TWI857133B - Polarizer composite and optical laminate - Google Patents

Abstract

An object of the present invention is to provide a polarizer composite with a novel polarizer and an optical laminate.

The polarizer composite has a polarizer, a retardation layer, and a reinforcing material. The polarizer has a polarizing region having a thickness of 15 μm or less and a non-polarizing region surrounded by the polarizing region in a plan view. The retardation layer has a retardation region having retardation characteristics and existing in a region corresponding to the polarizing region, and anon-retardation region having no retardation characteristics and existing in a region corresponding to the non- polarizing region. The reinforcing material has a plurality of cells having open end faces, and each open end face is arranged so as to face the surface of the polarizer. The reinforcing material has a cell region in which cells exists and which exists in a region corresponding to the polarizing region, and a non-cell region in which cells do not exist and which exists in a region corresponding to the non-polarizing region. The non-polarizing region, the non- retardation region and the non-cell region contain a cured product of an active energy ray-curable resin.

Description

Polarizer composites and optical laminates

The present invention relates to a polarizer composite and an optical laminate.

Polarizers are widely used as polarized light supply elements or polarized light detection elements in display devices such as liquid crystal display devices or organic electroluminescent (EL) display devices. Display devices equipped with polarizers have also expanded to mobile devices such as laptop computers and mobile phones. Due to the requirements for diversified display purposes, clear display partitions, and decoration, polarizers with different transmittance areas are expected. In particular, in small and medium-sized portable terminals such as smartphones or tablet terminals, in order to create a design without boundaries on the entire surface from a decorative point of view, polarizers are sometimes attached to the entire display surface. In this case, the polarizing film is sometimes overlapped on the camera lens area, the area where the icon or logo is printed under the screen, and therefore, there is a problem of poor camera sensitivity and poor design.

For example, Patent Document 1 describes that a dichroic substance low concentration portion with a relatively low content of dichroic substance is partially provided in the polarizer contained in the polarizing plate, and the camera is configured in a manner corresponding to the dichroic substance low concentration portion, thereby not causing adverse effects on the camera performance.

[Prior Art Literature]

[Patent Literature]

Patent document 1: Japanese Patent Publication No. 2015-215609

In Patent Document 1, a resin film containing a dichroic substance is chemically treated by contacting an alkaline solution to partially decolorize the resin film to form a dichroic substance low concentration portion. The alkaline solution used for decolorization requires time and cost because it is treated as waste liquid. In addition, Patent Document 1 states that when iodine is used as a dichroic substance, the iodine content can be reduced by contacting it with an alkaline solution to form a dichroic substance low concentration portion. However, a specific method for forming a dichroic substance low concentration portion when using a dichroic substance other than iodine is not disclosed.

The purpose of the present invention is to provide a polarizer composite and an optical laminate having a novel polarizer, which replaces the polarizer having a region with a low content of dichroic substances formed by chemical treatment such as decolorization.

The present invention provides the following polarizer composite and optical laminate.

[1] A polarizer composite, comprising a polarizer, a phase difference layer and a reinforcing material, wherein:

The polarizer has a polarizing region with a thickness of less than 15 μm, and a non-polarizing region surrounded by the polarizing region when viewed from above.

The aforementioned phase difference layer has a phase difference region and a non-phase difference region, the phase difference region has a phase difference characteristic and exists in a region corresponding to the aforementioned polarization region, and the non-phase difference region does not have a phase difference characteristic and exists in a region corresponding to the aforementioned non-polarization region;

The aforementioned reinforcing material has a plurality of cells with open end faces, and each open end face is arranged in a manner opposite to the surface of the aforementioned polarizer;

The aforementioned reinforcing material has a cell cavity region and a non-cell cavity region, the cell cavity region has the aforementioned cell cavity and the cell cavity region exists in a region corresponding to the aforementioned polarization region, the non-cell cavity region does not have the aforementioned cell cavity and the non-cell cavity region exists in a region corresponding to the aforementioned non-polarization region,

The aforementioned non-polarizing region, the aforementioned non-phase difference region, and the aforementioned non-cell cavity region contain a hardened material of an active energy ray-hardening resin,

The aforementioned hardened material contained in the aforementioned non-polarizing area is provided in a through hole surrounded by the aforementioned polarizing area when viewed from above.

The aforementioned hardened material contained in the aforementioned non-phase difference region is provided in a through hole surrounded by the aforementioned phase difference region when viewed from above.

[2] The polarizer composite as described in [1], wherein the reinforcing material is disposed on one side of the polarizer, and the phase difference layer is provided on the side of the reinforcing material opposite to the polarizer.

[3] The polarizer composite as described in [1], wherein the phase difference layer is disposed on one side of the polarizer, and the reinforcing material is provided on the side of the phase difference layer opposite to the polarizer.

[4] The polarizer composite as described in [2] or [3] further comprises the aforementioned reinforcing material on the other side of the aforementioned polarizer.

[5] A polarizer composite as described in any one of [1] to [4], wherein the thickness of the cured product is the same as the thickness of the layered structure portion of the polarizer composite including the polarization region, the phase difference region, and the cell region.

[6] A polarizer composite as described in any one of [1] to [4], wherein the thickness of the cured product is smaller than the thickness of the layered structure of the polarizer composite including the polarization region, the phase difference region and the cell region.

[7] A polarizer composite as described in any one of [1] to [4], wherein the thickness of the cured product is greater than the thickness of the layered structure portion of the polarizer composite including the polarization region, the phase difference region, and the cell region.

