cation or an aluminum cation, and for example, is Na+, K+, Mg++, Ca++, or Al+++.
A preferable compound represented by Formula (I) is a compound in which, when n is 1, R1 is a phenyl group each of which is unsubstituted or substituted at the para-position by an alkoxy group having a carbon number of 1-18, an alkylthio group having a carbon number of 1-18 or a di(alkyl having a carbon number of 1-4)-amino group; an alkylphenyl group which is substituted by 1-5 alkyl groups simultaneously containing carbon atoms of up to 18 in the alkyl groups; a naphthyl group, a biphenyl group, a terphenyl group, a phenanthryl group, an anthryl, a fluorenyl group, a carbazolyl group, a thienyl group, a pyrrolyl group, a phenothiazinyl group or a 5,6,7,8-tetrahydronaphthyl group, each of which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4, an alkoxy group an alkylthio group having a carbon number of 1-4, a hydroxyl group or an amino group.
Another preferable compound represented by Formula (I) is, a compound in which, when n is 2, R1 is —R12—X—R13—; R12 and R13 is a phenylen group; X is an oxygen atom or —NR31—; and R31 is an alkyl group having a carbon number of 1-4.
A further preferable compound represented by Formula (I) is a compound, in which, when n is 1, R1 each is a naphthyl, group, a phenanthryl group, a thienyl group, a dibenzofuryl group, a carbazolyl group, a fluorenyl group, or a group represented by formula (II)
each of which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4, an alkoxy group having a carbon number of 1-4, an alkylthio group having a carbon number of 1-4, a hydroxyl group, a halogen atom, an amino group, an alkylamino group having a carbon number of 1-4 or a di(alkyl having a carbon number of 1-4)-amino group; R7, R8, R9, R10 and R11 are a hydrogen atom, a chlorine atom, a bromine atom, a hydroxyl group, an alkyl group having a carbon number of 1-18; an alkyl group having a carbon number of 2-18, which is disconnected by an oxygen atom or a sulfur atom; an alkoxy group having a carbon number of 1-18; an alkoxy group having a carbon number of 2-18, which is disconnected by an oxygen atom or a sulfur atom; an alkylthio group having a carbon number of 1-18, an alkenyloxy group having a carbon number of 3-12, an alkynyloxy group having a carbon number of 3-12, a phenylalkyl group having a carbon number of 7-9, a phenylalkoxy group having a carbon number of 7-9, an unsubstituted or an (alkyl having a carbon number of 1-4)-substituted phenyl group, a phenoxy group, a cyclohexyl group, a cycloalkoxy group having a carbon number of 5-8, an alkylamino group having a carbon number of 1-4, a di(alkyl having a carbon number of 1-4)amino group, an alkanoyl group having a carbon number of 1-12; an alkanoyl group having a carbon number of 3-12, which is disconnected by an oxygen atom or a sulfur atom; an alkanoyloxy group having a carbon number of 3-12; an alkanoyloxy group having a carbon number of 3-12, which is disconnected by an oxygen atom or a sulfur atom; an alkanoylamino group having a carbon number of 1-12, an alkenoyl group having a carbon number of 3-12, an alkenoyloxy group having a carbon number of 3-12, a cyclohexylcarbonyl group, a cyclohexylcarbonyloxy group, a benzoyl group or an (alkyl having a carbon number of 1-4)-substituted benzoyl group; a benzoyloxy group or an (alkyl having a carbon number of 1-4)-substituted benzoyloxy group;
or in formula (II), each pair of substituents R7 and R8 or R8 and R11 may form a benzene ring together with the bonded carbon atoms. R16 is a hydroxyl group, an alkoxy group having a carbon number of 1-12 or
R18 and R19 each independently are a hydrogen atom or an alkyl group having a carbon number of 1-4; R20 is a hydrogen atom; R21 is a hydrogen atom, a phenyl group, an alkyl group having a carbon number of 1-18, an alkyl group having a carbon number of 2-18 which is disconnected by an oxygen atom or a sulfur atom, a phenylalkyl group having a carbon number of 7-9, an phenylalkyl group having a carbon number of 7-18 which is disconnected by an oxygen atom or a sulfur atom and is substituted by 1-3 alkyl groups having a carbon number of 1-4 at the phenyl portion; or R20 and R21 form a cyclohexylene ring, which is unsubstituted or substituted by an alkyl group having a carbon number of 1-4 together with the bonded carbon atoms; R22 is a hydrogen atom or an alkyl group having a carbon number of 1-4; R23 is a hydrogen atom or an alkanoyl group having a carbon number of 1-18, or an alkenoyl group having a carbon number of 3-12; an alkanoyl group having a carbon number of 3-12 which is disconnected by an oxygen atom or a sulfur atom; an alkanoyl group having a carbon number of 2-12 which is substituted by a di(alkyl having a carbon number of 1-6)-phosphonate group; a cycloalkylcarbonyl group having a carbon number of 6-9, a benzoyl group;
(wherein, s is 1 or 2); R24 and R25 each independently are a hydrogen atom or an alkyl group having a carbon number of 1-12; R26 is a hydrogen atom or an alkyl group having a carbon number of 1-4; R27 is a hydrogen atom or an alkylene group having a carbon number of 1-12, an alkenylene group having a carbon number of 2-8, an alkylidene group having a carbon number of 2-8, a phenylalkylidene group having a carbon number of 7-12, an cycloalkenylene group having a carbon number of 5-8, or a phenylene group; R28 is a hydroxyl group or an alkoxy group having a carbon number of 1-12 or
R28 is an oxygen atom or —NH—; R30 is a carbon atom, an alkyl group having a carbon number of 1-18 or a phenyl group.
Further, preferable is a compound represented by Formula (I), in which, when n is 1, R1 is a phenanthryl group, a thienyl group, a dibenzofuryl group; an unsubstituted or (alkyl having a carbon number of 1-4)-substituted carbazolyl group; or a fluorenyl group, or a group represented by formula (II)
R7, R8, R9, R10 and R11 each independently are a hydrogen atom, a chlorine atom, a hydroxyl group, an alkyl group having a carbon number of 1-18, an alkoxy group having a carbon number of 1-18, an alkylthio group having a carbon number of 1-18, an alkenyloxy group having a carbon number of 3-4, an alkynyloxy group having a carbon number of 3-4, a phenyl group, a benzoyl group, a benzoyloxy group or
R20 is a hydrogen atom; R21 is a hydrogen atom, a phenyl group, an alkyl group having a carbon number of 1-18; or R20 and R11 form cyclohexylene ring which is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4 together with the bonded carbon atoms; R22 is a hydrogen atom or an alkyl group having a carbon number of 1-4; R23 is a hydrogen atom or an alkanoyl group having a carbon number of 1-12 or a benzoyl group.
A compound represented by Formula (I), in which R7, R8, R9, R10 and R11 each independently are a hydrogen atom, an alkyl group having a carbon number of 1-4, or an alkoxy group having a carbon number of 1-8, is specifically preferable.
A specifically preferable compound represented by Formula (I) is a compound, in which R2, R3, R4 and R5 each independently are a hydrogen atom, a chlorine atom, a hydroxyl group, an alkyl group having a carbon number of 1-18, a benzyl group, a phenyl group, a cycloalkyl group having a carbon number of 5-8, an alkoxy group having a carbon number of 1-18, an alkylthio group having a carbon number of 1-18, an alkanoyloxy group having a carbon number of 1-18, an alkanoylamino group having a carbon number of 1-18, an alkenoyloxy group having a carbon number of 3-18 or a benzoyloxy group; or substituents R2 and R3, R3 and R4, or R4 and R5 form a benzene ring together with the bonded carbon atoms; R4 further is —(CH2)p—COR15 or —(CH2)q—OH (wherein, p is 1 or 2; q is 2, 3, 4, 5 or 6.); or R4 is a group represented by formula (III) when R3, R5 and R6 are a hydrogen atom; R16 is a hydroxyl group, an alkoxy group having a carbon number of 1-12 or
R16 and R17 are a methyl group or form a cycloalkylidene ring having a carbon number of 5-8, which is unsubstituted or substituted by 1-3 alkyl groups having a carbon number of 1-4, together with the bonded carbon atoms; R24 and R25 each independently are a hydrogen atom or an alkyl group having a carbon number of 1-12.
Specifically preferable compound represented by Formula (I) further is a compound, in which at least two of R2, R3, R4 and R5 are a hydrogen atom.
Very specifically preferable compound represented by Formula (I) is also a compound, in which R2 is an alkyl group having a carbon number of 1-4; R3 is a hydrogen atom; R4 is an alkyl group having a carbon number of 1-4; or when R6 is a hydrogen atom, R4 further is a group represented by formula (III); R6 is a hydrogen atom.
Next, a compound of Formula (I-1) of the present invention will be detailed.
In Formula (I-1), R2-R5 are identical with R2-R5 in aforesaid Formula (I), and each independently are a hydrogen atom or a substituent. A substituent represented by R2-R5 is not specifically limited, however, includes groups similar to the substituents represented by R2-R5 in aforesaid Formula (I).
In aforesaid Formula (I-1), when R2-R5 are substituents, a substituent is preferably an unsubstituted or substituted alkyl group having a carbon number of 1-18, more preferably an unsubstituted or substituted alkyl group having a carbon number of 1-8 and specifically preferably an unsubstituted or substituted alkyl group having a carbon number of 1-4.
R7-R11 each independently are a hydrogen atom, an alkyl group having a carbon number of 1-18 or an alkoxy group having a carbon number of 1-18.
Next a compound of Formula (I-2) according to the present invention will be detailed.
In Formula (I-2), R2-R5 are identical with R2-R5 in aforesaid Formula (I), and each independently are a hydrogen atom or a substituent. A substituent represented by R2-R5 is not specifically limited, however, includes groups similar to the substituents represented by R2-R5 in aforesaid Formula (I).
In aforesaid Formula (I-2), when R2-R5 are substituents, a substituent is preferably an unsubstituted or substituted alkyl group having a carbon number of 1-18, more preferably an unsubstituted or substituted alkyl group having a carbon number of 1-8 and specifically preferably an unsubstituted or substituted alkyl group having a carbon number of 1-4.
In Formula (I-3), R1, R2, R3, R5 and R6 each dependently represent a hydrogen atom or a substituent. R2 and R3 may be combined to form a ring. The substituent is common to the substituents represented by R1-R5 in Formula (I). R6 is preferably a hydrogen atom. X represents a divalent linkage group. Examples of a divalent linkage group include a divalent alkylene group which may be substituted, a divalent arylene group which may be substituted, an oxygen atom, a sulfur atom and a combination of these linkage groups.
The addition amount of compounds represented by Formulas (I), (Ia), (I-1), (I-2) and (I-3) according to the present invention is preferably 0.01-10 weight %, more preferably 0.1-5 weight % and most preferably 0.2-2 weight %, against cellulose ester. These compounds may be utilized in combination of at least two types.
A compound represented by Formulas (I), (Ia), (I-2) and (I-3) according to the present invention itself can be manufactured by a method well known in the art.
Specific examples of a compound represented by Formulas (I), (I-1), (I-2) and (I-3) will be shown in below, however, the present invention is not limited thereto.
The following describes the details of the cellulose ester used in the present invention:
The cellulose ester film used in the present invention is produced by the solution casting method or melt casting method. In the solution casting method, a solution (dope) with a cellulose ester dissolved in a solvent is cast on the support member and the solvent is evaporated to produce a film. In the melt casting, a cellulose ester is molten by heating, and the resultant product (melt) is cast on the support member to form a film.
The melt casting method permits a substantial reduction in the amount of the organic solvent used to produce the film. As compared with the solution casting method requiring use of a great amount of conventional organic solvent, the melt casting method provides a film characterized by a substantial improvement in environmental adaptability. Thus, the cellulose ester film is preferably manufactured by the melt casting method.
The melt casting method of the present invention is a method of producing a film by heating and melting a cellulose ester up to the temperature wherein it becomes fluid, virtually without using a solvent. It is exemplified by the method of producing a film by pushing fluid cellulose ester through a die.
The solvent may be used in part of the process of preparing the molten cellulose ester. In the melt film formation process for molding a film-like product, molding operation is performed virtually without using solvent.
There is no restriction to the cellulose ester constituting the film for a display if it is a cellulose ester that can be molten to form a film. It is used for aromatic carboxylic acid ester and others. When the film properties obtained such as optical properties are taken into account, the lower fatty acid ester of cellulose is preferably used.
In the present invention, the lower fatty acid in lower fatty acid ester cellulose is defined as a fatty acid containing 5 or less carbon atoms. Cellulose acetate, cellulose propionate, cellulose butylate and cellulose pivalate can be mentioned as preferable lower fatty acid esters of cellulose.
Although the cellulose ester replaced by the fatty acid containing six or more carbon atoms has a good melt film formation property, the cellulose ester film having been obtained therefrom has poor dynamic characteristics. This cellulose ester can hardly be used as an optical film.
To ensure compatibility between the dynamic characteristics and melt film formation property, it is preferred to use a mixed fatty acid ester such as cellulose acetate propionate and cellulose acetate butylate, namely, a cellulose ester having an acyl group other than the acetyl group.
In the cellulose ester constituting the cellulose ester film of the present invention, the total number of the carbon atoms contained in the acyl group of the cellulose ester is preferably 6.1 to 7.5. Still more preferred is the cellulose ester having an aliphatic acyl group containing 2 or more, and the total number of carbon atoms of the acyl group in the cellulose ester is 6.2 through 7.5. The total number of carbon atoms of the acyl group in the cellulose ester is more preferably 6.5 through 7.2, still more preferably 6.7 through 7.1.
It should be noted, however, that the total number of carbon atoms contained in the acyl group is the total sum of the product between the replacement ratio and the number of carbons in the acyl group of the cellulose ester. Further, the number of carbon atoms contained in the aliphatic acyl group is preferably 2 through 6 from the viewpoint of productivity and cost in cellulose synthesis.
Cellulose acylate is a polymer in which all or a part of hydroxyl groups bonded to the carbon atoms at 2-, 3- and 6-positions of the glucose unit are esterified by an acyl group. The “substitution degree by acyl group” is a measure representing the number of the hydroxyl groups bonded with the acyl groups among 3n hydroxyl groups (n is polymerization degree). The substitution degree is represented by the average number of hydroxyl groups substituted with an acyl group among the three hydroxyl groups at 2-, 3 and 6-positions per glucose unit. Accordingly, the substitution degree comes up to the maximum of 3.0 when the three hydroxyl groups are entirely esterified by the acyl groups.
The portion not replaced by acyl group is normally present as a hydroxyl group. This can be synthesized by the method known in the conventional art.
The acyl group is exemplified by acetyl group, propionyl group, butyryl group, pentanate group and hexanate group. The cellulose ester is exemplified by cellulose propionate, cellulose butylate and cellulose pentanate.
So long as the aforementioned number of carbon atoms of the side chain is satisfied, it is also possible to use a mixed fatty acid ester such as cellulose acetate propionate, cellulose acetate butylate, cellulose acetate pentanate.
Of these substances, cellulose acetate propionate and cellulose acetate butylate are preferably employed. It should be noted, however, that triacetyl cellulose and diacetyl cellulose as a cellulose ester commonly in use for solution-casting film formation are not included in the present invention since it fails to meet the requirement of the number of carbon atoms of the side chain.
Generally, the mechanical property and saponifiability of the cellulose ester film and melt film formation property of the cellulose ester are kept in a trade-off relationship with respect to the total replacement ratio in the acyl group of cellulose ester.
For example, in the cellulose acetate propionate, an increase in the overall replacement ratio of the acyl group denotes a decrease in the mechanical property and improvement in melt film formation property. Thus, compatibility is difficult to achieve. In the present invention, the total number of carbon atoms contained in the acyl group of the cellulose ester is 6.2 through 7.2, whereby compatibility among the film mechanical property, saponifiability and melt film formation property can be ensured, according to the findings by the present inventors. Although the details of this arrangement are not very clear, it is considered that there are differences in the degree of impact upon the film mechanical property, saponifiability and melt film formation property, depending on the number of carbon atoms contained in the acyl group.
To be more specific, if the replacement ratio remains the same, a long-chained acyl group such as propionyl group butyryl group rather than acetyl group provides a higher degree of hydrophobicity, and hence more enhanced melt film formation property.
Thus, to achieve the same level of melt film formation property, the replacement ratio of the propionyl group, butyryl group can be lower than that of the acetyl group. This retards reduction in the mechanical property and saponifiability.
In the cellulose ester preferably used in the present invention, the ratio of the weight average molecular weight Mw to number average molecular weight Mn is 1.0 through 5.5. This ratio is more preferably 1.4 through 5.0, still more preferably 2.0 through 3.0. Further, the Mw is preferably 100,000 through 500,000, more preferably 150,000 through 300,000.
The average molecular weight of cellulose ester and the distribution of the molecular weight can be measured by the high-speed liquid chromatography according to the conventionally known method. This is used to calculate the number average molecular weight and weight average molecular weight. The following describes the measuring requirements:
Column temperature: 40° C.
Sample temperature: 0.1% by mass
Flow rate: 0.6 ml/min
Calibration curve: Standard polystyrene: PS-1 (by Polymer Laboratories Inc.)
Based on a calibration curve having Mw=2,560,000 through 580 using nine samples
The cellulose material of the cellulose ester used in the present invention can be either a wood pulp or cotton linter. The wood pulp can be either a conifer or a broad-leaved tree. The conifer is more preferred.
When a film is manufactured, a cotton linter is preferably utilized from the viewpoint of separability.
The cellulose esters manufactured therefrom can be mixed properly and used, or can be used independently.
For example, the ratio of the cotton linter-derived cellulose ester to the wood pulp (conifer)-derived cellulose ester to the wood pulp (broad-leaved tree)-derived cellulose ester can be 100:0:0, 90:10:0, 85:15:0, 50:50:0, 20:80:0, 10:90:0, 0:100:0, 0:0:100, 80:10:10, 85:0:15, and 40:30:30.
The cellulose ester can be obtained, for example, by replacing the hydroxyl group of the material cellulose by the acetic anhydride, anhydrous propionic acid and/or anhydrous butyric acid according to the normal method in such a way that the acetyl group, propionyl group and/or butyl group are kept within the aforementioned range.