[8] A polarizer composite as described in any one of [1] to [7], wherein the phase difference region is a polymerized cured layer of a polymerizable liquid crystal compound.

[9] A polarizer composite as described in any one of [1] to [8], wherein the non-polarizing region is light-transmissive.

[10] A polarizer composite as described in any one of [1] to [9], wherein the diameter of the non-polarizing region when viewed from above is greater than 0.5 mm and less than 20 mm.

[11] A polarizer composite as described in any one of [1] to [10], wherein the active energy ray-curable resin contains an epoxy compound.

[12] The polarizer composite as described in [11], wherein the epoxy compound comprises an aliphatic epoxy compound.

[13] A polarizer composite as described in any one of [1] to [12], wherein the shape of the aforementioned opening of the aforementioned cell cavity is polygonal, circular or elliptical.

[14] A polarizer composite as described in any one of [1] to [13], wherein a light-transmitting filling material is provided in the internal space of the aforementioned cell cavity.

[15] An optical laminate having a protective layer on one or both sides of the polarizer composite described in any one of [1] to [14].

[16] The optical laminate as described in [15], wherein the protective layer provided on one side of the polarizer composite is an active energy ray-curable resin, and the active energy ray-curable resin is the same as the active energy ray-curable resin of the aforementioned cured product included in the non-polarizing region, the non-phase difference region, and the non-cell region.

The present invention can provide a polarizer composite and an optical laminate having a novel polarizer.

10: Polarizer

11: Polarization area

11m: First plane

11n: Second plane

12: Non-polarized area

17,18: Protective layer

20: Raw polarizer

21: Polarizer with opening

22: Perforation

25: First support layer

26: Second support layer

27: The fourth support layer

28: The fifth support layer

29: Sixth support layer

31: First layer of body

32: Second layer of body

33: Perforation

34: The third layer

35: The fourth layer of the body

36: Perforation

37: The fifth layer

38: Perforation

39: The sixth layer of the body

40~43: Polarizer composite

45~48: Optical layered body

50: Reinforcement material

51:Cell cavity

52: Perforation

53: Cell wall

55:Cellular region

56: Non-luminal region

58: Structures and structures for forming reinforcing materials

59: Structure with openings

70,71: Phase difference layer

72: Perforation

75: Phase difference area

76: Non-phase difference area

80: Polymerization hardening layer attached to the base material layer

81: Phase difference layer with opening

84: Base material layer

85: Polymerization hardening layer

91: Perforation

92: Seventh support layer

FIG. 1(a) is a schematic cross-sectional view schematically showing an example of the polarizer composite of the present invention, FIG. 1(b) is a schematic top view of the reinforcing material side of the polarizer composite shown in FIG. 1(a), and FIG. 1(c) is a schematic top view of the phase difference layer side of the polarizer composite shown in FIG. 1(a).

Figures 2(a) to 2(d) are schematic cross-sectional views showing another example of the polarizer composite of the present invention.

Figures 3(a) and 3(b) schematically show an example of a cross section of the non-polarizing region, non-cell region, and non-phase difference region of a polarizer composite, and are explanatory diagrams for explaining a method for determining the thickness of a hardened material disposed in the non-polarizing region, non-cell region, and non-phase difference region.

FIG4 is a schematic cross-sectional view showing another example of the polarizer composite of the present invention.

FIG5 is a schematic cross-sectional view showing another example of the polarizer composite of the present invention.

FIG6 is a schematic cross-sectional view showing another example of the polarizer composite of the present invention.

Figures 7(a) to 7(d) are schematic cross-sectional views showing an example of a method for manufacturing the polarizer composite of the present invention.

Figures 8(a) to 8(d) are schematic cross-sectional views showing the subsequent steps of the manufacturing method of the polarizer composite shown in Figure 7.

Figures 9(a) to 9(c) are schematic cross-sectional views showing another example of the method for manufacturing the polarizer composite of the present invention.

Figures 10(a) to 10(c) are schematic cross-sectional views showing the subsequent steps of the manufacturing method of the polarizer composite shown in Figure 9.

Figures 11(a) to 11(e) are schematic cross-sectional views showing yet another example of the method for manufacturing the polarizer composite of the present invention.

Figures 12(a) to 12(d) are schematic cross-sectional views showing the subsequent steps of the manufacturing method of the polarizer composite shown in Figure 11.

Figures 13(a) to 13(d) are schematic cross-sectional views showing yet another example of the method for manufacturing the polarizer composite of the present invention.

Figures 14(a) to 14(c) are schematic cross-sectional views showing the subsequent steps of the manufacturing method of the polarizer composite shown in Figure 13.

FIG15 is a schematic cross-sectional view showing an example of the optical laminate of the present invention.

FIG16 is a schematic cross-sectional view showing another example of the optical multilayer body of the present invention.

FIG17 is a schematic cross-sectional view showing yet another example of the optical multilayer body of the present invention.

FIG18 is a schematic cross-sectional view showing yet another example of the optical multilayer body of the present invention.

The following is a description of the preferred implementation of the polarizer composite and optical laminate of the present invention with reference to the drawings. In all the following drawings, the scales are appropriately adjusted to facilitate the understanding of each component, and the scales of each component shown in the drawings are not necessarily consistent with the scales of the actual components.

<Polarizer composite>

(Polarizer composite (1))

FIG. 1(a) is a schematic cross-sectional view schematically showing an example of a polarizer composite of the present embodiment, FIG. 1(b) is a schematic top view of the reinforcing material side of the polarizer composite shown in FIG. 1(a), and FIG. 1(c) is a schematic top view of the phase difference layer side of the polarizer composite shown in FIG. 1(a). FIG. 2(a) to FIG. 2(d) are schematic cross-sectional views schematically showing another example of a polarizer composite of the present embodiment. The polarizer composite 40 shown in FIG. 1(a) has a polarizer 10, a reinforcing material 50, and a phase difference layer 71 in sequence.

The polarizer 10 of the polarizer composite 40 is shown in FIG1(a) and has a polarizing region 11 and a non-polarizing region 12. The thickness of the polarizing region 11 is less than 15 μm. The non-polarizing region 12 is a region surrounded by the polarizing region 11 when the polarizer 10 is viewed from above.

The polarizing region 11 and the non-polarizing region 12 in the polarizer 10 can be arranged in such a way that the polarizing region 11 surrounds the non-polarizing region 12, and there is no particular limitation. When the polarizer 10 is viewed from above, the total area occupied by the polarizing region 11 is preferably larger than the total area occupied by the non-polarizing region 12. The polarizer 10 can have one non-polarizing region 12, or it can have two or more non-polarizing regions 12. When there are two or more non-polarizing regions 12, the shapes of the non-polarizing regions 12 can be the same or different from each other.

The reinforcing material 50 of the polarizer composite 40 has a plurality of cells 51 with open end faces as shown in FIG1(b), and each open end face is arranged in a manner opposite to the surface of the polarizer 10. The reinforcing material 50 has a cell region 55 where the cell 51 exists, and a non-cell region 56 where the cell 51 does not exist. The cell 51 has a hollow columnar (cylindrical) structure surrounded by a cell partition wall 53 that divides the cell 51, and both ends of the columnar structure in the axial direction are opened to form open end faces. The non-cell region 56 where the cell 51 does not exist refers to a region where there is no cell partition wall 53 constituting the cell 51 and a hollow columnar (cylindrical) space surrounded by the cell partition wall 53.

In the reinforcing material 50, the cell region 55 exists in a region corresponding to the polarizing region 11 in the polarizer 10, and the non-cell region 56 exists in a region corresponding to the non-polarizing region 12 of the polarizer 10. Here, the cell region 55 exists in a region corresponding to the polarizing region 11, which means that the cell region 55 and the polarizing region 11 are substantially the same shape and size in the top view direction. Similarly, the non-cell region 56 exists in a region corresponding to the non-polarizing region 12, which means that the non-cell region 56 and the non-polarizing region 12 are substantially the same shape and size (diameter) at substantially the same position in the top view direction. In other words, when the non-cell region 56 is projected onto the polarizer 10 in the top view direction, the projection area of the non-cell region 56 is roughly consistent with the non-polarizing region 12 in the polarizer 10. By means of the manufacturing method of the polarizer composite described later, a polarizer composite in which the cell region 55 exists in the region corresponding to the polarizing region 11 can be efficiently manufactured. When the polarizer 10 contained in the polarizer composite 40 has two or more non-polarizing regions 12, if the non-cell region 56 exists in at least one region corresponding to the non-polarizing region 12, the cell region 55 may also exist in other regions corresponding to (projected from) the non-polarizing region 12.

The phase difference layer 71 can be disposed on the side of the reinforcing material 50 opposite to the polarizer 10 via a bonding layer not shown in the figure. The bonding layer can be an adhesive layer or a bonding agent layer. The adhesive used to form the adhesive layer and the bonding agent used to form the bonding agent layer can be, for example, an adhesive and a bonding agent used to form the filler described later. The bonding layer between the reinforcing material 50 and the phase difference layer 71 is preferably also disposed in the internal space of the cell cavity 51 of the reinforcing material 50. If the inner space of the cell cavity 51 of the reinforcing material 50 is hollow, the visibility of the display device may be reduced due to the difference in refractive index between the cell wall 53 and the inner space of the cell cavity 51. Therefore, it is preferable to set the material constituting the bonding layer between the reinforcing material 50 and the phase difference layer 71 in a manner of filling the inner space of the cell cavity 51 of the reinforcing material 50, thereby suppressing the reduction in the visibility of the display device. As described later, when there is a gap between a plurality of cell cavities 51, it is preferable to also set the material constituting the bonding layer in the gap.

As shown in FIG. 1(a), the phase difference layer 71 has a phase difference region 75 having a phase difference characteristic and a non-phase difference region 76 having no phase difference characteristic. The phase difference region 75 refers to a region where at least one of the in-plane phase difference value (R0) and the thickness direction phase difference value (Rth) exceeds 40nm at a wavelength of 590nm. The non-phase difference region 76 refers to a region where the in-plane phase difference value (R0) and the thickness direction phase difference value (Rth) are respectively less than 40nm at a wavelength of 590nm.

The in-plane phase difference value (R0) is the phase difference value in the direction perpendicular to the thickness direction (in-plane direction) of the phase difference layer 70, and can be obtained by the following formula (I). The thickness direction phase difference value (Rth) is the phase difference value in the thickness direction of the phase difference layer 70, and can be obtained by the following formula (II). Both the in-plane phase difference value (R0) and the thickness direction phase difference value (Rth) are measured with light of a wavelength of 590nm at a temperature of 23°C.

R0=(Nx-Ny)×d (I)

Rth=[{(Nx+Ny)/2}-Nz]×d (II)

[In formula (I) and formula (II),

Nx is the refractive index in the direction where the refractive index in the plane is the largest (i.e., the slow axis direction),

Ny is the refractive index in the direction orthogonal to the slow axis (i.e., the fast axis direction) within the plane,

Nz is the refractive index in the thickness direction,

d is the thickness of the phase difference layer [nm].