There is no restriction to the method of synthesizing such a cellulose ester. For example, it can be synthesized by using the method disclosed in the Japanese Non-Examined Patent Publication 10-45804 (Tokkaihei) or Tokuhyohei 6-501040.
The replacement ratio of acyl group such as acetyl group, propionyl group and butyl group can be measured according to the ASTM-D817-96.
From the industrial viewpoint, cellulose ester is synthesized by sulfuric acid used as a catalyst. This sulfuric acid is not completely removed, and the remaining sulfuric acid causes various forms of decomposition reaction at the time of melt film formation. This will affect the quality of the cellulose ester film to be obtained. Thus, the amount of the residual sulfuric acid contained in the cellulose ester used in the present invention is 0.1 through 40 ppm in terms of the sulfur element.
They are considered to be included as salts. When the amount of the residual sulfuric acid contained therein exceeds 40 ppm, the deposition on the die lip at the time of heat-melting will increase, and therefore, such an amount is not preferred. Further, at the time of thermal drawing or slitting subsequent to thermal drawing, the material will be easily damaged, and therefore, such an amount is not preferred.
The amount of the residual sulfuric acid contained therein should be reduced as much as possible, but when it is to be reduced below 0.1, the load on the cellulose ester washing process will be excessive and the material tends to be damaged easily. This should be avoided.
This may be because an increase in the frequency of washing affects the resin, but the details are not yet clarified. Further, the preferred amount is in the range of 0.1 through 30 ppm. The amount of the residual sulfuric acid can be measured according to the ASTM-D817-96 in the similar manner.
The total amount of the residual amount of acid (e.g., acetic acid) is preferably 1000 ppm or less, more preferably 500 ppm or less, still more preferably 100 ppm or less.
The amount of the residual acid can be kept within the aforementioned range if the synthesized cellulose ester is washed more carefully than in the case of the solution casting method. Then, when a film is manufactured by the melt casting, the amount of depositions on the lip portion will be reduced so that a film characterized by a high degree of flatness is produced. Such a film will be further characterized by excellent resistance to dimensional changes, mechanical strength, transparency, resistance to moisture permeation, Rt value (to be described later) and Ro value.
Further, the cellulose ester can be washed using water as well as a poor solvent such as methanol or ethanol. It is also possible to use a mixture between a poor solvent and a good solvent if it is a poor solvent as a result. This will remove the inorganic substance other than residual acid, and low-molecular organic impurities.
The cellulose ester is washed preferably in the presence of an antioxidant such as a hindered amine and phosphorous acid ester. This will improve the heat resistance and film formation stability of the cellulose ester.
To improve the heat resistance, mechanical property and optical property of the cellulose ester, the cellulose ester is settled again in the poor solvent, subsequent to dissolution of the good solvent of the cellulose ester. This will remove the low molecular weight component and other impurities of the cellulose ester. In this case, similarly to the aforementioned case of washing the cellulose ester, washing is preferably carried out in the presence of an antioxidant.
Subsequent to re-settling of the cellulose ester, another polymer or low molecular compound may be added.
The cellulose ester used in the present invention is preferred to be such that there are few bright defects when formed into a film. The bright defect can be defined as follows: Two polarizing plates are arranged perpendicular to each other (crossed-Nicols), and a cellulose ester film is inserted between them. Light of the light source is applied from one of the surfaces, and the cellulose ester film is observed from the other surface. In this case, a spot formed by the leakage of light from the light source. This spot is referred to as a bright detect.
The polarizing plate employed for evaluation in this case is preferably made of the protective film free of a bright defect. A glass plate used to protect the polarizer is preferably used for this purpose.
The bright defect may be caused by non-acetified cellulose or cellulose with a low degree of acetification contained in the cellulose ester. It is necessary to use the cellulose ester containing few bright defects (use the cellulose ester with few distributions of replacement ratio), or to filter the molten cellulose ester. Alternatively, the material in a state of solution is passed through a similar filtering step in either the later process of synthesizing the cellulose ester or in the process of obtaining the precipitate, whereby the bright defect can be removed. The molten resin has a high degree of viscosity, and therefore, the latter method can be used more efficiently.
The smaller the film thickness, the fewer the number of bright defects per unit area and the fewer the number of the cellulose esters contained in the film. The number of the bright defects having a bright spot diameter of 0.01 mm or more is preferably 200 pieces/cm2 or less, more preferably 100 pieces/cm2 or less, still more preferably 50 pieces/cm2 or less, further more preferably 30 pieces/cm2 or less, still further more preferably 10 pieces/cm2 or less. The most desirable case is that there is no bright defect at all.
The number of the bright defects having a bright spot diameter of 0.005 through 0.01 mm is preferably 200 pieces/cm2 or less, more preferably 100 pieces/cm2 or less, still more preferably 50 pieces/cm2 or less, further more preferably 30 pieces/cm2 or less, still further more preferably 10 pieces/cm2 or less. The most desirable case is that there is no bright defect at all.
When the bright defect is to be removed by melt filtration, the bright defect is more effectively removed by filtering the cellulose ester composition mixed with a plasticizer, anti-deterioration agent and antioxidant, rather than filtering the cellulose ester melted independently.
It goes without saying that, at the time of synthesizing the cellulose ester, the cellulose ester can be dissolved in a solvent, and the bright defect can be reduced by filtering. Alternatively, the cellulose ester mixed with an appropriate amount of ultraviolet absorber and other additive can be filtered. At the time of filtering, the viscosity of the melt including the cellulose ester is preferably 10000 P or less, more preferably 5000 P or less, still more preferably 1000 P or less, further more preferably 500 P or less.
A conventionally known medium including a fluoride resin such as a glass fiber, cellulose fiber, filter paper and tetrafluoroethylene resin is preferably used as a filter medium. Particularly, ceramics and metal can be used in preference. The absolute filtration accuracy is preferably 50 μm or less, more preferably 30 μm or less, still more 10 μm or less, further more preferably 5 μm or less.
They can be appropriately combined for use. Either a surface type or depth type filter medium can be used. The depth type is more preferably used since it has a greater resistance to clogging.
In another embodiment, it is also possible that the cellulose ester as a material is dissolved in a solvent at least once, and is dried and used. In this case, the cellulose ester is dissolved in the solvent together with one or more of the plasticizer, ultraviolet absorber, anti-deterioration agent, antioxidant and matting agent, and is dried and used.
Such a good solvent as methylene chloride, methyl acetate or dioxolane that is used in the solution casting method can be used as the solvent. At the same time, the poor solvent such as methanol, ethanol or butanol can also be used. In the process of dissolution, it can be cooled down to −20° C. or less or heated up to 80° C. or more. Use of such a cellulose ester allows uniform additives to be formed in the molten state, and the uniform optical property is ensured in some cases.
The film for a display of the present invention can be made of an adequate mixture of high polymer components other than the cellulose ester. The high polymer components to be mixed are preferably characterized by excellent compatibility with the cellulose ester compatibility. When formed into a film, the transmittance is preferably 80% or more, more preferably 90% or more, still more preferably 92% or more.
Since decomposition of cellulose ester is accelerated not only by heat but also by oxygen, it is preferable to incorporate an antioxidant as a stabilizer in a polarizing plate protective film of the present invention.
Specifically, under a high temperature environment such as in a melt casting process, decomposition of the material for forming a cellulose ester film is accelerated by heat and oxygen, accordingly, an antioxidant is preferably incorporated in the film forming material.
In the present invention, it is also preferable to use an antioxidant in a suspension-washing process of cellulose ester using a poor solvent. Any antioxidant are employable without limitation, as far as the antioxidant contained in a poor solvent inactivates radicals generated in cellulose ester, or the antioxidant restrains deterioration of cellulose ester due to oxygen added to the generated radicals.
An antioxidant utilized in the suspension-washing of cellulose ester may remain in cellulose ester after washing. The remaining amount is preferably 0.01-2,000 ppm, more preferably 0.05-1,000 ppm and furthermore preferably 0.1-100 ppm.
As a useful antioxidant in the present invention, a compound which restrains deterioration of the material for forming a cellulose ester film due to oxygen can be utilized without limitation, however, examples of a useful compound include: phenol, hindered amine, a phosphorus-containing compound, a sulfur-containing compound, a heat resistant processing stabilizer and an oxygen scavenger. Specifically preferable among them are phenol, hindered amine and a phosphorus-containing compound.
By blending such a compound, it is possible to prevent coloring and strength decrease of a cellulose ester film while keeping the transparency or heat resistance of the film. These antioxidants each can be utilized alone or in combination of at least two types.
A phenol type compound is a compound well known in the art and is described, for example, in columns 12-14 of U.S. Pat. No. 4,839,405 including 2,6-dialkylphenol derivative compounds. Among these compounds, examples of a preferable compound include those represented by Formula (A).
In Formula (A), R11-R16 each represent a substituent. Examples of the substituent include: a hydrogen atom, a halogen atom (for example, a fluorine atom and a chlorine atom), an alkyl group (for example, a methyl group, an ethyl group, an isopropyl group, a hydroxyethyl group, a methoxy methyl group, a trifluoro methyl group and a t-butyl group), a cycloalkyl group (for example, a cyclopentyl group and a cyclohexyl group), an aralkyl group (for example, a benzyl group and a 2-phenethyl group), an aryl group (for example, a phenyl group, a naphthyl group, p-tolyl group and a p-chlorophenyl group), an alkoxy group (for example, a methoxy group, an ethoxy group, an isopropoxy group and a butoxy group), an aryloxy groups (for example, a phenoxy group), a cyano group, an acylamino group (for example, an acetylamino group and a propionylamino group), an alkylthio group (for example, a methylthio group, an ethylthio group and a butylthio group), an arylthio group (for example, a phenylthio group), a sulfonylamino group (for example, a methanesulfonylamino group and a benzene sulfonyl amino group), an ureido group (for example, a 3-methylureido group, a 3,3-dimethylureido group and a 1,3-dimethylureido group), a sulfamoylamino group (for example, a dimethylsulfamoyl amino group), a carbamoyl group (for example, a methylcarbamoyl group, an ethylcarbamoyl group and a dimethylcarbamoyl group), a sulfamoyl group (for example, an ethylsulfamoyl group and a dimethylsulfamoyl group), an alkoxycarbonyl group (for example, a methoxycarbonyl group and an ethoxycarbonyl group), an aryloxycarbonyl group, (for example, a phenoxycarbonyl group), a sulfonyl group (for example, a methanesulfonyl group, a butane sulfonyl group and a phenylsulfonyl group), an acyl group (for example, an acetyl group, a propanoyl group and a butyroyl group), an amino group (for example, a methylamino group, an ethylamino group and a dimethylamino group), a cyano group, a hydroxy group, a nitro group, a nitroso group, an amineoxide group (for example, a pyridine oxide group), an imide group (for example, a phthalimide group), disulfide group (for example, a benzene disulfide group and a benzothiazolyl-2-disulfide group), a carboxyl group, a sulfo group and a heterocycle group (for example, a pyrrole group, a pyrrolidyl group, a pyrazolyl group, an imidazolyl group, a pyridyl group, a benzimidazolyl group, a benzthiazolyl group and a benzoxazolyl group). These substituents may be further substituted.
Further, R11 is preferably a hydrogen atom, and R12 and R16 each are preferably a t-butyl group which is a phenol compound. Examples of the phenol compound include: n-octadecyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, n-octadecyl-di-t-butyl-4-hydroxyphenyl)acetate, n-octadecyl-3,5-di-t-butyl-4-hydroxybenzoate, n-hexyl-3,5-di-t-butyl-4-hydroxyphenylbenzoate, n-dodecyl-3,5-di-t-butyl-4-hydroxyphenylbenzoate, neo-dodecyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, dodecyl-β-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, ethyl-α-(4-hydroxy-3,5-di-t-butylphenyl)isobutyrate, octadecyl-α-(4-hydroxy-3,5-di-t-butylphenyl)isobutyrate, octadecyl-α-(4-hydroxy-3,5-di-t-butyl-4-hydroxyphenyl)propionate, 2-(n-octylthio)ethyl-3,5-di-t-butyl-4-hydroxy-benzoate, 2-(n-octylthio)ethyl-3,5-di-t-butyl-4-hydroxyphenylacetate, 2-(n-octadecylthio)ethyl-3,5-di-t-butyl-4-hydroxyphenylacetate, 2-(n-octadecylthio)ethyl-3,5-di-t-butyl-4-hydroxybenzoate, 2-(2-hydroxyethylthio)-ethyl-3,5-di-t-butyl-4-hydroxybenzoate, diethylglycol-bis-(3,5-di-t-butyl-4-hydroxyphenyl)propionate, 2-(n-octadecylthio)ethyl-3,5-di-t-butyl-4-hydroxyphenyl)-propionate, stearamide-N,N-bis-[ethylene-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate], N-butylimino-N,N-bis-[ethylene-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate], 2-(2-stearoyloxyethylthio)ethyl-3,5-di-t-butyl-4-hydroxybenzoate, 2-(2-stearoyloxyethylthio)ethyl-7-(3-methyl-5-t-butyl-4-hydroxyphenyl)heptanoate, 1,2-propylene glycol-bis-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate], ethyleneglycol-bis-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate], neopentylglycol-bis-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate], ethyleneglycol-bis-(3,5-di-t-butyl-4-hydroxyphenylacetate), glycerol-1-n-octadecanoate-2,3-bis-(3,5-di-t-butyl-4-hydroxyphenylacetate), pentaerythritoltetrakis[3-(3′, 5′ di-t-butyl-4′-hydroxyphenyl)propionate], 1,1,1-trimethylolethane-tris-[3-(3,5-di-t-butyl-4-hydroxyphenyl) propionate], sorbitol-hexa-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate], 2-hydroxyethyl-7-(3-methyl-5-t-butyl-4-hydroxyphenyl)propionate, 2-stearoyloxyethyl-7-(3-methyl-5-t-butyl-4-hydroxyphenyl)heptanoate, 1,6-n-hexanediol-bis-[(3′,5′-di-butyl-4-hydroxyphenyl)propionate] and pentaerythritoltetrakis(3,5-di-t-butyl-4-hydroxyhydrocinnamate). Above phenol compounds have been commercialized, for example, as “Irganox1076” and “Irganox1010” from Ciba Specialty Chemicals, Inc.
In the present invention, a hindered amine compound represented by Formula (B) is preferably used as one of the useful antioxidants.
In Formula (B), R21-R27 each represent a substituent. Examples of the substituent are common to the substituents R11-R16 described for Formula (A). R24 is preferably a hydrogen atom or a methyl group, R27 is preferably a hydrogen atom and R22, R23, R25 and R26 each are preferably a methyl group.
Examples of a hindered amine compound include: bis(2,2,6,6-tetramethyl-4-piperidyl)sebacate, bis(2,2,6,6-tetramethyl-4-piperidyl)succinate, bis(1,2,2,6,6-pentamethyl-4-piperidyl)sebacate, bis(N-octoxy-2,2,6,6-tetramethyl-4-piperidyl)sebacate, bis(N-benzyloxy-2,2,6,6-tetramethyl-4-piperidyl)sebacate, bis(N-cyclohexyloxy-2,2,6,6-tetramethyl-4-piperidyl)sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidyl)-2-(3,5-di-t-butyl-4-hydroxybenzyl)-2-butylmalonate, bis(1-acroyl-2,2,6,6-tetramethyl-4-piperidyl)-2,2-bis(3,5-di-t-butyl-4-hydroxybenzyl)-2-butylmalonate, bis(1,2,2,6,6-pentamethyl-4-piperidyl)decanedioate, 2,2,6,6-tetramethyl-4-piperidylmethacrylate, 4-[3-(3,5-di-t-butyl-4-hydroxyphenyl)propionyloxy]-1-[2-(3-(3,5-di-t-butyl-4-hydroxyphenyl) propionyloxy)ethyl]-2,2,6,6-tetramethylpiperidine, 2-methyl-2-(2,2,6,6-tetramethyl-4-piperidyl)amino-N-(2,2,6,6-tetramethyl-4-piperidyl)propioneamide, tetrakis(2,2,6,6-tetramethyl-4-piperidyl)-1,2,3,4-butanetetracarboxylate and tetrakis(1,2,2,6,6-pentamethyl-4-piperidyl)-1,2,3,4-butanetetracarboxylate.
Also, a polymer compound is preferable, examples of which include: N,N′,N″,N′″-tetrakis[4,6-bis-[butyl(N-methyl-2,2,6,6-tetramethylpiperidine-4-yl)amino]-triazine-2-yl]-4,7-diazadecane-1,10-diamine; a polycondensation compound of dibutylamine, 1,3,5-triazine N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl)-1,6-hexamethylenediamine and N-(2,2,6,6-tetramethyl-4-piperidyl) butyl amine; a polycondensation compound of dibutylamine, 1,3,5-triazine and N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl) butylamine; poly[{(1,1,3,3-tetramethylbutyl)amino-1,3,5-triazine-2,4-diyl}{(2,2,6,6-tetramethyl-4-piperidyl)imino}hexamethylenel{(2,2,6,6-tetramethyl-4-piperidyl)imino}]; a polycondensation compound of 1,6-hexanediamine-N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl) and morpholine-2,4,6-trichloro-1,3,5-triazine; a high molecular weight HALS in which plurality of piperidine rings are combined via a triazine moiety, such as poly[(6-morpholino-s-triazine-2,4-diyl) [(2,2,6,6-tetramethyl-4-piperidyl)imino]-hexamethylene [(2,2,6,6-tetramethyl-4-piperidyl)imino]]; a polymer of dimethyl succinate and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidineethanol; and a compound in which a piperidine ring is combined via a ester bond, such as a mixed ester compound of 1,2,3,4-butanetetracarboxylic acid, 1,2,2,6,6-pentamethyl-4-piperizinol and 3,9-bis(2-hydroxy-1,1-dimethylethyl)-2,4,8,10-tetraoxaspiro[5,5]undecane, however, the present invention is not limited thereto.