The in-plane phase difference value (R0) and the thickness direction phase difference value (Rth) can be measured by, for example, a birefringence measuring device (trade name KOBRA-WPR) manufactured by Oji Scientific Instruments Co., Ltd.

In the phase difference layer 71 included in the polarizer composite 40, the phase difference region 75 exists in the region corresponding to the polarizing region 11 of the polarizer 10, and the non-phase difference region 76 exists in the region corresponding to the non-polarizing region 12 of the polarizer 10. Here, the phase difference region 75 exists in the region corresponding to the polarizing region 11, which means that the phase difference region 75 and the polarizing region 11 are substantially the same shape and size in the plan view direction; similarly, the non-phase difference region 76 exists in the region corresponding to the non-polarizing region 12, which means that the non-phase difference region 76 and the non-polarizing region 12 are substantially the same shape and size (diameter) at substantially the same position in the plan view direction. In other words, when the non-phase difference region 76 is projected onto the polarizer 10 in a top-view direction, the projection area of the non-phase difference region 76 is substantially the same as the non-polarizing region 12 of the polarizer 10. By means of the manufacturing method of the polarizer composite described later, a polarizer composite in which the phase difference region 75 exists in the region corresponding to the polarizing region 11 can be efficiently manufactured. When the polarizer 10 included in the polarizer composite 40 has two or more non-polarizing regions 12, it is sufficient if the non-phase difference region 76 exists in at least one region corresponding to the non-polarizing region 12, and the phase difference region 75 may also exist in other regions corresponding to the non-polarizing region 12. At least one non-phase difference region 76 is preferably disposed in a region corresponding to the non-polarization region 12 and a region corresponding to the non-cell region 56.

The polarizer composite 40 may have one phase difference layer 71 on the side of the reinforcement 50 opposite to the polarizer 10, or may have two or more phase difference layers 71. When there are two or more phase difference layers, the phase difference layers may be stacked on each other through a bonding layer, and the phase difference characteristics may be the same or different. When there are two or more phase difference layers, if at least one layer is the phase difference layer 71, the other phase difference layers may be phase difference layers composed entirely of phase difference regions (phase difference layers without non-phase difference regions). At this time, the phase difference layer 71 is preferably disposed on the side relatively close to the polarizer 10.

The non-polarizing area 12 of the polarizer 10, the non-cell area 56 of the reinforcement 50, and the non-phase difference area 76 of the phase difference layer 71 are hardened materials containing active energy ray hardening resin (hereinafter, also referred to as "hardening resin (X)"). The non-polarizing area 12 can be set as an area where the hardened material of the hardening resin (X) is set in the through hole 22 surrounded by the polarizing area 11 when viewed from above. The non-cell area 56 can be set as an area where the hardened material of the hardening resin (X) is set in the through hole 52, and the through hole 52 is set in a manner that the entirety or a part of the plurality of cells 51 is missing and is set in the area corresponding to the above-mentioned through hole 22. The non-phase difference region 76 is a region in which a hardened material of a curable resin (X) is disposed in the through hole 72. The through hole 72 is surrounded by the phase difference region 75 when viewed from above and is disposed in a region corresponding to the through hole 22.

The through hole 22 of the polarizer 10, the through hole 52 of the reinforcing material 50 and the through hole 72 of the phase difference layer 71 can be set to have the same shape when viewed from above. The through hole 22, the through hole 52 and the through hole 72 can be set to be connected in the thickness direction of the polarizing region 11, and the hardened material of the curable resin (X) can be continuously set in the above-mentioned connected through holes 22, 52, 72.

The polarizer 10 of the polarizer composite 40 has a non-polarizing area 12 as shown in FIG. 1(a). Therefore, when the polarizer composite 40 is applied to a display device such as a liquid crystal display device or an organic EL display device, which is expanded to a smart phone or a tablet terminal, the reduction in the sensitivity and design of the camera can be suppressed by configuring the printed parts such as a camera lens, an icon or a logo in a manner corresponding to the non-polarizing area 12. In particular, in the polarizer composite 40, the phase difference layer 71 has a non-phase difference area 76. Therefore, by configuring the printed parts such as a camera lens, an icon or a logo in a manner corresponding to the non-polarizing area 12 and the non-phase difference area 76, the reduction in the sensitivity and design of the camera can be further suppressed.

It is believed that since the polarizer 10 contains the non-polarizing area 12, cracks are easily generated around the non-polarizing area 12 due to the contraction of the polarizer 10, and the contraction of the polarizer 10 is accompanied by temperature changes when applied to a display device. In addition, it is believed that since the thickness of the polarizing area 11 of the polarizer 10 is as thin as 15μm or less, cracks are easily generated when impacted. In the polarizer composite 40, it is believed that since the reinforcing material 50 is provided on one side of the polarizer 10 as described above, the generation of cracks due to temperature changes or impacts, or the deterioration of small cracks into large cracks, can be suppressed.

In the polarizer composite 40, by making the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 contain a hardened material of a hardening resin (X), the through hole 22 of the polarizer 10, the through hole 52 of the non-cell region 56, and the through hole 72 of the non-phase difference region 76 can be made solid. Since the polarizer 10 of the polarizer composite 40 is as thin as 15 μm or less, if the hardened material of the hardening resin (X) is not provided in the non-polarizing region 12 and the through hole 22 is made hollow, there is a risk of cracks and other undesirable conditions occurring around the through hole 22 due to the shrinkage of the polarizer caused by the temperature change when it is applied to a display device. In contrast, the polarizer 10 of the polarizer composite 40 can prevent the occurrence of the above-mentioned adverse conditions by providing a hardened material of a hardening resin (X) in the through hole 22 so that the non-polarizing area 12 can be made solid.