Among these compounds, preferable are, for example, a polycondensation compound of dibutylamine, 1,3,5-triazine and N,N′-bis(2,2,6,6-tetramethyl-4-piperidyl)butylamine; poly[{(1,1,3,3-tetramethylbutyl)amino-, 3,5-triazine-2,4-diyl}{(2,2,6,6-tetramethyl-4-piperidyl)imino}hexamethylene{(2,2,6,6-tetramethyl-4-piperidyl)imino}]; and a polymer of dimethyl succinate and 4-hydroxy-2,2,6,6-tetramethyl-1-piperidine ethanol, which have a number average molecular weight (Mn) of 2,000-5,000.
Above hindered-phenol compounds have been commercialized, for example, as “Tinuvin144” and “Tinuvin770” from Ciba Specialty Chemicals, Inc.; and as “ADK STAB LA-52” from ADEKA Corp.
A compound having a substructure represented by Formula (C-1), (C-2), (C-3), (C-4) or (C-5) is preferably used as one of the preferable antioxidants in the present invention.
In Formula (C-1), Ph1 and Ph′1 each represent a substituent. More preferably, Ph1 and Ph′1 each represent a phenylene group, and the hydrogen atom of the phenylene group may be replaced with a phenyl group, an alkyl group having 1 to 8 carbon atoms, a cycloalkyl group having 5 to 8 carbon atoms, an alkylcycloalkyl group having 6 to 12 carbon atoms, or an aralkyl group having 7 to 12 carbon atoms.
Ph1 and Ph′1 may be mutually the same, or may be different. X represents a single bond, a sulfur atom, or a —CHR6-group. R6 represents a hydrogen atom, an alkyl group having 1 to 8 carbon atoms, or a cycloalkyl group having 5 to 8 carbon atoms. Further, these groups may be substituted with one of the substituents which are common to the substituents R11-R16 described in Formula (A).
Ph2 and Ph′2 each represent one of the substituents which are common to the substituents R11-R16 described in Formula (A).
Ph2 and Ph′2 may be mutually the same or may be different, and Ph2 and Ph′2 may further be substituted with one of the substituents which are common to the substituents R11-R16 described in Formula (A).
Ph3 represents one of the substituents which are common to the substituents R11-R16 described in Formula (A). More preferably, Ph3 represents a phenyl group or a biphenyl group. The hydrogen atom of the phenyl group or the biphenyl group may be replaced with an alkyl group having 1 to 8 carbon atoms, a cycloalkyl group having 5 to 8 carbon atoms, an alkylcycloalkyl group having 6 to 12 carbon atoms, or an aralkyl group having 7 to 12 carbon atoms.
Ph3 may further be substituted with one of the substituents which are common to the substituents R11-R16 described in Formula (A).
Ph4 represents one of the substituents which are common to the substituents R11-R16 described in Formula (A). More preferably, Ph4 represents an alkyl group or a phenyl group each having 1 to 20 carbon atoms. The alkyl group or the phenyl group may further be substituted with one of the substituents which are common to the substituents R11-R11 described in Formula (A).
Ph5, Ph′5, and Ph″5 each represent a substituent. Example of the substiture are common to the substituents R11-R16 described in Formula (A). More preferably, Ph5, Ph′5, and Ph″5 each represent an alkyl group or a phenyl group each having 1 to 20 carbon atoms. The alkyl group or the phenyl group may further be substituted with one of the substituents which are common to the substituents R11-R16 described in Formula (A).
Specific examples of a phosphorus-containing compound include: mono-phosphite compounds such as triphenyl phosphate, diphenylisodecyl phosphate, phenyldiisodecyl phosphate, tris(nonylphenyl) phosphate, tris(dinonylphenyl) phosphate, tris(2,4-di-t-butylphenyl) phosphite, 10-(3,5-di-t-butyl-4-hydroxybenzyl-9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, 6-[3-(3-t-butyl-4-hydroxy-5-methylphenyl)propoxy]-2,4,8,10-tetra-t-butyldibenz[d,f][1.3.2]dioxaphosphepin and tridecyl phosphite; diphosphite compounds such as 4,4′-butylidene-bis(3-methyl-6-t-butylphenyl-di-tridecyl phosphite) and 4,4′-isopropylidene-bis(phenyl-di-alkyl (C12-C15) phosphite); phosphonite compounds such as triphenyl phosphonite, tetrakis(2,4-di-tert-butylphenyl) [1,1-biphenyl]-4,4′-diylbisphosphonite and tetrakis(2,4-di-tort-butyl-5-methylphenyl) [1,1-biphenyl]-4,4′-diylbisphosphonite; phosphinite compounds such as triphenyl phosphinite and 2,6-dimethylphenyldiphenyl phosphinite; and phosphine compounds such as triphenyl phosphine and -tris(2,6-dimethoxyphenyl)phosphine. Specifically preferable are phosphonite compounds.
Examples of above-mentioned commercially available phosphorus-containing compounds include: “Sumilizer GP” from Sumitomo Chemical Co., Ltd.; “ADK STAB PEP-24”, “ADK STAB PEP-36” and “ADK STAB 3010” from ADEKA Corp.; “IRGAFOS P-EPQ” from Ciba Specialty Chemicals, Inc.; and GSY-P101 from SAKAI CHEMICAL INDUSTRY CO., LTD.
Also, the following compounds are cited.
In the present invention, a sulfur-containing compound represented by Formula (D) is preferably used as one of the useful antioxidants.
R31—S—R32 Formula (D)
In Formula (D), R31 and R32 each represent one of the substituents which are common to the substituents R11-R16 described in Formula (A).
Examples of a sulfur-containing compound include: dilauryl-3,3-thio-dipropionate, dimyristyl-3,3′-thio dipropionate, distearyl-3,3-thio-dipropionate, laurylstearyl-3,3-thio-dipropionate, pentaerythritol-tetrakis(β-lauryl-thio-propionate), 3,9-bis(2-dodecylthioethyl-2,4,8,10-tetra-oxaspiro[5,5]undecane.
The above sulfur-containing compounds have been commercialized, for example, as “Sumilezer TPL-R” and “Sumilezer TP-D” from Sumitomo Chemical Co., Ltd.
As a heat resistant processing stabilizer, for example, 2-t-butyl-6-(3-t-butyl-2-hydroxy-5-methylbenzyl)-4-methylphenyl acrylate, 2-[1-(2-hydroxy-3,5-di-t-pentylphenyl)ethyl]-di-t-pentylphenyl acrylate are cited.
The above type of heat resistant processing stabilizers are commercialized as product names of “Sumilizer GM” and “Sumilizer GS” from Sumitomo Chemical Co., Ltd.
Similarly to the case of the aforementioned cellulose ester, the antioxidant is preferably treated to remove the impurities such as residual acid, inorganic salt and organic low-molecule compound that have been carried over from the process of manufacturing, or that have occurred during preservation. The antioxidant has more preferably a purity of 99% or more. The amount of residual acid and water is preferably 0.01 through 100 ppm. This reduces thermal deterioration in the melt-casting film formation of the cellulose ester, and improves the film formation stability, film optical property and mechanical property.
The adding amount of the antioxidant is preferably 0.1-10% by weight, more preferably 0.2-5% by weight, and still more preferably 0.5-2% by weight, based on the weight of cellulose ester. Two or more types of antioxidants may be used in combination.
If the amount of the antioxidant to be added is too small, expected advantages cannot be achieved due to lower stabilizing effect at the time of melting. If the amount to be added is too much, transparency of the film may be reduced from the viewpoint of compatibility with the cellulose ester, and the film may become brittle, which is not preferred.
Under a high temperature condition where melt-casting film formation of cellulose ester is carried out, decomposition of cellulose ester may also be accelerated with an acid. Accordingly, an acid scavenger is preferably contained as one of the stabilizers in the film for a display of the present invention. As the acid scavenger, any compound which react with an acid to inactivate the acid can be used without limitation in the present invention. Of these, preferable is, for example, a compound having an epoxy group as disclosed in U.S. Pat. No. 4,137,201.
Such epoxy compounds as the acid acavenger have been known in the field of the art, and examples thereof include glycidyl ether of various polyglycols, particularly a polyglycol driven by condensation of approximately 8 to 40 moles of ethylene glycol per mole of the polyglycol, diglycidyl ether of glycerol, an metal epoxy compound (for example, ones usually used in a vinyl chloride polymer composition, or one usually used together with a vinyl chloride polymer composition), an epoxide ether condensate, diglycidyl ether of bisphenol A (namely, 4,4′-dihydroxydiphenyldimethylmethane), an epoxide unsaturated fatty acid ester (specifically, an ester of alkyl having 2-4 carbon atoms of a fatty acid having 2-22 carbon atoms such as butyl epoxystearate), and a triglyceride of one of various epoxide long chain fatty acids (for example, an epoxide soybean oil composition. The examples further include an epoxide of plant oil or another unsaturated natural oil. The epoxide oils are sometimes called as epoxide of natural glyceride or epoxide of unsaturated fatty acid and these fatty acids are each contains 12-22 carbon atoms.
As an epoxy group-containing epoxide resin compound available on the market, EPON 815C, and an epoxide ether oligomer condensation product represented by Formula (5) are preferably employed.
In the above formula, n represents an integer of 0-12. Further employable acid scavenger includes those disclosed in JP-A No. 5-194788, paragraphs 87 to 105.
The adding amount of the acid scavenger is preferably 0.1-10% by weight, more preferably 0.2-5% by weight, and still more preferably 0.5-2% by weight, based on the weight of cellulose ester. Two or more types of acid scavengers may be used in combination.
An acid scavenger is also referred to as an acid remover, an acid trapping agent, an acid catcher, however, in the present invention, any of these agents are usable regardless of the difference in the address term.
A UV absorbent (an ultraviolet light absorber) preferably has excellent ultraviolet light absorbance for wavelengths of 370 nm or less in view of preventing deterioration of the polarizer film or the display device due to ultraviolet light, and from the viewpoint of the liquid crystal display it is preferable that there is little absorbance of visible light having wavelengths of 400 nm or more.
Examples of the UV absorbent include: oxybenzophenone compounds, benzotriazole compounds, salicylic acid ester compounds, benzophenone compounds, cyano acrylate compounds nickel complex compounds, and triazine compounds. Of these, preferable are benzophenone compounds, benzotriazole compounds which exhibit little coloration and triazine compounds. In addition, UV absorbents disclosed in JP-A Nos. 10-182621 and 8-337574, and polymer UV absorbents disclosed in JP-A Nos. 6-148430 and 20003-113317 are also applicable.
Specific examples of the benzotriazole UV absorbents include 2-(2′-hydroxy-5′-methylphenyl)benzotriazole, 2-(2′-hydroxy 3′,5′-di-tert-butylphenyl)benzotriazole, 2-(2′-hydroxy-3′-tert-butyl-5′-methylphenyl)benzotriazole, 2-(2′-hydroxy 3′, 5′-di-tert-butylphenyl)-5-chlorobenzotriazole, 2-(2′-hydroxy-3′-(3″, 4″, 5″, 6″-tetrahydrophthalimide methyl)-5′-methylphenyl)benzotriazole, 2,2-methylenebis(4-(1,1,3,3,-tetramethylbutyl)-6-(2H-benzotriazole-2-yl) phenyl), 2-(2′-hydroxy-3′-tert-butyl-5′-methylphenyl)-5-chlorobenzotriazole, 2-(2H-benzotriazole-2-yl)-6-(straight chain or side chain dodecyl)-4-methylphenol, 2-(2′-hydroxy-3′,5′-di-(1-methyl-1-phenylethyl)-phenyl)benzotriazole, 6-(2-benzotriazole)-4-t-octyl-6′-t-butyl-4′-methyl-2,2′-methylenebisphenol, a mixture of octyl-3-[3-tert-butyl-4-hydroxy-5-(chloro-2H-benzotriazole-2-yl) phenyl]propionate and 2-ethylhexyl-3-[3-tert-butyl-4-hydroxy-5-(5-chloro-2H-benzotriazole-2-yl)phenyl]propionate and 2-(2′-hydroxy-3′-(1-methyl-1-phenylethyl)-5′-(1,1,3,3-tetramethylbutyl)-phenyl)benzotriazole. However, the present invention is not limited thereto.
As commercially available UV absorbents, TINUVIN 171, TINUVIN 234, and TINUVIN 360, TINUVIN 928 and TINUVIN 109 (all of which are manufactured by Chiba Specialty Chemical Co., Ltd.); LA31 (manufactured by ADEKA Corp.); JAST-500 (manufactured by JOHOKU CHEMICAL Co., Ltd.); and Sumisorb 250 (manufactured by Sumitomo Chemical Co., Ltd.) are cited.
Examples of the benzophenone compound include: 2,4-dihydroxy benzophenone, 2,2′-dihydroxy-4-methoxy benzophenone, 2-hydroxy-4-methoxy-5-sulfobenzophenone, bis (2-methoxy-4-hydroxy-5-benzoylphenylmethane), however, the present invention is not limited thereto.
The amount of the UV absorbent used in the present invention is preferably 0.1-5 weight %, and more preferably 0.2-3 weight %, and still more preferably 0.5-2 weight %, based on the weight of cellulose ester. Two or more UV absorbents may be used in combination.
Also, these benzotriazole structure or benzophenone structure may be partially or regularly pendant to a polymer, or may be introduced in a part of the molecular structure of an additive such as a plasticizer, an antioxidant or an acid scavenger.
As conventionally known UV absorbing polymers, although they are not specifically limited, for example, a homopolymer obtained by polymerizing RUVA-93 (produced by OTSUKA Chemical Co., Ltd.) or a copolymer obtained by polymerizing RUVA-93 and other polymer are cited. Specifically, cited are, for example, RUVA-30M obtained by copolymerizing RUVA-93 and methylmethacrylate in a weight ratio of 3:7 and RUVA-50M obtained by copolymerizing RUVA-93 and methylmethacrylate in a weight ratio of 5:5. Further cited are polymers disclosed in JP-A No. 2003-112217.
In the production process of the film for a display of the present invention, specifically, of the cellulose ester film, at least one plasticizer is preferably added.
A plasticizer, as described herein, commonly refers to an additive which decreases brittleness and result in enhanced flexibility upon being incorporated in polymers. In the present invention, a plasticizer is added so that the melting temperature of a cellulose ester resin is lowered, and at the same temperature, the melt viscosity of the film forming materials including a plasticizer is lower than the melt viscosity of a cellulose ester resin containing no additive.
Further, addition is performed to enhance hydrophilicity of cellulose ester so that the water vapor permeability of cellulose ester films is lowered. Therefore, the plasticizers of the present invention have a property of an anti-moisture-permeation agent.
The melting temperature of a film forming material, as described herein, refers to the temperature at which the above materials are heated to exhibit a state of fluidity. In order that cellulose ester results in melt fluidity, it is necessary to heat cellulose ester to a temperature which is at least higher than the glass transition temperature. At or above the glass transition temperature, the elastic modulus or viscosity decreases due to heat absorption, whereby fluidity is observed.
However, at higher temperatures, cellulose ester melts and simultaneously undergoes thermal decomposition to result in a decrease in the molecular weight of the cellulose ester, whereby the dynamical characteristics of the resulting film may be adversely affected. Consequently, it is preferable to melt cellulose ester at a temperature as low as possible.
Lowering the melting temperature of the film forming materials is achieved by the addition of a plasticizer having a melting point or a glass transition temperature which is equal to or lower than the glass transition temperature of the cellulose ester.
The film for a display of the present invention preferably contains 1-25 weight % of an ester compound, as a plasticizer, having a structure obtained by condensing the organic acid represented by Formula (1) and a polyalcohol having a valence of 3 to 20.
When the amount of the plasticizer is less than 1 weight %, the effect of improving the flatness of the film may not be obtained, and when the amount of the plasticizer is more than 25 weight %, bleeding out of the plasticizer tends to occur resulting in lowering the long term stability of the film, both of which are not preferable.
More preferable is a cellulose ester film containing 3-20 weight % of plasticizer, based on the weight of cellulose ester, and still more preferable is a cellulose ester film containing 5-15 weight % of plasticizer.
In above Formula (1), R1-R5 each independently represent a hydrogen atom, a cycloalkyl group, an aralkyl group, an alkoxy group, a cycloalkoxy group, an aryloxy group, an aralkyloxy group, an acyl group, a carbonyloxy group, an oxycarbonyl group, or an oxycarbonyloxy group, any of which may further be substituted. L represents a linkage group, which includes a substituted or unsubstituted alkylene group, an oxygen atom or a direct bond.
Preferred as the cycloalkyl group represented by R1-R5 is a cycloalkyl group having 3-8 carbon atoms, and specific examples include cycloproyl, cyclopentyl and cyclohexyl groups. These groups may be substituted. Examples of preferred substituents include: halogen atoms such as a chlorine atom, a bromine atom and a fluolinr atom, a hydroxyl group, an alkyl group, an alkoxy group, an aralkyl group (the phenyl group may further be substituted with an alkyl group or a halogen atom), an alkenyl group such as a vinyl group or an allyl group, a phenyl group (the phenyl group may further be substituted with an alkyl group, or a halogen atom), phenoxy group (the phenyl group may further be substituted with an alkyl group or a halogen atom), an acyl group having 2-8 carbon atoms such as an acetyl group or a propionyl group, and a non-substituted carbonyloxy group having 2-8 carbon atoms such as an acetyloxy group and a propionyloxy group.
The aralkyl group represented by R1-R5 includes a benzyl group, a phenetyl group, and a γ-phenylpropyl group, which may be substituted. Listed as the preferred substituents may be those which may substitute the above cycloalkyl group.
The alkoxy group represented by R1-R5 include an alkoxy group having 1-8 carbon atoms. The specific examples include an methoxy group, an ethoxy group, an n-propoxy group, an n-butoxy group, an n-octyloxy group, an isopropoxy group, an isobutoxy group, a 2-ethylhexyloxy group and a t-butoxy group.
The above groups may further be substituted. Examples of preferred substituents include: halogen atoms such as a chlorine atom, a bromine atom and a fluorine atom; a hydroxyl group; an alkoxy group; a cycloalkoxy group; an aralkyl group (the phenyl group may be substituted with an alkyl group or a halogen atom); an alkenyl group; a phenyl group (the phenyl group may further be substituted with an alkyl group or a halogen atom); an aryloxy group (for example, a phenoxy group (the phenyl group may further be substituted with an alkyl group or a halogen atom)); an acyl group having 2-8 carbon atoms such as an acetyl group or a propionyl group; an acyloxy group such as a propionyloxy group; and an arylcarbonyloxy group such as a benzoyloxy group.