The thickness of the hardened material of the hardening resin (X) disposed in the polarizer composite 40 may be the same as the thickness of the layered structure portion of the polarizer composite 40 including the polarizing region 11, the cell region 55, and the phase difference region 75 (FIG. 1(a)), may be less than the thickness of the layered structure portion (FIG. 2(a), FIG. 2(b)), or may be greater than the thickness of the layered structure portion (FIG. 2(c), FIG. 2(d)). The thickness of the layered structure portion may be the total thickness of the thickness of the polarizing region 11, the thickness of the cell region 55, and the thickness of the phase difference region 75, and the total thickness may also include the thickness of the layer between the polarizing region 11, the cell region 55, and the phase difference region 75. For example, when the polarizer composite 40 has a bonding layer between the polarizer 10 and the phase difference layer 71, the thickness of the laminated structure portion is the total thickness of the polarization region 11, the thickness of the cell region 55, and the thickness of the phase difference region 75 plus the thickness of the bonding layer. The cured product of the curable resin (X) disposed in the polarizer composite 40 may be disposed to fill at least a portion of the through hole 22 of the polarizer 10, at least a portion of the through hole 52 of the reinforcing material 50, and at least a portion of the through hole 72 of the phase difference layer 71. When the polarizer composite 40 has a bonding layer between the polarizer 10 and the phase difference layer 71, the cured product of the curable resin (X) can be provided in a manner of filling at least a portion of the through-holes provided in the bonding layer. The cured product of the curable resin (X) is preferably provided to fill the entire through-hole 22 of the polarizer 10, and more preferably provided to fill the entire through-hole 22 of the polarizer 10, the entire through-hole 52 of the reinforcing material 50, the entire through-hole 72 of the phase difference layer 71, and the entire through-hole of the above-mentioned bonding layer.

The thickness of the layered structure of the polarizer composite 40 including the polarizing region 11, the cell region 55, and the phase difference region 75 is preferably 30 μm or less, more preferably 25 μm or less, and even more preferably 20 μm or less, and can be 18 μm or less, and can also be 16 μm or less, and is usually 2 μm or more. If the thickness of the layered structure exceeds the above range, as described later, the workability of the hardened material used to set the hardening resin (X) in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 is easily reduced. The thickness can be measured using, for example, a contact film thickness measuring device (MS-5C, manufactured by Nikon Co., Ltd.). In addition, the thickness of the cell region refers to the height of the cell 51 (the length of the cell 51 in the direction perpendicular to the opening end face).

The thickness of the hardened material disposed in the polarizer composite 40 is determined as follows. First, in the polarizer composite 40, a first plane including the surface of the polarizing region 11 of the polarizer 10 (the surface on the opposite side of the reinforcing material 50) and a second plane including the surface of the phase difference region 75 of the phase difference layer 71 (the surface on the opposite side of the reinforcing material 50) are assumed. Next, in the non-polarizing region 12, a first position and a second position are determined, the first position being the position where the shortest distance between the hardened material surface on the polarizer 10 side and the first plane is the largest, and the second position being the position where the shortest distance between the hardened material surface on the phase difference layer 71 side and the second plane is the largest. Then, the shortest distance at the first position (dm), the shortest distance at the second position (dn), and the total value (dm+dn+D) of the distance between the first plane and the second plane (D) are used as the thickness of the hardened material set on the polarizer composite 40.

According to Figure 3, a method for determining the thickness when the "thickness of the hardened material of the hardening resin (X) set in the non-polarizing area 12, the non-cell area 56 and the non-phase difference area 76" and the "thickness of the layered structure of the polarizer composite 40 including the polarizing area 11, the cell area 55, and the phase difference area 75" are different is specifically described. Figures 3(a) and 3(b) are diagrams schematically showing an example of a cross-section of the non-polarizing area, the non-cell area and the non-phase difference area periphery of the polarizer composite, and are explanatory diagrams for explaining the method for determining the thickness of the hardened material set in the non-polarizing area, the non-cell area and the non-phase difference area.

When a hardened material is provided in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 as shown in FIG3(a), a "straight line along the surface side of the polarizer 10 opposite to the reinforcing material 50 side to the non-polarizing region 12" is assumed to be a first plane 11m. Among the straight lines where the straight line connecting "an arbitrary point on the first plane 11m" and "an arbitrary point on the surface of the hardened material provided in the non-polarizing region 12" is the shortest distance, the position where the length of the straight line ("dm" in FIG3(a)) becomes the maximum is taken as the first position. Next, as shown in FIG3(a), the "straight line indicated by a dotted line along the surface side of the phase difference layer 71 opposite to the reinforcing material 50 side in the non-phase difference region 76" is assumed to be the second plane 11n. Among the straight lines connecting "an arbitrary point on the second plane 11n" and "an arbitrary point on the surface of the hardened material provided in the non-phase difference region 76" with the shortest distance, the position where the length of the straight line ("dn" in FIG3(a)) becomes the maximum is set as the second position. Here, as shown in FIG3(a), in the thickness direction of the polarizer composite 40, when the surface of the hardened material disposed in the non-polarizing region 12 and the non-phase difference region 76 exists closer to the inner side (the reinforcing material 50 side) than the first plane 11m and the second plane 11n, dm and dn are negative values. In addition, the distance between the first plane 11m and the second plane 11n (equivalent to the thickness of the laminated structure part) is set to D. In this way, the thickness of the hardened material disposed in the non-polarizing region 12, the non-cell region 56 and the non-phase difference region 76 shown in FIG3(a) can be determined as D+dm+dn (dm and dn are negative values).

Furthermore, when a hardened material is provided in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 as shown in FIG3(b), the thickness of the hardened material provided in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 can be determined by assuming the first plane 11m and the second plane 11n as described above. Specifically, first, among the straight lines connecting "an arbitrary point on the first plane 11m" and "an arbitrary point on the surface of the hardened material provided in the non-polarizing region 12" with the shortest distance, the position where the length of the straight line ("dm" in FIG3(b)) becomes the maximum is set as the first position. Next, among the straight lines connecting "any point on the second plane 11n" and "any point on the surface of the hardened material provided in the non-phase difference region 76" with the shortest distance, the position where the length of the straight line ("dn" in FIG. 3(b)) becomes the maximum is set as the second position. Here, as shown in FIG. 3(b), in the thickness direction of the polarizer composite 40, when the surface of the hardened material provided in the non-polarizing region 12 and the non-phase difference region 76 exists closer to the outside side (the opposite side of the reinforcing material 50) than the first plane 11m and the second plane 11n, dm and dn show positive values. Thus, the thickness of the hardened material disposed in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 shown in FIG3(b) can be determined as D+dm+dn (dm and dn are positive values).

(Polarizer composite (2))

FIG4 is a schematic cross-sectional view schematically showing another example of the polarizer composite of the present embodiment. The polarizer composite 41 shown in FIG4 is a composite of the polarizer composite 40 shown in FIG1(a) in which a reinforcing material 50 is further provided on the side of the polarizer 10, and has a reinforcing material 50, a polarizer 10, a reinforcing material 50 and a phase difference layer 71 in sequence. The reinforcing material 50, the polarizer 10 and the phase difference layer 71 are as described above.

The polarizer composite 41 can suppress the reduction of camera sensitivity and design by configuring the printed part of the camera lens, icon or logo in the same way as the above-mentioned polarizer composite 40, and can suppress the occurrence of the above-mentioned adverse conditions. In addition, it is believed that the polarizer composite 41 can suppress the cracks of the polarizer 10 caused by temperature changes or impacts, or the deterioration of small cracks into large cracks because the reinforcing material 50 is provided on both sides of the polarizer 10.

The thickness of the hardened material of the hardening resin (X) disposed in the polarizer composite 41 may be the same as the thickness of the layered structure portion of the polarizer composite 41 including the polarizing region 11, the cell region 55 of the two reinforcing materials, and the phase difference region 75 (FIG. 4), may be less than the thickness of the layered structure portion, or may be greater than the thickness of the layered structure portion. The thickness of the layered structure portion may be the total thickness of the polarizing region 11, the thickness of the two cell regions 55, and the thickness of the phase difference region 75, and the total thickness may also include the thickness of the layer between the polarizing region 11, the cell region 55, and the phase difference region 75. For example, when the intermediate layer is a bonding layer, the thickness of the above-mentioned laminated structure portion is the total thickness of the polarizing region 11, the thickness of the two cell regions 55, and the thickness of the phase difference region 75 plus the thickness of the bonding layer. When there is a bonding layer, the hardened material of the hardening resin (X) can be set in a manner to fill at least a portion of the through holes set in the bonding layer. The hardened material of the hardening resin (X) set in the polarizer composite 41 can be set to fill at least a portion of each through hole 52 of the two reinforcement materials 50, at least a portion of the through hole 22 of the polarizer 10, and at least a portion of the through hole 72 of the phase difference layer 71. The cured product of the curable resin (X) is preferably arranged to fill the entire through hole 22 of the polarizer 10, and more preferably arranged to fill the entire through hole 52 of the two reinforcing materials 50, the entire through hole 22 of the polarizer 10, the entire through hole 72 of the phase difference layer 71, and the entire through hole of the above-mentioned bonding layer.

The thickness of the layered structure of the polarizer composite 41 including the polarizing region 11, the cell region 55 of the two reinforcement materials, and the phase difference region 75 is preferably 30 μm or less, more preferably 25 μm or less, and even more preferably 20 μm or less, and can be 18 μm or less, and can be 16 μm or less, and is usually 2 μm or more. If the thickness of the layered structure exceeds the above range, as described later, the workability of the hardened material used to set the hardening resin (X) in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 is easily reduced. Each thickness and the thickness measurement method are as described above.

The thickness of the hardened material disposed on the polarizer composite 41 can be measured according to the above-described method for measuring the thickness of the hardened material disposed on the polarizer composite 40. Specifically, in the above-described measuring method, the first plane is set as a plane including "the opening end surface of the cell region 55 of the two reinforcing materials 50 disposed on the opposite side of the phase difference layer 71 side of the polarizer 10 (the opening end surface on the opposite side of the polarizer 10 side)", and the thickness of the hardened material of the curable resin (X) can be determined.