The cycloalkoxy groups represented by R1-R5 include an cycloalkoxy group having 1-8 carbon atoms as an unsubstituted cycloalkoxy group. Specific examples include a cyclopropyloxy group, a cyclopentyloxy group and a cyclohexyloxy group.
These groups may further be substituted. Listed as the preferred substituents may be those which may substitute the above cycloalkyl group.
The aryloxy groups represented by R1-R5 include a phenoxy group, the phenyl group of which may further be substituted with the substituent listed as a substituent such as an alkyl group or a halogen atom which may substitute the above cycloalkyl group.
The aralkyloxy group represented by R1-R6 includes a benzyloxy group and a phenethyloxy group, which may further be substituted. Listed as the preferred substituents may be those which may substitute the above cycloalkyl group.
The acyl group represented by R1-R5 includes an unsubstituted acyl group having 1-8 carbon atoms such as an acetyl group and a propionyl group (an alkyl, alkenyl, or alkynyl group is included as a hydrocarbon group of the acyl group), which may further be substituted. Listed as the preferred substituents may be those which may substitute the above cycloalkyl group.
The carbonyloxy group represented by R1-R5 includes an unsubstituted acyloxy group (an alkyl, alkenyl, or alkynyl group is included as a hydrocarbon group of the acyl group) having 2-8 carbon atoms such as an acetyloxy group or a propionyloxy group, and an arylcarbonyloxy group such as a benzoyloxy group, which may further be substituted with the group which may substitute the above cycloalkyl group.
The oxycarbonyl group represented by R1-R5 includes an alkoxycarbonyl group such as a methoxycarbonyl group, an ethoxycarbonyl group or a propyloxycarbonyl group, and an aryloxycarbonyl group such as a phonoxycarbonyl group, which may further be substituted. Listed as the preferred substituents may be those which may substitute the above cycloalkyl group.
The oxycarbonyloxy group represented by R1-R5 includes an alkoxycarbonyloxy group having 1-8 carbon atoms such as a methoxycarbonyloxy group, which may further be substituted. Listed as the preferred substituents may be those which may substitute the above cycloalkyl group.
Further, any of R1-R5 may be combined with each other to form a ring structure.
Further, the linkage group represented by L includes a substituted or unsubstituted alkylene group, an oxygen atom, or a direct bond. The alkylene group includes a methylene group, an ethylene group, and a propylene group, which may further be substituted with the substituent which is listed as the substituent which may substitute the groups represented by above R1-R5.
Of these, one which is particularly preferred as the linking group is the direct bond which forms an aromatic carboxylic acid.
As the organic acid represented by Formula (1), which constitutes an ester compound to be used as a plasticizer in the present invention, R1-R5 each are preferably a hydrogen atom, or at least one of R1-R5 is preferably the above mentioned alkoxy group, acyl group, oxycarbonyl group, carbonyloxy group or oxycarbonyloxy group. Further, the organic acids represented by above Formula (1) may contain a plurality of substituents.
In the present invention, the organic acids which substitute the hydroxyl groups of a polyalcohol having a valence of 3-20 may either be of a single kind or of a plurality of kinds.
In the present invention, the polyalcohol which reacts with the organic acid represented by above Formula (1) to form a polyalcohol ester is preferably an aliphatic polyalcohol having a valence of 3-20. In the present invention, preferred as a polyalcohol having a valence of 3-20 is represented by following Formula (3).
R′—(OH)m Formula (3)
wherein R′ represents a m-valent organic group, m represents an integer of 3-20, and the OH group represents an alcoholic hydroxyl group. Specifically preferable is a polyalcohol with a “m” value of 3 or 4.
The following examples of a polyalcohol are cited, however, the present invention is not limited thereto.
Examples of the preferred polyalcohol include: adonitol, arabitol, 1,2,4-butanetriol, 1,2,3-hexanetriol, 1,2,6-hexanetriol, glycerin, diglycerin, erythritol, pentaerythritol, dipentaerythritol, tripentaerythritol, galactitol, glucose, cellobiose, inositol, mannitol, 3-methylpentane-1,3,5-triol, pinacol, sorbitol, trimethylolpropane, trimethylolethane, and xylitol.
Of these, specifically preferable are glycerin, trimethylolethane, trimethylolpropane, and pentaerythritol.
An ester of an organic acid represented by Formula (1) and a polyalcohol having a valence of 3-20 can be synthesized employing methods known in the art. Typical synthesis examples are shown in the examples. Examples of the synthetic method include: (i) a method in which an organic acid represented by Formula (1) and a polyalcohol undergo etherification via condensation in the presence of, for example, an acid; (ii) a method in which an organic acid is converted to an acid chloride or an acid anhydride which is allowed to react with a polyalcohol; and (iii) a method in which a phenyl ester of an organic acid is allowed to react with a polyalcohol. Depending on the targeted ester compound, it is preferable to select an appropriate method which results in a high yield.
As an example of a plasticizer containing an ester of an organic acid represented by Formula (1) and a polyalcohol, the compound represented by Formula (2) is cited.
In Formula (2), R6 to R20 each independently represent a hydrogen atom, a cycloalkyl group, an aralkyl group, an alkoxy group, a cycloalkoxy group, an aryloxy group, an aralkyloxy group, an acyl group, a carbonyloxyl group, an oxycarbonyl group or an oxycarbonyloxy group, provided that R6 to R20 may further have a substituent. R6 to R10 each preferably represent a hydrogen atom or an alkoxy group. R21 represents a hydrogen atom or an alkyl group.
As examples of the above described cycloalkyl group, aralkyl group, alkoxy group, cycloalkoxy group, aryloxy group, aralkyloxy group, acyl group, carbonyloxyl group, oxycarbonyl group and oxycarbonyloxy group represented by R6 to R20, the same groups as described for R1 to R5, in Formula (1) can be cited.
The molecular weight of the polyalcohol esters prepared as above is not particularly limited, but is preferably 300-1,500, more preferably 400-1,000. A greater molecular weight is preferred due to reduced volatility, while a smaller molecular weight is preferred in view of reducing water vapor permeability and improving the compatibility with cellulose ester.
Specific compounds of polyalcohol esters according to the present invention will be exemplified below.
An ester compound derived from an organic acid represented by Formula (1) and a polyalcohol exhibits high compatibility with cellulose ester and can be incorporated in the cellulose ester at a high addition content. Consequently, bleeding-out tends not to occur even when another plasticizer or additive is used together, whereby other plasticizer or additive can be easily used together, if desired.
Further, when another plasticizer is simultaneously employed, the ratio of the incorporated plasticizers of the present invention is preferably at least 50 percent by weight, more preferably at least 70 percent, but still more preferably at least 80 percent, based on the total weight of the plasticizers. When the plasticizer of the present invention is employed in the above range, it is possible to achieve a definite effect that the flatness of cellulose ester film produced by a melt-casting method is improved even under simultaneous use of other plasticizers.
Examples of other plasticizers which are simultaneously employed include: an aliphatic carboxylic acid-polyalcohol based plasticizer; an unsubstituted aromatic carboxylic acid or cycloalkylcaroboxylic acid-polyalcohol based plasticizer disclosed in paragraphs 30-33 of JP-A No. 2002-12823; dioctyl adipate; dicyclohexyl adipate; diphenyl succinate; di-2-naphthyl-1,4-cyclohexane dicarboxylate; tricyclohexyl tricarbalate; tetra-3-methylphenyltetrahydrofurane-2,3,4,5-tetracarboxylate; tetrabutyl-1,2,3,4-cyclopentane teracarboxylate; triphenyl-1,3,5-cyclohexyl tricarboxylate; triphenylbenzne-1,3,5-tetracarboxylate; multivalent carboxylates such as phthalic acid based plasticizers (for example, diethyl phthalate, dimethoxyethyl phthalate, dimethyl phthalate, dioctyl phthalate, dibutyl phthalate, di-2-ethylhexyl phthalate, dioctyl phthalate, dicyclohexyl phthalate, dicyclohexyl terephthalate, methylphthalyl methyl glycolate, ethylphthalyl ethyl glycolate, propylphthalyl propyl glycolate, and butylphthalyl butyl glycolate) and citric acid based plasticizers (acetyltrimethyl citrate, acetyltriethyl citrate and acetyltributyl citrate); phosphoric acid ester based plasticizers such as triphenyl phosphate, biphenyl diphenyl phosphate, butylenebis(diethyl phosphate), ethylenebis(diphenyl phosphate), phenylenebis(dibutyl phosphate), phenylenebis(diphenyl phosphate) (ADK STAB PFR, produced by ADEKA Corp.), phenylenebis(dixylenyl phosphate) (ADK STAB FP500, produced by ADEKA Corp.) and bisphenol A diphenyl phosphate (ADK STAB FP600, produced by ADEKA Corp.); carbohydrate ester based plasticizers; polymer plasticizers; polymer polyesters disclosed in paragraphs 49-56 of JP-A No. 2002-22956; and polyether based plasticizers.
Carbohydrate plasticizer will now be explained. A carbohydrate means a monosaccharide, a disaccharide, or a trisaccharide in which the saccharide exist with a form of pyranose or furanose (a six-membered ring or a 5 member ring).
Examples of a carbohydrate unrestrictively include: glucose, saccharose, lactose, cellobiose, mannose, xylose, ribose, galactose, arabinose, fructose, sorbose, cellotriose and raffinose.
Carbohydrate ester refers to an ester compound formed via dehydration condensation of the hydroxyl groups of the carbohydrate and the carboxylic acids, and, in more detail, means an aliphatic carboxylic acid ester or an aromatic carboxylic acid ester of a carbohydrate.
Examples of an aliphatic carboxylic acid include: acetic acid and propionic acid, and examples of an aromatic-carboxylic acid include: benzoic acid, toluic acid and anisic acid.
The number of hydroxyl groups contained in a carbohydrate depends on the type of the carbohydrate. When an ester compound is formed, only a part of the hydroxyl groups may react with a carboxylic acid or all the hydroxyl groups may react with a carboxylic acid.
In the present invention, a carbohydrate ester in which all the hydroxyl groups of the carbohydrate are reacted with a carboxylic acid is preferably used, and examples of such a carbohydrate ester include: acryl polymers such as a copolymer of methyl methacrylate and 2-hydroxyethyl methacrylate, and a copolymer of acrylic acid, methyl methacrylate and 2-hydroxyethyl methacrylate; vinyl polymers such as polyvinyl isobutyl ether and poly(N-vinyl pyrrolidone); styrene polymers such as polystyrene and poly(4-hydroxy styrene); polyesters such as polybutylene succinate, polyethylene terephthalate and polyethylenenaphthalate; polyethers such as polyethylene oxide and polypropylene oxide; polyamide; polyurethane; and polyurea.
The number average molecular weight of the carbohydrate ester is preferably 1000 to about 500000 and specifically preferably 5000 to 200000. When the number average molecular weight is less than 1000, the volatility of the carbohydrate ester may become too high, and when it exceeds 500000, the plasticizing ability of the carbohydrate ester may be lowered, which may affect the mechanical property of the film.
The polymer plasticizer may be a homoplolymer containing a single repeating unit or may be a copolymer containing a plurality of repeating units. Also, two or more of the above polymers may be used in combination.
However, a phosphorus-containing plasticizer generates a strong acid when it is hydrolyzed, whereby hydrolysis of the plasticizer itself and the cellulose ester is accelerated. Accordingly, a phosphorus-containing plasticizer may have problems in that it exhibits a poorer storage stability and coloration of a cellulose ester film tends to occur when the film is produced via a melt-casting method. Therefore, a phthalate ester plasticizer, a polyalcohol ester plasticizer, a citrate ester plasticizer, a polyester plasticizer and a polyether plasticizer are preferably used in the present invention.
In the film for a display of the present invention, coloration of the film affects the optical property of the film. Accordingly, the yellow index Y1 of the film is preferably 3.0 ore less, and more preferably 1.0 or less. The yellow index can be determined according to the method of JIS-K7103. These plasticizers may be used alone, or in combination of two or more. The adding amount of the plasticizer is 1-30 weight %, more preferably 2-25 weight %, and specifically preferably 7-20 weight %, based on the weight of cellulose ester, when the film is a cellulose ester film.
The transmittance of the film for a display of the present invention for a light flux having a wavelength of 450 nm is preferably 90% or more. When the film is a laminate of a cellulose ester film and another film, the transmittance of only the cellulose ester film for a light flux having a wavelength of 450 nm is preferably 90% or more.
In order to provide a lubricant property, as well as optical and mechanical functions, a matting agent is incorporated into to the film for a display of the present invention. Listed as such matting agents are particles of inorganic or organic compounds.
Preferably employed matting agents are spherical, rod-shaped, acicular, layered and tabular. Examples of a matting agent include: inorganic particles of metal oxides, metal phosphates, metal silicates and metal carbonates such as silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, calcium carbonate, kaolin, talc, calcined calcium silicate, hydrated calcium silicate, aluminum silicate, magnesium silicate, or calcium phosphate; and crosslinking polymer particles.
Of these, silicon dioxide is preferred due to a resulting decrease in film haze. It is preferable that these particles are subjected to a surface treatment, since it is possible to lower the film haze.
The above surface treatment is preferably carried out employing halosilane, alkoxysilane, silazane, or siloxane. As the average diameter of the particles increases, lubricant effect is enhanced, while, as the average diameter decreases, the transparency of the film increases.
The average diameter of the primary particles is 0.01-1.0 μm, preferably 5-50 nm, but is more preferably 7-14 nm. These particles are preferably employed to form unevenness of 0.01-1.0 μm on the surface of the film.
Examples of silicon dioxide particles include AEROSIL 200, 200V, 300, R972, R972V, R974, R202, R812, OX50, TT600 and NAX50 (all of which are produced by Nihon Aerosil Co., Ltd); KE-P10, KE-P30, KE-P100, KE-P150 (Produced by NIPPON SHOKUBAI Co., Ltd.). Of these, preferred are AEROSIL 200V, R972, NAX50, KE-P30 and KE-P100.
When two types of the particles are employed in combination, they may be mixed at an optional ratio to use. It is possible to use particles different in the average particle diameter or in materials, for example, AEROSIL 200V and R972V can be used at a weight ratio in the range of 0.1:99.9 to 99.9:0.1.
These matting agents are preferably added by kneading, or, alternatively, the matting agent is added by: (i) previously dispersing a matting agent in a solvent; (ii) further dispersing the matting agent after mixed with a cellulose ester and/or a plasticizer and/or a UV absorbent; (iii) separating the solid content by evaporating the solvent or by precipitation of the solid content; and (iv) using the product in the production process of a melt of cellulose ester. The latter method is preferable because the matting agent can be more uniformly dispersed in the cellulose ester.
The above matting agent may also be used in order to improve a mechanical property, an electric property or an optical property of the film.
The addition of more amount of matting agent into the film for a display of the present invention results in improving the lubricant property of the film, however, haze of the film also increases. Accordingly, the content of a matting agent in the film is preferably 0.001-5 weight %, more preferably 0.005-1 weight %, and still more preferably 0.01-0.5 weight %, based on the weight of cellulose ester.
The haze value of the film for a display of the present invention is preferably less than 1.0%, but is more preferably less than 0.5%, since the haze of 1% or more may affect the optical property of the film. The haze value is determined according to the method of JIS K 7136.
The film constituting material is required to generate very small amount of volatile matter or no volatile matter at all in the melting and film formation process. This is intended to ensure that the foaming occurs at the time of heating and melting to remove or avoid the defect inside the film and poor flatness on the film surface.
When the film constituting material is molten, the amount of the volatile matter contained is 1% by mass or less, preferably 0.5% by mass or less, more preferably 0.2% by mass or less, still more preferably 0.1% by mass or less.
In the present invention, a differential thermogravimetric apparatus (differential weight calorimetry (TG/DTA 200 by Seiko Denshi Kogyo Co., Ltd.) is used to get a weight loss on heating from 30° C. through 250° C. The result is used as the amount of the volatile matter contained.
Before film formation or at the time of heating, the moisture and the volatile components represented the aforementioned solvent are preferably removed from the film constituting material to be used. They can be removed by the conventional known method. A heating method, depressurization method, or heating/depressurization method can be used to remove them in air or in nitrogen atmosphere as an inert gas atmosphere.
When the known drying method is used, this procedure is carried out in the temperature range wherein the film constituting material is not decomposed. This is preferred to ensure good film quality.
Generation of the volatile components can be reduced by the drying step prior to film formation. It is possible to dry the resin independently, or dry the resin and film constituting materials by separating into a mixture or compatible substances made of at least one or more types other than the resin. The drying temperature is preferably 70° C. or more.
If the material to be dried contains any substance having a glass-transition temperature, and is heated up to a drying temperature higher than that glass-transition temperature, the material will be fused and will become difficult to handle. To avoid this, the drying temperature is preferably kept at a level not exceeding the glass-transition temperature.
If a plurality of substances has a glass-transition temperature, the glass-transition temperature of the substance having a lower glass-transition temperature should be used as a standard. This temperature is preferably 70° C. or more through (glass-transition temperature −5)° C. or less, more preferably 110° C. or more through (glass-transition temperature −20)° C. or less.
The drying time is preferably 0.5 through 24 hours, more preferably 1 through 18 hours, still more preferably 1.5 through 12 hours. If the drying temperature is too low, the rate of removing the volatile components will be reduced and much time will be required for drying.
The drying process can be divided into two or more steps. For example, the drying process may includes a pre-drying step for storing the material, and a preliminary drying step for the period one week before film formation through the period immediately before film formation.
The display apparatus film of the present invention is preferably formed by melt casting of the cellulose ester. The molding by melt casting wherein heating and melting are conducted without using the solvent used in the solution casting method (e.g., methylene chloride) can be divided into a melt-extrusion molding method, press molding method, inflation method, injection molding method, blow molding method, draw molding method, and others.
Of these methods, melt-extrusion molding method is preferred to produce a polarizing plate protective film characterized by excellent mechanical strength and surface accuracy.