The reinforcing material 50 is applied to a display device and the like in a state of being contained in the polarizer composite 41. If the internal space of the cell 51 of the reinforcing material 50 is hollow, there is a possibility that the visibility of the display device is reduced due to the difference in refractive index between the cell partition 53 and the internal space of the cell 51. In the reinforcing material 50, when a gap is provided between a plurality of cell cavities 51 as described later, this gap may also become a cause of reduced visibility of the display device. Therefore, as described in the above-mentioned polarizer composite 40, it is preferable to provide a bonding layer between the reinforcing material 50 and the phase difference layer 71 in the internal space of the cell 51 of the reinforcing material 50 between the polarizer 10 and the phase difference layer 71 and in the gaps between the plurality of cell cavities 51. On the other hand, in the cell region 55 of the reinforcing material 50 disposed on the opposite side of the phase difference layer 71 of the polarizer 10 in the polarizer composite 41, it is preferred to provide a light-transmitting filler in the internal space of the cell 51 and in the gaps between the plurality of cells 51. Such a filler will be described later.

In this manual, light transmittance refers to the property (transmittance) of transmitting more than 80% of visible light in the wavelength range of 400nm to 700nm, preferably more than 85%, more preferably more than 90%, and more preferably more than 92%. The following definition of "light transmittance" and the preferred range of visible light transmittance are the same as above.

(Polarizer composite (3))

FIG5 is a schematic cross-sectional view schematically showing another example of the polarizer composite of the present embodiment. The polarizer composite 42 shown in FIG5 sequentially comprises a polarizer 10, a phase difference layer 71, and a reinforcing material 50. The polarizer 10, the phase difference layer 71, and the reinforcing material 50 are as described above.

The phase difference layer 71 can be disposed on one side of the polarizer 10 via a bonding layer not shown in the figure. The polarizer composite 42 can have one layer of phase difference layer 71 on one side of the polarizer 10, or can have two or more layers of phase difference layer 71. When there are two or more phase difference layers, the phase difference layers can be stacked on each other via a bonding layer, and a phase difference layer can be further disposed on the opposite side of the polarizer 10 side of the reinforcement 50. The phase difference characteristics of the two or more phase difference layers can be the same or different from each other. In the polarizer composite 42, when there is a phase difference layer on the opposite side of the polarizer 10 side of the reinforcing material 50, the phase difference layer can be the phase difference layer 71, or a phase difference layer composed entirely of phase difference regions (a phase difference layer without a non-phase difference region).

The polarizer composite 42 is similar to the polarizer composite 41. The non-polarizing area 12 of the polarizer 10, the non-phase difference area 76 of the phase difference layer 71, and the non-cell area 56 of the reinforcing material 50 are hardened materials containing an active energy ray hardening resin composition (hereinafter, sometimes referred to as "hardening resin (X)").

The polarizer composite 42 can further suppress the reduction of camera sensitivity and design by configuring the printed parts such as camera lens, icon or logo in the same manner as the above-mentioned polarizer composites 40 and 41, and can suppress the occurrence of the above-mentioned adverse conditions. In addition, it is believed that the polarizer composite 42 is provided with a reinforcing material 50, so that cracks in the polarizer 10 caused by temperature changes or impacts can be suppressed, or small cracks can be deteriorated into large cracks. In particular, it is believed that the polarizer composite 42 is easily improved in impact resistance because the reinforcing material 50 is provided on the opposite side of the phase difference layer 71 to the polarizer 10 side.

The thickness of the hardened material of the hardening resin (X) disposed on the polarizer composite 42 may be the same as the thickness of the laminated structure portion of the polarizer composite 42 including the polarizing region 11, the phase difference region 75, and the cell region 55 (FIG. 5), may be less than the thickness of the laminated structure portion, or may be greater than the thickness of the laminated structure portion. The thickness of the laminated structure portion may be the total thickness of the polarizing region 11, the phase difference region 75, and the cell region 55, and the total thickness may also include the thickness of the layer between the polarizing region 11, the phase difference region 75, and the cell region 55. For example, when the intermediate layer is a bonding layer, the thickness of the laminated structure portion is the sum of the thickness of the polarizing region 11, the thickness of the cell region 55, and the thickness of the phase difference region 75 plus the thickness of the bonding layer. When there is a bonding layer, the cured material of the curable resin (X) can be provided in a manner to fill at least a portion of the through hole provided in the bonding layer. The cured material of the curable resin (X) provided in the polarizer composite 42 can be provided to fill at least a portion of the through hole 22 of the polarizer 10, at least a portion of the through hole 72 of the phase difference layer 71, and at least a portion of the through hole 52 of the reinforcing material 50. The cured product of the curable resin (X) is preferably arranged to fill the entire through hole 22 of the polarizer 10, and more preferably arranged to fill the entire through hole 22 of the polarizer 10, the entire through hole 72 of the phase difference layer 71, the through hole 52 of the reinforcing material 50, and the entire through hole of the above-mentioned bonding layer.

The thickness of the layered structure of the polarizer composite 42 including the polarizing region 11, the phase difference region 75, and the cell region 55 is preferably 30 μm or less, more preferably 25 μm or less, and even more preferably 20 μm or less, and can be 18 μm or less, and can also be 16 μm or less, and is usually 2 μm or more. If the thickness of the layered structure exceeds the above range, as described later, the workability of the hardened material used to set the hardening resin (X) in the non-polarizing region 12, the non-phase difference region 76, and the non-cell region 56 is easily reduced, and the productivity is easily reduced. Each thickness and the thickness measurement method are as described above.

The thickness of the hardened material provided on the polarizer composite 42 can be measured according to the above-described method for measuring the thickness of the hardened material provided on the polarizer composite 40. Specifically, in the above-described measuring method, the second plane is set as a plane including the "opening end surface of the cell region 55 of the reinforcement material 50 (the opening end surface on the opposite side of the phase difference layer 71)", and the thickness of the hardened material of the curable resin (X) can be determined.