The following describes the film manufacturing method of the present invention with reference to the melt extrusion method:
In the cellulose ester film manufacturing method shown in
With both ends gripped by a drawing apparatus 12, the film 10 separated by a separation roll 9 is drawn across the width and is wound by a winding apparatus 16. To correct flatness, a touch roll 6 is provided. This is used to press the film against the surface of the first cooling roll 5.
This touch roll 6 has an elastic surface and forms a nip with the first cooling roll 5. The details of the touch roll 6 will be described later.
The conditions for the cellulose ester film manufacturing method are the same as those for thermoplastic resins such as other polyesters. The material is preferably dried in advance. A vacuum or depressurized dryer, or dehumidified hot air dryer is used to dry the material until the moisture is reduced to 1000 ppm or less, preferably 200 ppm or less.
For example, the cellulose ester based resin having been dried under hot air, vacuum or depressurized atmosphere is extruded by the extruder 1 and is molten at a temperature of about 200 through 300° C. The leaf disk filter 2 is used to filter the material to remove foreign substances.
When the material is fed from the feed hopper (not illustrated) to the extruder 1, the material is preferably placed in the vacuum, depressurized or insert gas atmosphere to prevent oxidation and decomposition.
When additives such as plasticizer are not mixed in advance, they can be kneaded into the material during the process of extrusion. To ensure uniform mixing, a mixer such as a static mixer 3 is preferably utilized.
In the present invention, the cellulose resin and the additives such as a stabilizer to be added as required are preferably mixed before being molten. It is more preferred that the cellulose resin and stabilizer should be mixed first.
A mixer may be used for mixing. Alternatively, mixing may be completed in the process of preparing the cellulose resin, as described above. It is possible to use a commonly used mixer such as a V-type mixer, conical screw type mixer, horizontal cylindrical type mixer, Henschel mixer and ribbon mixer.
As described above, subsequent to mixing of the film constituting material, the mixture can be directly molten by the extruder 1 to form a film. Alternatively, it is also possible to palletize the film constituting material, and the resultant pellets may be molten by the extruder 1, whereby a film is formed.
The following arrangement can also be used: When the film constituting material contains a plurality of materials having different melting points, so-called patchy half-melts are produced at the temperature wherein only the material having a lower melting point is molten. The half-melts are put into the extruder 1, whereby a film is formed.
Further, the following arrangement can also be used: If the film constituting material contains the material vulnerable thermal decomposition, a film is directly formed without producing pellets, thereby reducing the frequency of melting. Alternatively, a film is produced after patchy half-melts have been formed, as described above.
Various types of commercially available extruders can be used as the extruder 1. A melt-knead extruder is preferably utilized. Either a single-screw extruder or a twin-screw extruder can be used.
When producing a film directly without pellets being formed from the film constituting material, an adequate degree of mixing is essential. In this sense, a twin-screw extruder is preferably used. A single-screw extruder can be used if the screw is changed into a kneading type screw such as a Madoc screw, Unimelt screw or Dulmage screw, because a proper degree of mixing can be obtained by this modification.
When pellets or patchy half-melts are used as film constituting materials, both the single screw extruder and twin screw extruder can be used.
In the cooling process inside the extruder 1 and after extrusion, oxygen density is preferably reduced by an inert gas such as nitrogen gas or by depressurization.
The preferred conditions for the melting temperature of the film constituting material inside the extruder 1 vary according to the viscosity and discharge rate of the film constituting material as well as the thickness of the sheet to be produced. Generally, it is Tg or more through Tg+130° C. or less with respect to the glass-transition temperature Tg of the film, preferably Tg+10° C. or more through Tg+120° C. or less. The melt viscosity at the time of extrusion is 10 through 100000 poises, preferably 100 through 10000 poises.
The retention time of the film constituting material inside the extruder 1 should be as short as possible. It is within five minutes, preferably within three minutes, more preferably within two minutes. The retention time varies according to the type of the extruder and the conditions for extrusion. It can be reduced by adjusting the amount of the material to be supplied, the L/D, the speed of screw and the depth of screw groove.
The shape and speed of the screw of the extruder 1 are adequately selected in response to the viscosity and discharge rate of the film constituting material. In the present invention, the shear rate of the extruder 1 is 1/sec. through 10000/sec., preferably 5/sec. through 1000/sec., more preferably 10/sec. through 100/sec.
The extruder 1 that can be used in the present invention can be obtained as a plastic molding machine generally available on the market.
The film constituting material extruded from the extruder 1 is fed to the flow casting die 4, and the slit of the flow casting die 4 is extruded as a film There is no restriction to the flow casting die 4 if it can be used to manufacture a sheet or film.
The material of the flow casting die 4 are exemplified by hard chromium, chromium carbonate, chromium nitride, titanium carbide, titanium carbonitride, titanium nitride, cemented carbide, ceramic (tungsten carbide, aluminum oxide, chromium oxide), which are sprayed or plated. Then they are subjected to surface processing, as exemplified by buffing and lapping by a grinder having a count of #1000 or later planar cutting (in the direction perpendicular to the resin flow) by a diamond wheel having a count of #1000 or more, electrolytic grinding, and electrolytic complex grinding.
The preferred material of the lip of the flow casting die 4 is the same as that of the flow casting die 4. The surface accuracy of the lip is preferably 0.5 S or less, more preferably 0.2 S or less.
The slit of this flow casting die 4 is designed in such a way that the gap can be adjusted. This is shown in
Each heat bolt 5 includes a block 36 containing a recessed type electric heater 37 and a cooling medium passage. Each heat bolt 35 penetrates the block 36 in the vertical direction. The base of the heat bolt 35 is fixed on the die (main body) 31, and the front end is held in engagement with the outer surface of the flexible lip 33.
While the block 36 is constantly cooled, the input of the recessed type electric heater 37 is adjusted to increase or decrease the temperature of the block 36, this adjustment causes thermal extension and contraction of the heat bolt 35, and hence, displacement of the flexible lip 33, whereby the film thickness is adjusted.
The following arrangement can also be used: A thickness gauge is provided at predetermined positions in the wake of the die. The web thickness information detected by this gauge is fed back to the control apparatus. This thickness information is compared with the preset thickness information of the control apparatus, whereby the power of the heat generating member of the heat bolt or the ON-rate thereof is controlled by the signal for correction control amount sent from this apparatus. The heat bolt preferably has a length of 20 through 40 cm, and a diameter of 7 through 14 mm. A plurality of heat bolts, for example, several tens of heat bolts are arranged preferably at a pitch of 20 through 40 mm.
A gap adjusting member mainly made up of a bolt for adjusting the slit gap by manually movement in the axial direction can be provided, instead of a heat bolt. The slit gap adjusted by the gap adjusting member normally has a diameter of 200 through 1000 μm, preferably 300 through 800 μm, more preferably 400 through 600 μm.
The first through third cooling roll is made of a seamless steel pipe having a wall thickness of about 20 through 30 mm. The surface is mirror finished. It incorporates a tune for feeding a coolant. Heat is absorbed from the film on the roll by the coolant flowing through the tube. Of these first through third cooling rolls, the first cooling roll 5 corresponds to the rotary supporting member of the present invention.
In the meantime, the touch roll 6 held in engagement with the first cooling roll 5 has an elastic surface. It is deformed along the surface of the first cooling roll 5 by the pressure against the first cooling roll 5, and forms a nip between this roll and the first roll 5. To be more specific, the touch roll 6 corresponds to the pressure rotary member of the present invention.
The metallic sleeve 41 is made of a stainless steel having a thickness of 0.3 mm, and is characterized by a high degree of flexibility. If the metallic sleeve 41 is too thin, strength will be insufficient. If it is too thick, elasticity will be insufficient. Thus, the thickness of the metallic sleeve 41 is preferably 0.1 through 1.5 mm.
The elastic roller 42 is a roll formed by installing a rubber 44 on the surface of the metallic inner sleeve 43 freely rotatable through a bearing. When the touch roll A is pressed against the first cooling roll 5, the elastic roller 42 presses the metallic sleeve 41 against the first cooling roll 5, and the metallic sleeve 41 and elastic roller 42 is deformed, conforming to the shape of the first cooling roll 5, whereby a nip is formed between this roll and the first cooling roll. The cooling water 45 is fed into the space formed inside the metallic sleeve 41 with the elastic roller 42.
To put it in greater details, the touch roll B is formed in such a way that the outer sleeve supporting flanges 56a and 56b are mounted on the rotary shafts 55a and 55b on both ends, and a thin-walled metallic outer sleeve 51 is mounted between the outer peripheral portions of these outer sleeve supporting flanges 56a and 56b. The fluid supply tube 59 is arranged coaxially inside the fluid outlet port 58 which is formed on the shaft center of the rotary shaft 55a and constitutes a fluid return passage 57. This fluid supply tube 59 is connected and fixed to the fluid shaft sleeve 60 arranged on the shaft center which is arranged inside the thin-walled metallic outer sleeve 51.
Inner sleeve supporting flanges 61a and 61b are mounted on both ends of this fluid shaft sleeve 60, respectively. A metallic inner sleeve 52 having a wall thickness of about 15 through 20 mm is mounted in the range from the position between the outer peripheral portions of these inner sleeve supporting flanges 61a and 61b to the outer sleeve supporting flange 56b on the other end.
For example, a coolant flow space 53 of about 10 mm is formed between this metallic inner sleeve 52 and thin-walled metallic outer sleeve 51. An outlet 52a and an inlet 52b communicating between the flow space 53 and intermediate passages 62a and 62b outside the inner sleeve supporting flanges 61a and 61b are formed on the metallic inner sleeves 52 close to both ends, respectively.
To provide pliability, flexibility and restoring force close to those of the rubber, the outer sleeve 51 is designed thin within the range permitted by the thin cylinder theory of elastic mechanics. The flexibility evaluated by the thin cylinder theory is expressed by wall thickness t/roll radium r. The smaller the t/r, the higher the flexibility.
The flexibility of this touch roll B meets the optimum condition when t/r≦0.03. Normally, the commonly used touch roll has a roll diameter R=200 through 500 mm (roll radius r=R/2), a roll effective width L=500 through 1600 mm, and an oblong shape of r/L<1.
As shown in
The amount of deflection in the nip width k is about 0.05 through 0.1 mm Here, t/r≦0.03 is assumed. In the case of the general roll diameter R=200 through 500 mm, sufficient flexibility is obtained if 2 mm≦t≦5 mm in particular. Thickness can be easily reduced by machining. Thus, this is very practical range. If the wall thickness is 2 mm or less, high-precision machining cannot be achieved due to elastic deformation during the step of processing.
The equivalent value of this 2 mm≦t≦5 mm can be expressed by 0.008≦t/r≦0.05 for the general roll diameter. In practice, under the conditions of t/r≈0.03, wall thickness is preferably increased in proportion to the roll diameter. For example, selection is made within the range of t=2 through 3 mm for the roll diameter: R=200; and t=4 through 5 mm for the roll diameter: R=500.
These touch rolls A and B are energized toward the first cooling roll by the energizing section (not illustrated). The F/W (linear pressure) obtained by dividing the energizing force F of the energizing section by the width W of the film in the nip along the rotary shaft of the first cooling roll 5 is set at 9.8 through 147 N/cm. According to the present embodiment, a nip is formed between the touch rolls A and B, and the first cooling roll 5. Flatness should be corrected while the film passes through this nip.
Thus, as compared to the cases where the touch roll is made of a rigid body, and no nip is formed between the touch roll and the first cooling roll, the film is sandwiched and pressed at a smaller linear pressure for a longer time. This arrangement ensures more reliable correction of flatness. To be more specific, if the linear pressure is smaller than 9.8 N/cm, the die line cannot be removed sufficiently.
Conversely, if the linear pressure is greater than 147 N/cm, the film cannot easily pass through the nip. This will cause uneven thickness of the film.
The surfaces of the touch rolls A and B are made of metal. This provides smooth surfaces of the touch rolls A and B, as compared to the case where touch rolls have rubber surfaces. The elastic body 44 of the elastic roller 42 can be made of ethylene propylene rubber, neoprene rubber, silicone rubber or the like.
To ensure that the die line is removed sufficiently by the touch roll 6, it is important that the film viscosity should lie within the appropriate range when the film is sandwiched and pressed by the touch roll 6. Further, cellulose ester is known to be affected by temperature to a comparatively high degree.
Thus, to set the viscosity within an appropriate range when the cellulose ester film is sandwiched and pressed by the touch roll 6, it is important to set the film temperature within an appropriate range when the cellulose ester film is sandwiched and pressed by the touch roll 6.
When the glass-transition temperature of the cellulose ester film is assumed as Tg, the temperature T of the film immediately before the film is sandwiched and pressed by the touch roll 6 is preferably set in such a way that Tg<T<Tg+110° C. can be met.
If the film temperature T is lower than T, the viscosity of the film will be too high to correct the die line. Conversely, if the film temperature T is higher than Tg+110° C., uniform adhesion between the film surface and roll cannot be achieved, and the die line cannot be corrected. This temperature is preferably Tg+10° C.<T<Tg+90° C., more preferably Tg+20° C.<T<Tg+70° C.
To set the film temperature within the appropriate range when the cellulose ester film is sandwiched and pressed by the touch roll 6, one has only to adjust the length L of the nip between the first cooling roll 5 and touch roll 6 along the rotating direction of the first cooling roll 5, from the position P1 wherein the melt pressed out of the flow casting die 4 comes in contact with the first cooling roll 5.
In the present invention, the material preferably used for the first roll 5 and second roll 6 is exemplified by carbon steel, stainless steel and resin. The surface accuracy is preferably set at a higher level. In terms of surface roughness, it is preferably set to 0.3 S or less, more preferably 0.01 S or less.
In the present invention, the portion from the opening (lip) of the flow casting die 4 to the first roll 5 is reduced to 70 kPa or less. This procedure has been found out to correct the die line effectively. Pressure reduction is preferably 50 through 70 kPa.
There is no restriction to the method of ensuring that the pressure in the portion from the opening (lip) of the flow casting die 4 to the first roll 5 is kept at 70 kPa or less. One of the methods is to reduce the pressure by using a pressure-resistant member to cover the portion from the flow casting die 4 to the periphery of the roll.
In this case, the vacuum suction machine is preferably heated by a heater or the like to ensure that a sublimate will be deposited on the vacuum suction machine. In the present invention, if the suction pressure is too small, the sublimate cannot be sucked effectively. To prevent this, adequate suction pressure must be utilized.
In the present invention, the film-like cellulose ester based resin in the molten state from the T-die 4 is conveyed in contact with the first roll (the first cooling roll) 5, second cooling roll 7, and third cooling roll 8 sequentially, and is cooled and solidified, whereby an unoriented cellulose ester based resin film 10 is produced.
In the embodiment of the present invention shown in
A known tender or the like can be preferably used to draw the film across the width. Especially when the film is drawn across the width, the lamination with the polarized film can be preferably realized in the form of a roll. Drawing across the width ensures that the low axis of the cellulose ester film made up of a cellulose ester based resin film is found across the width.
In the meantime, the transmission axis of the polarized film also lies across the width normally. If the polarizing plate wherein the transmission axis of the polarized film and the low axis of the optical film will be parallel to each other is incorporated in the liquid crystal display apparatus, the display contrast of the liquid crystal display apparatus can be increased and an excellent angle of field is obtained.
The glass transition temperature Tg of the film constituting material can be controlled when the types of the materials constituting the film and the proportion of the constituent materials are made different. When the phase difference film is manufactured as a cellulose film, Tg is 120° C. or more, preferably 135° C. or more.
In the liquid crystal display apparatus, the film temperature environment is changed in the image display mode by the temperature rise of the apparatus per se, for example, by the temperature rise caused by a light source. In this case, if the Tg of the film is lower than the film working environment temperature, a big change will occur to the retardation value and film geometry resulting from the orientation status of the molecules fixed in the film by drawing.
If the Tg of the film is too high, temperature is raised when the film constituting material is formed into a film This will increase the amount of energy consumed for heating. Further, the material may be decomposed at the time of forming a film, and this may cause coloring. Thus, Tg is preferably kept at 250° C. or less.
The process of cooling and relaxation under a known thermal setting conditions can be applied in the drawing process. Appropriate adjustment should be made to obtain the characteristics required for the intended optical film.
The aforementioned drawing process and thermal setting process are applied as appropriate on an selective basis to provide the phase film function for the purpose of improving the physical properties of the phase film and to increase the angle of field in the liquid crystal display apparatus. When such a drawing process and thermal setting process are included, the heating and pressing process should be performed prior to the drawing process and thermal setting process.
When a phase difference film is produced as a cellulose ester film, and the functions of the polarizing plate protective film are combined, control of the refractive index is essential. The refractive index control can be provided by the process of drawing. The process of drawing is preferred. The following describes the method for drawing:
In the phase difference film drawing process, required retardations Ro and Rt can be controlled by a drawing at a magnification of 1.0 through 2.0 times in one direction of the cellulose resin, and at a magnification of 1.01 through 2.5 times in the direction perpendicular to the inner surface of the film. Here Ro denotes an in-plane retardation. It is obtained by multiplying the thickness by the difference between the refractive index in the longitudinal direction MD in the same plane and that across the width TD. Rt denotes the retardation along the thickness, and is obtained by multiplying the thickness by the difference between the refractive index (an average of the values in the longitudinal direction MD and across the width TD) in the same plane and that along the thickness.
Drawing can be performed sequentially or simultaneously, for example, in the longitudinal direction of the film and in the direction perpendicular thereto in the same plane of the film, namely, across the width. In this case, if the drawing magnification at least in one direction is insufficient, sufficient phase difference cannot be obtained. If it is excessive, drawing difficulties may occur and the film may break.
Drawing in the biaxial directions perpendicular to each other is an effectively way for keeping the film refractive indexes nx, ny and nz within a predetermined range. Here nx denotes a refractive index in the longitudinal direction MD, ny indicates that across the width TD, and nz represents that along the thickness.
When the material is drawn in the melt-casting direction, the nz value will be excessive if there is excessive shrinkage across the width. This can be improved by controlling the shrinkage of the film across the width or by drawing across the width. In the case of drawing across the width, distribution may occur to the refractive index across the width.
This distribution may appear when a tenter method is utilized. Drawing of the film across the width causes shrinkage force to appear at the center of the film because the ends are fixed in position. This is considered to be what is called “bowing”. In this case, bowing can be controlled by drawing in the casting direction, and the distribution of the phase difference across the width can be reduced.
Drawing in the biaxial directions perpendicular to each other reduces the fluctuation in the thickness of the obtained film. Excessive fluctuation in the thickness of the phase difference film will cause irregularity in phase difference. When used for liquid crystal display, irregularity in coloring or the like will occur.
The fluctuation in the thickness of the cellulose ester film is preferably kept within the range of ±3%, preferably ±1%. To achieve the aforementioned object, it is effective to use the method of drawing in the biaxial directions perpendicular to each other. The magnification rate of drawing in the biaxial directions perpendicular to each other is preferably 1.0 through 2.0 times in the casting direction, and 1.01 through 2.5 times across the width. Drawing in the range of 1.01 through 1.5 times in the casting direction and in the range of 1.05 through 2.0 times across the width will be more preferred to get a retardation value.
When the absorption axis of the polarizer is present in the longitudinal direction, matching of the transmission axis of the polarizer is found across the width. To get a longer polarizing plate, the phase difference film is preferably drawn so as to get a low axis across the width.
When using the cellulose ester to get positive double refraction with respect to stress, drawing across the width will provide the low axis of the phase difference film across the width because of the aforementioned arrangement. In this case, to improve display quality, the low axis of the phase difference film is preferably located across the width. To get the target retardation value, it is necessary to meet the following condition:
(Drawing magnification across the width)>(drawing magnification in casting direction)
After drawing, the end of the film is trimmed off by a slitter 13 to a width predetermined for the product. Then both ends of the film are knurled (embossed) by a knurling apparatus made up of an emboss ring 14 and back roll 15, and the film is wound by a winder 16. This arrangement prevents sticking in the cellulose ester film F (master winding) or scratch.
Knurling can be provided by heating and pressing a metallic ring having a pattern of projections and depressions on the lateral surface. The gripping portions of the clips on both ends of the film are normally deformed and cannot be used as a film product. They are therefore cut out and are recycled as a material.
In the film winding process, the film is wound on the winding roll while the shortest distance between the outer peripheral surface of the cylindrically wound film and the outer peripheral surface of the traveling type conveyance roll immediately before is kept at a minimum. Further, the front side of the winding roll is provided with a blower or the like that removes or reduces the potential on the film surface.
The winding machine to be used in the manufacture of a polarizing plate protective film of the present invention can be the one commonly employed. The film can be wound according to such a winding method as a constant tension method, constant torque method, taper tension method, and program tension control method of constant internal stress. In this case, the initial winding tension at the time of winding the polarizing plate protective film is preferably 90.2 through 300.8 N/m.
In the film winding process of the present invention, the film is wound preferably at a temperature of 20° C. through 30° C., with a relative humidity of 20% through 60% RH. When the temperature and humidity in the film winding process are controlled in this manner, the resistance of the retardation (Rt) along the length against the fluctuation in humidity can be improved.
If the temperature in the winding process is less than 20° C., wrinkles will occur and film winding quality is deteriorated so that the film cannot be put into practical use. This must be avoided. If the temperature in the film winding process has exceeded 30° C., wrinkles will also occur and film winding quality is deteriorated so that the film cannot be put into practical use. This must be avoided.
If the humidity in the film winding process is less than 20% RH, electrostatic charge will occur easily and the film winding quality is deteriorated so that the film cannot be put into practical use. If the humidity in the film winding process has exceeded 60% RH, the winding quality, sticking trouble and conveyance property will be deteriorated.
When the polarizing plate protective film is wound in a roll, any core located on the cylinder can be used as a winding core. It is preferably a hollow plastic core. Any material can be used as a plastic material, if it is a heat resistant plastic material capable of resisting the temperature at the time of heating. It can be exemplified by phenol resin, xylene resin, melamine resin, polyester resin, and epoxy resin.
The thermosetting resin reinforced by such a filler as a glass fiber is preferably used, and is exemplified by a hollow plastic winding ore of FRP having an outer diameter of 6 inches (hereinafter an inch is equivalent to 2.54 cm) and an inner diameter of 5 inches.
The number of turns on such a winding core is preferably 100 or more, more preferably 500. The winding width is preferably 5 cm or more. The width of the film substrate is preferably 80 cm or more, more preferably 1 m or more.
When the phase difference film is a polarizing plate protective film, the thickness of the protective film is preferably 10 through 500 μm. In particular, the lower limit is 20 μm, preferably 35 μm. The upper limit is 150 μm, preferably 120 μm. The particularly preferred range is 25 through 90 μm.
If the phase difference film is too thick, the polarizing plate subsequent to machining will be too thick. This fails to meet low-profile light weight requirements when employed in the liquid crystal display for a notebook PC or mobile type electronic equipment. Conversely, if the phase difference film is too thin, retardation as a phase difference film cannot occur easily. Further, the film moisture permeability will be increased, with the result that the polarizer cannot be effectively protected from moisture. This must be avoided.
The low axis or high axis of the phase difference film is present in the same plane of the film Assume that the angle formed with the direction of film formation is θ1. Then the θ1 should be −1° through +1°, preferably −0.5° through +0.5°.
This θ1 can be defined as an orientation angle. It can be measured by an automatic double refractometer KOBRA-21ADH (by Oji Scientific Instruments).
If θ1 meets the aforementioned formula, a high degree of brightness is ensured in the display image and a leakage of light is reduced or prevented, with the result that faithful color representation is provided in the color liquid crystal display apparatus.
When the phase difference film is used in the multiple-domain VA mode, the phase difference film is arranged in the aforementioned range wherein the high axis of the phase difference film is θ1. This arrangement improves the display quality of the image.
In
The distribution of the retardation Ro in the in-plane direction of the cellulose ester film is adjusted to preferably 5% or less, more preferably 2% or less, still more preferably 1.5% or less. Further, the distribution of retardation Rt along the thickness of the film is adjusted to preferably 10% or less, more preferably 2% or less, still more preferably 1.5% or less.
In the phase difference film, the fluctuation in the distribution of the retardation value is preferred to be as small as possible. When a polarizing plate containing the phase difference film is used in the liquid crystal display apparatus, a smaller fluctuation in the distribution of the aforementioned retardation distribution is preferred for the purpose of preventing color irregularity.
In order to adjust the phase difference film so as to provide the retardation value suited for improvement of the display quality of the liquid crystal cell in the VA mode or TN mode and to divide into the aforementioned multi-domain especially in the VA mode for preferable use in the MVA mode, adjustment must be made to ensure that the in-plane retardation Ro is greater than 30 nm without exceeding 95 nm, and retardation Rt along the thickness is greater than 70 nm without exceeding 400 nm.
The aforementioned in-plane retardation Ro has the following function: In the configuration shown in
In the aforementioned TN mode and VA mode, particularly in the MVA mode, when the liquid crystal cell is set to the black-and-white display mode, the retardation along the thickness mainly compensates for the double refraction of the liquid crystal cell recognized when viewed obliquely in the same manner as above.
As shown in
In this case, the in-plane retardation Ro of the 22a and 22b and retardation Rt along the thickness retardation Rt are the same. This is preferred to improve the productivity of industrial polarizing plates. It is particularly preferred that the in-plane retardation Ro is greater than 35 nm without exceeding 65 nm, the retardation Rt along the thickness retardation Rt is greater than 90 nm without exceeding 180 nm, and the structure shown in
In the liquid crystal display apparatus, assume that the TAC film having an in-plane retardation Ro of 0 through 4 nm, a retardation Rt along the thickness of 20 through 50 nm and a thickness of 35 through 85 μm is used at the position 22b in
In this case, the polarizing film arranged on the other polarizing plate, for example, the polarizing film arranged in 22a of
The polarizing plate including the polarizing plate protective film of the present invention provides higher display quality than the normal polarizing plate. This is particularly suited for use in a multi-domain type liquid crystal display apparatus, more preferably to the multi-domain type liquid crystal display apparatus in the double refraction mode.
The polarizing plate of the present invention of the present invention can be used in the MVA (Multi-domain Vertical Alignment) mode, PVA (Patterned Vertical Alignment) mode, CPA (Continuous Pinwheel Alignment) mode and OCB (Optical Compensated Bend) mode, without being restricted to a specific liquid crystal mode or polarizing plate arrangement.
The liquid crystal display apparatus is coming into practical use as a colored and animation display apparatus. The display quality is improved by the present invention. The improved contrast and enhanced polarizing plate durability ensure faithful animation image display without easy fatigue on the part of the viewer.
In the liquid crystal display apparatus containing at least the polarizing plate incorporating a phase difference film, one polarizing plate containing the polarizing plate protective film of the present invention is arranged on the liquid crystal cell, or two polarizing plates are arranged on both sides of the liquid crystal cell.
In this case, the display quality is improved when means are provided to ensure that the side of the polarizing plate protective film of the present invention contained in the polarizing plate faces the liquid crystal cell of the liquid crystal display apparatus. Then the films 22a and 22b of
In the aforementioned structure, the polarizing plate protective film of the present invention provides optical compensation of the liquid crystal cell. When the polarizing plate of the present invention is used in the liquid crystal display apparatus, at least one of the polarizing plates of the liquid crystal display apparatus should be used as a polarizing plate of the present invention. Use of the polarizing plate of the present invention improves the display quality and provides a liquid crystal display apparatus having excellent angle of field.
In the polarizing plate of the present invention, a polarizing plate protective film of cellulose derivative is used on the surface opposite the polarizing plate protective film of the present invention as viewed from the polarizer. A general-purpose TAC film or the like can be employed.
The polarizing plate protective film located far from the liquid crystal cell can be provided with another functional layer for the purpose of improving the quality of the display apparatus.
For example, in order to avoid reflection, glare, scratch and dust, and to improve brightness, it is possible to bond a film containing as a constituent a known functional layer as a display on the surface of the polarizing plate protective film of the present invention, without being restricted thereto.
Generally, to ensure stable optical characteristics, the phase difference film is required to exhibit small fluctuations in the Ro or Rt as the aforementioned retardation value. Especially, these fluctuations may cause irregularities of an image in the liquid crystal display apparatus in the double refraction mode.
In the present invention, the polarizing plate protective film containing a cellulose ester film as a display apparatus film is wound in the form of a longer roll, and is unwound from the roll. This is to be interpreted as follows: The cellulose ester film produced by the solution casting method or melt casting is wound on the outer peripheral surface of the winding core to a length of 10 m or more, using the winding core (cylindrical core) as a shaft, whereby the film is wound into a roll. After that, the film is unwound from the roll and is used for processing of the polarizing plate. This is how the polarizing plate protective film containing this cellulose ester film is handled.
When the cellulose ester film is wound on a longer roll and is unwound from the roll, remarkable advantages of the present invention are exhibited.
The polarizing plate protective film manufactured in the present invention is mainly made of a cellulose resin. This arrangement makes it possible to use the process of alkaline treatment based on the saponification inherent to the cellulose ester. Similarly to the case of the conventional polarizing plate protective film, this can be bonded with the polarizing plate protective film, using an aqueous solution containing a completely saponified polyvinyl alcohol, when the resin constituting the polarizer is polyvinyl alcohol.
Thus, the embodiment of the present invention is superior in that the conventional method for manufacturing the polarizing plate can be applied. It is especially advantageous in that a longer roll polarizing plate can be obtained.
The production advantage of the present invention is remarkable especially in the case of a longer roll in excess of 100 meters. Greater advantages are observed in the production of a polarizing plate when it is longer, for example, in the order of 1500 m, 2500 m and 5000 m.
For example, in the production of a polarizing plate protective film, roll length is 10 m or more without exceeding 5000 m, preferably 50 m or more without exceeding 4500 m when the productivity and transportability are taken into account. The width of a polarizer in this case can be selected to suit the width of the polarizer or the width suitable for the production line.
It is possible to produce a film having a width of 0.5 m or more without exceeding 4.0 m, preferably 0.6 m or more without exceeding 3.0 m, and to wind the film in the form of a roll, which can be used to process a polarizing plate. It is also possible to manufacture a film having a width twice or more as great as the intended width, and to wind it in the form of a roll, which is cut to get the roll of an intended width. This roll can be used to process the polarizing plate.
When manufacturing the polarizing plate protective film, a functional layer such as antistatic layer, hard coated layer, easy glidability, adhesive layer, antiglare layer and barrier layer can be coated before and/or after drawing. In this case, various forms of surface treatment such as corona discharging, plasma processing, medical fluid treatment can be provided wherever required.
In the film making process, the gripping portions of the clips on both ends of the film having been cut can be recycled as the material of the same type or different type of films, after having been pulverized, or after having been palletized as required.
A cellulose ester film of lamination structure can be produced by co-extrusion of the compositions containing cellulose esters having different concentrations of additives such as the aforementioned plasticizer, ultraviolet absorber and matting agent.
For example, a cellulose ester film made up of a skin layer, core layer and skin layer can be produced. For example, a large quantity of matting agent can be put into the skin layer or the matting agent can be put only into the skin layer. Larger amounts of plasticizer and ultraviolet absorber can be put into the core layer than the skin layer. They can be put only in the core layer.
Further, the types of the plasticizer and ultraviolet absorber can be changed in response to the core layer or skin layer. For example, it is also possible to make such arrangements that the skin layer contains a plasticizer and/or ultraviolet absorber of lower volatility, and the core layer contains a plasticizer of excellent plasticity or an ultraviolet absorber of excellent ultraviolet absorbing performance.
The glass transition temperatures between the skin layer and core layer can be different from each other. The glass transition temperature of the core layer is preferably lower than that of the skin layer. In this case, the glass transition temperatures of both the skin and core are measured, and the average value obtained by calculation from the volume fraction thereof is defined as the aforementioned glass transition temperature Tg so that it is handled in the same manner. Further, the viscosity of the melt including the cellulose ester at the time of melt-casting can be different according to the skin layer or core layer. The viscosity of the skin layer can be greater than that of the core layer. Alternatively, the viscosity of the core layer can be equal to or greater than that of the skin layer.
In the display apparatus film of the present invention, assume that the dimensional stability is based on the standard dimensions of the film which has been left to stand for 24 hours at a temperature of 23° C. with a relative humidity of 55% RH. On this assumption, the dimensional stability of the film for display apparatus of the present invention is such that the fluctuation of the dimension at 80° C. and 90% RH is within ±2.0% (excl.), preferably within ±1.0% (excl.), more preferably within ±0.5% (excl.).
When the display apparatus film of the present embodiment is used as a polarizing plate protective film as a phase difference film, if the phase difference film itself has a fluctuation in excess of the aforementioned range, the absolute value of the retardation as a polarizing plate and the orientation angle will deviate from the initial setting. This may cause reduction in the capacity of improving the display quality, or may result in deterioration of the display quality.
The display apparatus film of the present invention, particularly the cellulose ester film, is used as a polarizing plate protective film, there is no restriction to the method of producing the polarizing plate. The polarizing plate can be manufactured by a commonly used method. The cellulose ester film having been obtained is subjected to alkaline treatment. In one method, using an aqueous solution of completely saponified polyvinyl alcohol, the polarizing plate protective film is bonded on both surfaces of the polarizer manufactured by immersion of the polyvinyl alcohol film in an iodonium solution. When this method is used, the polarizing plate protective film of the present invention is directly bonded to at least one of the surfaces of the polarizer.
Instead of the aforementioned alkaline treatment, the film can be provided with simplified adhesion as disclosed in the Japanese Non-Examined Patent Publication (Tokkaihei) 6-94915 and Japanese Non-Examined Patent Publication (Tokkaihei) 6-118232.
The polarizing plate is made of a polarizer and a protective film for covering both surfaces thereof.
Further, a protective film can be bonded onto one of the surfaces of the aforementioned polarizing plate and a separate film can be bonded on the opposite surface. The protective film and separate film are used to protect the polarizing plate at the time of product inspection before shipment of the polarizing plate.
In this case, the protective film is bonded to protect the surface of the polarizing plate, and is used on the surface opposite to the surface wherein the polarizing plate is bonded to the liquid crystal substrate. Further, the separate film is used to cover the adhesive layer to be bonded to the liquid crystal substrate, and is used on the surface wherein the polarizing plate is bonded to the liquid crystal cell.
The polarizer as the major component of the polarizing plate is an element that allows the passage of only the light on the plane of polarization in a predetermined direction. The typical polarizer currently known is a polyvinyl alcohol based polarized film This is available in two types—a polyvinyl alcohol based film stained by iodine, and a polyvinyl alcohol based film stained by dichromatic dye.
The polarizer is produced as follows: A film is formed from an aqueous solution containing polyvinyl alcohol. This is either stained after having been drawn uniaxially, or drawn uniaxially after having been stained. Preferably, this is treated by a boric acid compound to improve durability. One surface of the polarizing plate protective film of the present invention is bonded on the surface of this polarizer, whereby a polarizing plate is produced.
An aqueous adhesive mainly made up of completely saponified polyvinyl alcohol or the like is preferably used for this bondage. The polarizer film preferably used has a thickness of 10 through 30 μm.
In the following, the present invention will be specifically explained referring to examples, however, is not limited thereto.
Cellulose ester C-1-C-11, plasticizers and additives, which will be utilized in examples 1-4, were synthesized according to following synthesis examples 1-28.
Synthesis was performed referring to example B of Japanese Translation of PCT International Application Publication No. 6-501040.
Following mixed solutions A-E were prepared.
A: Propionic acid:pure water=5:3 (weight ratio)
B: Acetic acid:pure water=3:1 (weight ratio)
C: Acetic acid:pure water=1:1 (weight ratio)
D: Acetic acid:pure water:magnesium carbonate=12:11:1 (weight ratio)
E: An aqueous solution in which 0.5 mol of potassium carbonate and 1.0 mol of citric acid were dissolved in 14.6 kg of pure water
In a reaction vessel equipped with a mechanical stirrer, charged were 100 weight parts of cellulose purified from cotton, 317 weight parts of acetic acid and 67 weight parts of propionic acid, the resulting solution was stirred for 30 minutes at 55° C. After the temperature of the reaction vessel was cooled to 30° C., the solution was added with 2.3 weight parts of solution A and stirred for 30 minutes.
After the reaction vessel was cooled to −20° C., the reaction mixture was added with 100 weight parts of acetic acid anhydride and 250 weight parts of propionic acid anhydride and stirred for 1 hour. After the temperature of the reaction vessel was raised to 10° C., the resulting mixture was added with 4.5 weight parts of solution A and heated to 60° C. to be stirred for 3 hours.
Further, the resulting system was added with 533 weight parts of solution B and stirred for 17 hours. Further, the resulting system was added with 333 weight parts of solution C and 730 weight parts of solution D and stirred for 15 minutes.
After the impurities were filtered, the solution was added with water while stirring until generation of precipitate was completed, and then the generated white precipitate was filtered. The prepared white solid was washed with pure water until the washed solution became neutral. This wet product was added with 1.8 weight parts of solution E followed by being dried under vacuum at 70° C. for 3 hours, whereby cellulose ester (cellulose acetatepropionate) C-1 was prepared.
The substitution degree of the prepared cellulose ester was calculated based on ASTM-D817-96; the substitution degree by an acetyl group was 2.08 and a substitution degree by a propionyl group was 0.72. Further, GCP measurement under the following conditions was performed to determine the weight average molecular weight to be 200,000.
The total carbon number of an acyl group of cellulose ester was 6.32.
Solvent: Tetrahydrofuran
Equipment: HLC-8220 (manufactured by Toso Co., Ltd.)
Column: TSK gel Super HM-M (manufactured by Toso Co., Ltd.)
Column temperature: 40° C.
Sample concentration: 0.1 weight %
Injection amount: 10 μl
Flow rate: 0.6 ml/min
Correction curve: Standard polystyrene: PS-1 (manufactured by Polymer Laboratories Co., Ltd.), A correction curve based on 9 samples having Mw=2,560,000-580 was employed.
Cellulose ester of 30 g purified from cotton was added with 87 g of acetic acid and 20 g of propionic acid and the resulting mixture was stirred for 30 minutes at 54° C. The mixture, after having been cooled, was subjected to esterification by adding 51 g of acetic acid unhydride, 50 g of propionic acid unhydride and 1.2 g of sulfuric acid in an ice bath. In esterification, stirring was continued for 150 minutes while the temperature was adjusted not to exceed 40° C. After finishing the reaction, the excess unhydrides were hydrolyzed by titration of a mixed solution of 30 g of acetic acid and 10 g of water over 20 minutes. The reaction solution was added with 90 g of acetic acid and 30 g of water followed by being stirred for 1 hour while keeping the temperature at 40° C. The mixture was poured into an aqueous solution containing 2 g of magnesium acetate, and was filtered and dried after having been stirred for a while, whereby cellulose ester C-2 was prepared. The acetyl substitution degree of prepared cellulose ester was 2.45, the propionyl substitution degree was 0.43 and the weight average molecular weight was 211,000. Herein, the total carbon number of an acyl group of cellulose ester is shown in table 1.
Utilizing acetic acid, propionic acid, propionic acid anhydride, butylic acid and butylic acid unhydride, which are described in table 1, cellulose ester C-3-C-8 were prepared by operations similar to synthesis example 2.
Herein, the measurement of a weight average molecular weight is performed by the method described in synthesis example 1: cellulose ester C-1.
Following cellulose ester C-9-C-11 were prepared utilizing corresponding fatty acid and fatty acid unhydride similar to example 1.
C-9: Cellulose acetate propionate (Acetyl group substitution degree: 1.4, Propionyl group substitution degree: 1.3, Molecular weight Mw=220,000, Mw/Mn=2.5, Total carbon number of an acyl group: 6.7)
C-10: Cellulose acetate propionate (Acetyl group substitution degree: 1.3, Propionyl group substitution degree: 1.2, Molecular weight Mw=200,000, Mw/Mn=3.0, Total carbon number of an acyl group: 6.2)
C-11: Cellulose acetate propionate (Acetyl group substitution degree: 1.7, Propionyl group substitution degree: 1.0, Molecular weight Mw=200,000, Mw/Mn=2.9, Total carbon number of an acyl group: 6.4)
A mixed solution of 45 weight parts of trimethylolpropane and 101 weight parts of triethylamine kept at 100° C. was titrated with 71 weight parts of benzoyl chloride over 30 minutes while stirring, and the resulting solution was further stirred for 30 minutes.
The resulting mixture was cooled to room temperature after finishing the reaction and the precipitate was filtered. Then, the filtrate was washed by addition of ethyl acetate pure water; the organic phase was separated and ethyl acetate was removed by evaporation under reduced pressure; whereby 126 weight parts (yield of 85%) of white crystals were obtained. Herein, the molecular weight of this compound was 446.
Monomethylphthalate of 180 weight parts, 180 weight parts of toluene, 1 weight part of dimethylformamide and 130 weight parts of thionyl chloride were mixed and stirred for 30 minutes at 60° C. The resulting solution was cooled after finishing the reaction to prepare light yellow liquid.
A solution comprising glycerin of 31 weight parts, 101 weight parts of triethylamine and 200 weight parts of ethyl acetate was titrated with light yellow liquid obtained in the above reaction at room temperature over 30 minutes, and stirring was continued for 1 hour.
After the produced white precipitate, which had been filtered, was washed by addition of water, the organic phase was separated and the organic solvents were eliminated by evaporation under reduced pressure, whereby 116 weight parts (yield of 60%) of white crystals were prepared. Herein the molecular weight of this compound was 579.
A mixed solution, comprising 54 weight parts of trimethylol propane, 127 weight parts of pyridine and 500 weight parts of ethyl acetate, kept at 10° fC. was titrated with 240 weight parts of o-methoxybenzoyl chloride over 30 minutes while stirring, followed by being heated to 80° C. and stirred for 3 hours.
After finishing the reaction, the resulting mixture was cooled to room temperature and the precipitate was filtered. After the filtrate was washed by addition of 1 mol/L HCl aqueous solution, followed by being further washed by addition of 1% Na2CO3 aqueous solution, the organic phase was separated and the organic solvents were eliminated by evaporation under reduced pressure, whereby 193 weight parts (yield of 90%) of transparent liquid were prepared. Herein the molecular weight of this compound was 537.
A mixed solution, comprising 27 weight parts of trimethylol propane, 111 weight parts of pyridine and 300 weight parts of ethyl acetate, kept at 10° C. was titrated with a solution, in which 180 weight parts of acetylsalicyloyl chloride were dissolved in 200 weight parts of acetic acid, over 30 minutes while stirring, followed by being heated to 80° C. and stirred for 5 hours.
After finishing the reaction, the resulting mixture was cooled to room temperature and the precipitate was filtered. After the filtrate was washed by addition of 1 mol/L HCl aqueous solution, followed by being further washed by addition of 1% Na2CO3 aqueous solution, the organic phase was separated and the organic solvents were eliminated by evaporation under reduced pressure, whereby 99 weight parts (yield of 80%) of transparent liquid were prepared. Herein the molecular weight of this compound was 621.
A mixed solution, comprising 36 weight parts of trimethylol propane, 107 weight parts of pyridine and 300 weight parts of ethyl acetate, kept at 10° C. was titrated with a solution, in which 250 weight parts of 3,4,5-trimethoxybenzoyl chloride were dissolved in 300 weight parts of ethyl acetate, over 30 minutes while stirring, followed by being heated to 80° C. and stirred for 5 hours.
After finishing the reaction, the resulting mixture was cooled to room temperature and the precipitate was filtered. After the filtrate was washed by addition of 1 mol/L HCl aqueous solution, followed by being further washed by addition of 1% Na2CO3 aqueous solution, the organic phase was separated and the organic solvents were eliminated by evaporation under reduced pressure, whereby 153 weight parts (yield of 80%) of white crystals were prepared. Herein the molecular weight of this compound was 717.
A mixed solution, comprising 37 weight parts of glycerin, 111 weight parts of pyridine and 500 weight parts of ethyl acetate, kept at 10° C. was titrated with a solution, in which 277 weight parts of 3,4,5-trimethoxybenzoyl chloride were dissolved in 500 weight parts of toluene, over 30 minutes while stirring, followed by being heated to 110° C. and stirred for 5 hours.
After finishing the reaction, the resulting mixture was cooled to room temperature and the precipitate was filtered. After the filtrate was washed by addition of 1 mol/L HCl aqueous solution, followed by being further washed by addition of 1% Na2CO3 aqueous solution, the organic phase was separated and toluene was eliminated by evaporation under reduced pressure and purified, whereby 224 weight parts (yield of 83%) of white crystals were prepared. Herein the molecular weight of this compound was 675.
A mixed solution, comprising 60 weight parts of 2-hydroxymethyl-2-methyl-propane-1,3-diol, 140 weight parts of pyridine and 500 weight parts of ethyl acetate, kept at 10° C. was titrated with 210 weight parts of benzoyl chloride over 30 minutes while stirring, followed by being heated to 100° C. and stirred for 5 hours.
After finishing the reaction, the resulting mixture was cooled to room temperature and the precipitate was filtered. After the filtrate was washed by addition of 1 mol/L HCl aqueous solution, followed by being further washed by addition of 1% Na2CO3 aqueous solution, the organic phase was separated and ethyl acetate was eliminated by evaporation under reduced pressure, whereby 193 weight parts (yield of 90%) of a white solid were prepared. Herein the molecular weight of this compound was 433.
A mixed solution, comprising 37 weight parts of glycerin, 120 weight parts of pyridine and 450 weight parts of ethyl acetate, kept at 10° C. was titrated with 210 weight parts of p-methoxybenzoyl chloride over 30 minutes while stirring, followed by being heated to 80° C. and stirred for 3 hours.
After finishing the reaction, the resulting mixture was cooled to room temperature and the precipitate was filtered. After filtrate was washed by addition of 1 mol/L HCl aqueous solution, followed by being further washed by addition of 1% Na2CO3 aqueous solution, the organic phase was separated and ethyl acetate was eliminated by evaporation under reduced pressure to obtain the aimed product. Herein the molecular weight of this compound was 494.
Pentaerythritol teterapivaiate, which is utilized in an example of patent literature 5 as PL2, was synthesized.
A solution comprising 34 weight parts of pentaerythritol, 101 weight parts of triethylamine and 2,000 weight parts of ethyl acetate, was titrated with 121 weight parts of pivaloyl chloride over 30 minutes at an ambient temperature, and stirring was further continued for 1 hour.
The produced white precipitate, after having been filtered, was washed by addition of pure water, and the organic phase was separated, followed by elimination of an organic solvent by evaporation under reduced pressure, whereby 89 weight parts (yield of 75%) of white crystals were obtained. Herein, the molecular weight of this compound was 473.
5,7-di-tert-Bu-3-(2,5-dimethylphenyl)-3H-benzofuran-2-one (compound 101) was synthesized starting from 5,7-di-tert-Bu-3-hydroxy-3H-benzofuran-2-one, p-xylene and Fulcat 22B as a catalyst.
2,4-di-tert-Bu-phenol (97%) of 212.5 g (1.00 mol), 163.0 g (1.10 mol) of 50% water based glyoxylic acid and 0.5 g (2.6 mmol) of p-toluene sulfonic acid monohydrate in 300 ml of 1,2-dichloroethane were refluxed on a water separator in a nitrogen gas flow for 3.5 hours.
Thereafter, the reaction mixture was concentrated by use of a reduced pressure rotary evaporator. The residue was dissolved in 800 ml of hexane and washed by water three times. In a separating funnel, the water phase was separated and further extracted by 300 ml of hexane. The organic phase was collected to be dried with magnesium sulfate and concentrated by a reduced pressure evaporator. Analytically purified 5,7-di-tert-Bu-3-hydroxy-3H-benzofuran-2-one of 262.3 g (approximately 100%), which had a deep yellow resin form, were prepared from the residue.
A solution of 5,7-di-tert-Bu-3-(2,5-dimethylphenyl)-3-hydroxy-3H-benzofuran-2-one of 262.3 g (1.00 mol) in 500 ml of p-xylene (4.05 mol) was added with 40 g of Fulcat 22B, and the mixture was refluxed for 1.5 hours on a water separator. Next Fulcat 22B catalyst was removed by filtration and excess p-xylene was removed by use of a reduced pressure evaporator.
5,7-di-tert-Bu-3-(2,5-dimethylphenyl)-3H-benzofuran-2-one (Compound 101) having a melting point of 93-97° C., of 280.6 g (yield of 80%) was obtained by crystallization of the residue with 400 ml of methanol.
An approximately 5.7:1 mixture of 3-(3,4-dimethylphenyl)-5,7-di-tert-Bu-3H-benzofuran-2-one (compound 103) and 3-(2,3-dimethylphenyl)-5,7-di-tert-Bu-31′-benzofuran-2-one isomer (compound 134) were synthesized stating from 2,4-di-tert-Bu-phenol, glyoxylic acid, o-xylene, and Fulcat or Fulmont as a catalyst.
2,4-di-tert-Bu-phenol of 206.3 g (1.0 mol), 485 g (5.5 mol) of o-xylene, 0.5 g (2.6 mmol) of p-toluene sulfonic acid monohydrate and 163 g (1.1 mol) of 50% water-based glyoxylic acid were charged in a 1500 ml double layer reactor equipped with a water separator.
The mixture was heated to 85-90° C. with stirring and the equipment was simultaneously evacuated at approximately 450 mbar. Immediately when the temperature in the reactor reached 85-90° C., o-xylene began to be evaporated and refluxed while water was eliminated from the system.
The pressure was continuously raised to keep the temperature of the reactor at 85-90° C., and all the water of approximately 90-100 ml was evaporated over 3-4 hours. Reduced pressure was released by nitrogen, and 40 g of a catalyst (Fulcat 30 or 40, or Fulmont XMP-3 or XMP-4) were added to the transparent yellow solution.
The equipment was evacuated at 700 mbar and the suspension was stirred at a heating bath temperature of 165° C. Reaction water began to be removed by evaporation as a co-boiling product at approximately 128° C. The temperature of the equipment was raised to 140° C. at the highest in the ending of the reaction.
The total volume of approximately 20 ml of water was removed by evaporation from the system in 1-2 hours. Next, reduced pressure was released by nitrogen. The reaction mixture was cooled to 90-100° C. and filtered. The equipment and filter residue were rinsed with 100 g of o-xylene. The filtrate was transferred into a double layer reaction vessel to be concentrated under reduced pressure, and recovered with 360 g of o-xylene.
The slightly reddish yellow residue was cooled to 70° C., and was carefully added with 636 g of methanol from a titrating funnel while keeping the temperature at 60-65° C. Crystal seeds were added into the solution to perform crystallization by stirring for approximately 30 minutes at 60-65° C. Next the crystallized slurry was cooled to −5° C. over 2 hours, and stirring was continued for further 1 hour at this temperature.
The crystals were collected by suction filtration, and the residue was washed in 5 times by use of 400 ml of cold methanol (−5° C.). The sufficiently drying pressed product was dried in a vacuum drier of 50-60° C. to prepare 266 g of a white solid.
The gas chromatographic analysis showed this substance was comprised of approximately 85% of 3-(3,4-dimethylphenyl)-5,7-di-tert-Bu-3H-benzofuran-2-one (compound 103) and approximately 15% of 3-(2,3-dimethylphenyl)-5,7-di-tert-Bu-3H-benzofuran-2-one isomer (compound 134).
5,7-di-tert-Bu-3-(4-ethylphenyl)-3H-benzofuran-2-one (compound 105) was synthesized starting from 5,7-di-tert-Bu-3-hydroxy-3H-benzofuran-2-one, ethylbenzene and Fulcat 22B as a catalyst.
5,7-di-tert-Bu-3-hydroxy-3H-benzofuran-2-one of 262.3 g (1.00 mol) in 500 ml (4.08 mol) of ethylbenzene was added with 40 g of Fulcat 22B, and the mixture was refluxed for 1.5 hours on a water separator. Next Fulcat 22B catalyst was removed by filtration and excess ethylbenzene was removed by a reduced pressure evaporator.
GC-MS analysis showed the residue was comprised of 59.2% of para-isomer (compound 105), 10.8% of meta-isomer (compound 105A) and 21.1% of ortho-isomer (compound 105B).
5,7-di-tert-Bu-3-(4-ethylphenyl)-3H-benzofuran-2-one (compound 105) (para-isomer) of 163.8 g (47%) was obtained by crystallization of the residue from 400 ml of methanol, which further contained 5.7% of meta-isomer 5,7-di-tert-Bu-3-(3-ethylphenyl)-3,4-benzofuran-2-one (compound 105A) and 1.3% of ortho-isomer 5,7-di-tert-Bu-3-(2-ethylphenyl)-31′-benzofuran-2-one (compound 105B). By further crystallization from methanol, almost pure para-isomer (compound 105) having a melting point of 127-132° C. was prepared.
5,7-di-tert-Bu-3-(2,3,4,5,6-pentamethylphenyl)-3H-benzofuran-2-one (compound 111) was synthesized starting from 5,7-di-tert-Bu-3-hydroxy-3H-benzofuran-2-one, pentamethylbenzene and tin tetrachloride as a catalyst.
Pentamethylbenzene of 11.5 g (77.5 mmol) and 10 ml (85.0 mmol) of tin tetrachloride were added in a solution of 19.7 g (75.0 mmol) of 5,7-di-tert-Bu-3-hydroxy-3H-benzofuran-2-one is 50 ml of 1,2-dichloromethane, and the reaction mixture was refluxed for 1 hour.
The reaction mixture was diluted with water and extracted 3 times with toluene. The organic phase was collected, washed with water, dried with sodium sulfate and concentrated by a reduced pressure evaporator. By crystallization of the residue from ethanol, 26.3 g (yield of 89%) of 5,7-di-tert-Bu-3-(2,3,4,5,6-pentamethylphenyl)-3H-benzofuran-2-one (compound 111) having a melting point of 185-190° C. were prepared.
Mandelic acid of 15.2 g and 20.6 g of 2,4-di-t-butylphenol were mixed at room temperature, followed by being heated and refluxed at 160° C. under ordinary pressure for 30 minutes. Thereafter, the pressure was reduced by a vacuum pump and the reaction mixture was heated for 5 hours under reduced pressure, then the temperature was raised and the reaction was finished by heating at 180° C. for 4 hours.
The resulting mixture, after having been cooled, was added with ethanol and stirred to be dissolved. Thereafter, crystals were precipitated by stirring at room temperature, which was cooled one night in a refrigerator. The crystals were filtered, washed and dried to prepare 21.6 g of compound 108.
5,7-di-tert-Bu-3-(4-methylphenyl)-3H-benzofuran-2-one (compound 104) was synthesized starting from 5,7-di-tert-Bu-3-hydroxy-3H-benzofuran-2-one, glyoxylic acid, toluene and Fulcat 22B as a catalyst.
A mixture of 2,4-di-tert-Bu-phenol (97%) of 21.2 g (0.10 mol), 16.3 g (0.11 mol) of 50% water-based glyoxylic acid, 2.0 g of Fulcat 22B and 50 ml of toluene was refluxed under a nitrogen gas flow for 8 hours over a water separator.
Next, Fulcat 22B catalyst was eliminated by filtration and excess toluene was removed by use of a reduced pressure evaporator. 5,7-di-tert-Bu-3-(4-methylphenyl)-3H-benzofuran-2-one (compound 104) having a melting point of 130-133° C. of 14.2 g (yield of 42%) was prepared by crystallization of the residue from 40 ml of ethanol.
In a reaction vessel equipped with a condenser, 648 weight parts of ethylene glycol, 58 weight parts of diethylene glycol, 1121 weight parts of succinic acid, 83 weight parts of terephthalic acid and 0.03 weight parts of tetrabutyl titanate were charged, a dehydration condensation reaction was performed for 2 hours at 140° C., for 2 hours at 220° C., and for further 20 hours at 220° C. without the condenser, whereby aliphatic-aromatic copolyester compound A1 having a number average molecular weight of 1,500 was prepared. The average carbon numbers of diol and dicarboxylic acid, which were utilized in this reaction, were 2.1 and 4, respectively.
In a reaction vessel equipped with a condenser, 699 weight parts of ethylene glycol, 1180 weight parts of succinic acid and 0.03 weight parts of tetrabutyl titanate were charged, a dehydration condensation reaction was performed for 2 hours at 140° C., for 2 hours at 220° C., and for further 20 hours at 220° C. without the condenser, whereby aliphatic-aromatic copolyester compound A2 having a number average molecular weight of 2,000 was prepared. The average carbon numbers of diol and dicarboxylic acid, which were utilized in this reaction, were 2 and 4, respectively.
Utilizing the various compounds prepared in the above synthesis examples and various compounds available on the market as a plasticizer, cellulose ester film 1-1 was prepared by means of melt casting method.
Cellulose ester, after having been dried at 70° C. under reduced pressure for 3 hours and cooled to room temperature, was mixed with additives.
The above mixture was melting mixed to be pelleted at 250° C. by use of a biaxial extruder. Herein, the glass transition temperature Tg of this pellet was 141° C.
This pellet was melt at 250° C. and extruded from casting die 4 onto first cooling roll 5 under a nitrogen atmosphere, and film was molded by sandwiching pressed between first cooling roll 5 and touch roll 6. Further, from a hopper opening at the middle portion of extruder 1, silica particles 200V (manufactured by Nippon Aerosil Co.) as a sliding agent was added so as to make 0.5 weight parts.
A heat volt was adjusted so as to make the gap width of casting die 4 of 0.5 mm within 30 mm from the film edge portions in the width direction, and of 1 mm at the other portion. As a touch roll, touch roll A was utilized, and in the interior thereof, water of 80° C. was flown as cooling water.
The length L along the circumference surface of first cooling roll from position P1, where resin being extruded from casting die 4 contacts first cooling roll 5, to position P2, that is the upstream edge by 5 revolutions of first cooling roll 5 from the nip of first cooling roll 5 and touch roll 6, was set to 20 mm.
Thereafter, touch roll 6 is separated from first cooling roll 5, and measured was temperature T at the melting portion immediately before resin was sandwiching pressed between first cooling roll 5 and touch roll 6. Temperature T at the melting portion immediately before resin was sandwiching pressed between first cooling roll 5 and touch roll 6 was measured by a thermometer (HA-200E, produced by Anritsu Instruments Co., Ltd.) at the position of further upstream side by 1 mm from nip upstream edge P2.
As a result of measurement in this example, temperature T was 146° C. The line pressure of touch roll 6 against first cooling roll was set to 14.7 N/cm.
Further, the film was introduced into a tenter and cooled to 30° C. while being relaxed by 3% in the width direction after having been stretched at 160° C. by 1.3 times in the width direction. Then the film was released from clips to cut off the clipped portion, being subjected to a knurling treatment of 10 mm wide and 5 μm high at the both film edges, and was wound up on a core at a winding tension of 220 N/m and a taper of 40%.
The extrusion amount and pulling rate were adjusted to make the film thickness of 80 μm, and the finished film was slit to make a width of 1430 mm to be wound. The winding core had an inside diameter of 152 mm, an outside diameter of 165 mm and a length of 1550 mm.
As a mother material of this core, utilized was prepreg resin in which epoxy resin was sintered on glass fiber and carbon fiber. Epoxy conductive resin was coated on the surface of a core, and the surface was polished to make finish surface roughness Ra of 0.3 μm. Herein the roll length was 2,500 m. This film master roll sample of the present invention was designated as No. 1-1.
Further, in a method similar to film master roll sample No. 1 except that the additives and addition amount were changed as described in table 2, cellulose ester film master roll samples 1-2-1-16 of the present invention and comparative cellulose ester film master roll samples 1-17-1-21 were prepared.
Herein, addition of liquid additives at ordinary temperature was performed by a feeder immediately before the film composition entered into a biaxial extruder.
With respect to the prepared cellulose ester film master roll samples, evaluations were performed according to the following methods. The evaluation results will be shown in table 2.
(Horseback Defect, Core Set)
Wound cellulose ester film master roll samples were doubly wrapped with a polyethylene sheet and stored for 30 days under a condition of 25° C., 50% by a storing method shown in
A: The fluorescent tube is observed to be straight.
B: The fluorescent tube is observed to be partly curved.
C: The fluorescent tube is observed to be reflected spotting.
Further, film master roll samples after having been stored were rewound, and till how many meters from the tail end generated was spot form deformation not smaller than 50 μm, or core set in which clearly observable band form deformation along the width direction, was measured, whereby core set was ranked according to the following criteria.
A: Less than 15 m from the tail end
B: Not less than 15 m to less than 30 m from the tail end
C: Not less than 30 in to less than 50 m from the tail end
D: Not less than 50 m from the tail end
(Wrinkle at Start of Winding)
An operation to wind up master roll film on a core was performed, and the master roll film was detached from the core to restart the winding operation in the case that wrinkles were generated at the start of winding to cause a poor product. The times of this occasion were counted. This operation was repeated ten times to determine the average value. The ranking was performed based on the following criteria.
A: Not less than 0 and less than 1 time
B: Not less than 1 and less than 3 times
C: Not less than 3 and less than 5 times
D: Not less than 5 times
In
It is clear from the table, cellulose ester film master roll sample Nos. 1-1-1-16, which contain a compound represented by Formula (I), have few horseback defects and core sets and hardly cause deformation defects of a film master roll such as wrinkles at the start of winding.
In a method similar to cellulose ester master roll sample 1-1 of example 1 except that the additives and addition amounts were changed as described in tables 3-6, cellulose ester master roll samples 2-1-2-57 of the present invention and comparative cellulose ester master roll samples 2-58-2-61 were prepared.
The prepared cellulose film master roll samples were subjected to the evaluations similar to example 1. The evaluation results will be shown in tables 7 and 8.
It is clear from the table, cellulose ester film master roll sample Nos. 2-1-2-57, which incorporate such as a plasticizer and an antioxidant and contain a compound represented by Formula (I) according to the present invention, have few horseback defects and core sets and hardly cause deformation defects of a film master roll such as wrinkles at the start of winding.
In a method similar to cellulose ester film master roll sample No. 1-1 of example 1 except that the additives and addition amounts were changed as described in tables 9 and 10, cellulose ester film master roll samples 3-1-3-27 of the present invention and comparative cellulose ester film master roll samples 3-28 and 3-29 were prepared.
The prepared cellulose master roll samples were subjected to the evaluations similar to example 1. The evaluation results will be shown in table 11.
It is clear from the table, cellulose ester film master roll sample Nos. 3-1-3-27, which incorporate such as a plasticizer and an antioxidant and contain a compound represented by Formula (I) according to the present invention, have few horseback defects and core sets and hardly cause deformation defects of a film master roll such as wrinkles at the start of winding.
In a method similar to preparation of sample 2-9 of example 2, except that cellulose ester and a compound represented by Formula (I) were changed as described in table 12, cellulose ester film master roll samples 4-1-4-19 of the present invention were prepared.
The prepared cellulose master roll samples were subjected to the evaluations similar to example 1. The evaluation results will be shown in table 12.
It is clear from the table, even with respect to cellulose ester film in which an acyl group substitution degree was changed, cellulose ester film master roll samples 4-1-19, which contain a compound represented by Formula (I) according to the present invention, have few horseback defects and core sets and hardly cause deformation defects of a master roll film such as wrinkles at the start of winding. Further, among film according to the present invention, those containing at least Irganox 1010 as an additive exhibited a transmittance of not less than 90% for a bundle of rays at wavelength of 450 nm.
The following composition was prepared.
m:n = 93:7
In the following manner, polarizing plate protective film provided with functions was prepared.
(Polarizing Plate Protective Film)
Cellulose ester film master roll sample 1-1 prepared in an example was doubly wrapped with a polyethylene sheet and stored for 30 days under a condition of 25° C. and 50%, then for 10 days under a condition of 40° C. and 80%, by a storing method shown in
Thereafter, each polyethylene sheet was removed and, on the one surface of cellulose ester film unwound from each master roll sample, anti-curl layer coating composition (3) was coated by means of gravure coating so as to make a wet layer thickness of 13 μm followed by being dried at 80±5° C. This sample was designated as sample 1-1A.
On the other side of this cellulose ester film, anti-static layer coating composition (1) was coated under an environment of 28° C. and 82% RH so as to make a wet layer thickness of 7 μm at a film transport speed of 30 m/min and a coating width of 1 m, followed by being dried in a drying zone set at 80±5° C. to provide a resin layer having a dry layer thickness of 0.2 μm, whereby cellulose ester film provided with an anti-static layer was prepared. This was designated as sample 1-1B.
Further, on this anti-static layer, hard coat layer coating composition (2) was coated so as to make a wet layer thickness of 13 μm and dried at a drying temperature of 90° C., followed by being irradiated by ultraviolet rays to make irradiation of 150 mJ/m2, whereby a clear hard coat layer having a dry layer thickness of 5 vim was provided. This was designated as sample 1-1C.
Any of prepared cellulose ester film samples 1-1A, 1-1B and 1-1C had no brushing defect and no generation of cracks after drying resulting in good coating behavior.
Coating in a similar manner was performed utilizing cellulose ester film master roll samples 1-8, 2-2, 2-7, 2-9, 2-10, 2-27, 2-54, 2-56, 2-57, 3-1, 3-9, 3-10 and 4-1-4-19 instead of cellulose ester film master roll sample 1-1. As a result, it has been proved that any of the samples shows good coating behavior.
As a comparison, also with respect to cellulose ester film master roll samples 2-58, 2-59 and 2-60, coating was carried out in a similar manner as described above.
Those coated with anti-curl layer coating composition (3) were designated as samples 2-58A, 2-59A and 2-60A; those further coated with antistatic layer coating composition (1) were designated as samples 2-58B, 2-59B and 2-60B; and those further coated with hard coat layer coating composition (2) on this antistatic layer were designated as samples 2-58C, 2-59C and 2-60C.
As a result, when coating was performed in a high humidity environment, samples 2-58A, 2-59A and 2-60A caused brushing. Further, with samples 2-58B, 2-59B and 2-60B micro cracks were sometimes recognized after drying, and with samples 2-58C, 2-59C and 2-60C micro cracks were clearly recognized after drying.
(Preparation and Evaluation of Polarizing Plate)
Polyvinylalcohol film having a thickness of 120 μm was immersed in an aqueous solution containing 1 weight part of iodine, 2 weight parts of potassium iodide and 4 weight parts of boric acid and stretched at 50° C. by 4 times to prepare a polarizer.
Cellulose ester film master roll samples 1-1, 1-8, 2-2, 2-7, 2-9, 2-10, 2-27, 2-54, 2-56, 2-57, 3-1, 3-9, 3-10 and 4-1-4-19; and comparative cellulose ester master roll samples 2-58, 2-59 and 2-60, which were prepared in examples 1,2,3 and 4, were doubly wrapped with a polyethylene sheet and stored for 30 days under a condition of 25° C. and 50%, then for 10 days under a condition of 40° C. and 80%, by a storing method shown in
Thereafter, each polyethylene sheet was removed and cellulose ester film unwound from each master roll samples was alkaline processed with a 2.5 mol/L sodium hydroxide aqueous solution at 40° C. for 60 seconds, further washed with water and dried, whereby the surface was provided with an alkaline treatment.
On the both surfaces of the above-described polarizer, the alkaline processed surfaces of samples of the present invention 1-1, 1-8, 2-2, 2-7, 2-9, 2-10, 2-27, 2-54, 2-56, 2-57, 3-1, 3-9, 3-10 and 4-1-4-19, and comparative samples 2-58, 2-59 and 2-60 were pasted up by use of a 5% aqueous solution of completely saponificated type polyvinyl alcohol as an adhesive, whereby polarizing plates of the present invention 1-1, 1-8, 2-2, 2-7, 2-9, 2-10, 2-27, 2-54, 2-56, 2-57, 3-1, 3-9, 3-10 and 4-1-4-19, and comparative polarizing plates 2-58, 2-59 and 2-60 were prepared.
(Characteristics Evaluation as Liquid Crystal Display)
A polarizing plate of 15 type TFT color liquid crystal display LA-1529 HM (produced by NEC Corp.) was peeled off and each polarizing plate prepared above was cut to fit the size of the liquid crystal cell. Sandwiching the liquid crystal cell, two sheets of polarizing plates were pasted up so as not to change the polarizing axes from the original directions which are perpendicular to each other, to prepare a 15 type TFT color liquid crystal display, and characteristics of cellulose ester film as a polarizing plate were evaluated.
<Evaluation>
(Contrast Evaluation after Storage Under High Temperature and High Humidity)
Under an environment of 23° C. and 55% RH, measurement was performed after a back-light of this display was lit and kept as for 30 minutes as it is. As for the measurement, EZ-Contrast 160D produced by ELDIM Co., Ltd. was utilized and luminance from the perpendicular direction at a white display and a black display of the display was measured. The ratio was designated as a front surface contrast.
The front contrast in the case of employing each polarizing plate was evaluated, and determined was the ratio of a front contrast under a condition of 23° C. and 55% RH, and a front contrast after having been stored under a condition of 80° C. and 90% RH, of the polarizing plates prepared employing the same cellulose ester film. The nearer to 1 is the value, the smaller is the contrast variation due to storage under a condition of high temperature and high humidity, which is preferable. Contrast variation due to storage under a condition of high temperature and high humidity=(Contrast in the case of employing a polarizing plate, which has been stored under a condition of 80° C. and 90% RH for 7 days)/(Contrast in the case of employing a polarizing plate, which has been stored under a condition of 23° C. and 55% RH for 7 days)
The above results are shown in table 13.
(Evaluation on Scattering of Retardation Ro and Rt)
With respect to cellulose ester film master roll samples of the present invention 1-1, 1-8, 2-2, 2-7, 2-9, 2-10, 2-27, 2-54, 2-56, 2-57, 3-1, 3-9, 3-10 and 4-1-4-19, and comparative cellulose ester film master roll samples 2-58, 2-59 and 2-60, which were prepared in examples 1, 2, 3 and 4, retardation was measured at 1 cm intervals along the width direction, and coefficient of retardation variation (CV) was determined according to the following equation. In the measurement, Automatic Double Refractometer KOBURA 21ADH (produced by Oji Instruments Co., Ltd.) was utilized, and a 3 dimensional double refraction index measurement was performed under an environment of 23° C. and 55% RH at a wavelength of 590 nm at 1 cm intervals along the width direction of a sample, and the measured values were substituted into the following equation to determine Ro and Rt.
Retardation in the plane: Ro=(nx−ny)×d
Retardation in the thickness direction: Rt={(nx+ny)/2−nz}×d
(wherein, nx is a refraction index in the slow axis direction in the film plane, ny is a refraction index in the fast axis direction in the film plane, nz is a refraction index in the film thickness direction, and d is a film thickness (nm).)
A standard deviation by a (n−1) method was determined for each of retardations in the plane and in the thickness direction. The distribution of retardation was represented by an index according to the following equation. In practical measurement the “n” value was set to 130-140.
Coefficient of variation(CV)=standard deviation/mean value of retardation
The above results are shown in table 13.
It is clear that the case of employing a polarizing plate comprised of cellulose ester film 1-1, 1-8, 2-2, 2-7, 2-9, 2-10, 2-27, 2-54, 2-56, 2-57, 3-1, 3-9, 3-10 and 4-1-4-19, which is a film for display of the present invention, exhibits contrast variation after the polarizing plate having been stored under a condition of high temperature and high humidity smaller than the case of utilizing a polarizing plate comprised of comparative cellulose ester film 2-58, 2-59 and 2-60, and is superior in uniformity of retardation.
Other various embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2006097473 | Mar 2006 | JP | national |
| 2006197854 | Jul 2006 | JP | national |
| 2006311262 | Nov 2006 | JP | national |
This application is a Divisional Application of U.S. patent application Ser. No. 11/688,650, filed Mar. 20, 2007, which claimed the priority of Japanese Patent Applications Nos. 2006-097473 filed on Mar. 31, 2006; JP 2006-197854 filed on Jul. 20, 2006, and Japanese Patent Application No. 2006-311262 filed on Nov. 17, 2006, the entire contents of each of these four (4) applications are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11688650 | Mar 2007 | US |
| Child | 12718393 | US |