The reinforcing material 50 is used in a display device, etc., when it is contained in the polarizer composite 42. Therefore, as described in the above-mentioned polarizer composite 41, in the cell region 55 of the reinforcing material 50, it is preferred to set a light-transmitting filling material in the internal space of the cell 51 and the gaps between the plurality of cells 51.

(Polarizer composite (4))

FIG6 is a schematic cross-sectional view schematically showing another example of the polarizer composite of the present embodiment. The polarizer composite 43 shown in FIG6 is a composite of the polarizer composite 42 shown in FIG5 in which a reinforcing material 50 is further provided on the side of the polarizer 10, and has a reinforcing material 50, a polarizer 10, a phase difference layer 71, and a reinforcing material 50 in sequence. The reinforcing material 50, the polarizer 10, and the phase difference layer 71 are as described above.

The polarizer composite 43 can suppress the reduction of camera sensitivity and design by configuring the printed parts of the camera lens, icon or logo in the same way as the above-mentioned polarizer composites 40 to 42, and can suppress the occurrence of the above-mentioned adverse conditions. In addition, it is believed that the polarizer composite 43 can suppress the cracks of the polarizer 10 caused by temperature changes or impact, or the deterioration of small cracks into large cracks, and can easily improve the impact resistance of the polarizer composite 43 because the reinforcing material 50 is respectively provided on one side of the polarizer 10 and one side of the phase difference layer 71.

The thickness of the hardened material of the hardening resin (X) disposed in the polarizer composite 43 may be the same as the thickness of the laminated structure portion of the polarizer composite 43 including the cell region 55, the polarizing region 11, and the phase difference region 75 of the two reinforcing materials (FIG. 6), may be less than the thickness of the laminated structure portion, or may be greater than the thickness of the laminated structure portion. The thickness of the laminated structure portion may be the total thickness of the thickness of the two cell regions 55, the thickness of the polarizing region 11, and the thickness of the phase difference region 75, and the total thickness may also include the thickness of the layer between the cell region 55, the polarizing region 11, and the phase difference region 75. For example, when the intermediate layer is a bonding layer, the thickness of the above-mentioned laminated structure portion is the sum of the thickness of the two cell regions 55, the thickness of the polarizing region 11, and the thickness of the phase difference region 75 plus the thickness of the bonding layer. When there is a bonding layer, the hardened material of the hardening resin (X) can be set in a manner to fill at least a portion of the through holes set in the bonding layer. The hardened material of the hardening resin (X) set in the polarizer composite 43 can be set to fill at least a portion of each through hole 52 of the two reinforcement materials 50, at least a portion of the through hole 22 of the polarizer 10, and at least a portion of the through hole 72 of the phase difference layer 71. The cured product of the curable resin (X) is preferably configured to fill the entire through hole 22 of the polarizer 10, and more preferably configured to fill the entire through hole 52 of the two reinforcing materials 50, the entire through hole 22 of the polarizer 10, the entire through hole 72 of the phase difference layer 71, and the entire through hole of the above-mentioned bonding layer.

The thickness of the layered structure of the polarizer composite 43, which includes the cell region 55, the polarizing region 11, and the phase difference region 75 of the two reinforcing materials, is preferably 30 μm or less, more preferably 25 μm or less, and even more preferably 20 μm or less, and can be 18 μm or less, and can also be 16 μm or less, and is usually 2 μm or more. If the thickness of the layered structure exceeds the above range, as described later, the workability of the hardened material used to set the hardening resin (X) in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 is easily reduced. Each thickness and the method for measuring the thickness are as described above.

The thickness of the hardened material provided on the polarizer composite 43 can be measured according to the above-described method for measuring the thickness of the hardened material provided on the polarizer composite 40. Specifically, in the above-described measuring method, the first plane and the second plane are set as follows to determine the thickness of the hardened material of the curable resin (X). The first plane is set as a plane including "the opening end surface of the cell region 55 of the reinforcing material 50 provided on the opposite side of the phase difference layer 71 side of the polarizer 10 among the two reinforcing materials 50 (the opening end surface on the opposite side of the polarizer 10 side)". The second plane is set as a plane including "the opening end surface of the cell region 55 of the reinforcing material 50 disposed on the opposite side of the polarizer 10 side of the phase difference layer 71 among the two reinforcing materials 50 (the opening end surface on the opposite side of the phase difference layer 71 side)".

The reinforcing material 50 is used in a display device, etc., when it is contained in the polarizer composite 43. Therefore, as described in the above-mentioned polarizer composite 41, in the cell region 55 of the reinforcing material 50, it is preferred to set a light-transmitting filling material in the internal space of the cell 51 and the gaps between the plurality of cells 51.

The polarizer composites 40 to 43 described above may be circular polarizers. In this case, the phase difference region 75 of the phase difference layer 71 may have a phase difference characteristic that functions as a 1/4 wavelength plate. When the polarizer composites 40 to 43 are circular polarizers, two or more phase difference layers may be provided on one side of the polarizer 10. For example, on one side of the polarizer 10, the phase difference layer 71 is layered in such a manner that the phase difference characteristics of the phase difference region 75 are arranged in the order of [a] a 1/2 wavelength plate and a 1/4 wavelength plate, [b] a 1/4 wavelength plate with reverse wavelength dispersion and a positive C plate, or [c] a positive C plate and a 1/4 wavelength plate with reverse wavelength dispersion.

The polarizer composites 40 to 43 may be in the form of sheets or in the form of elongated bodies having a length that can be rolled into a roll during storage or transportation. The planar shape and size of the polarizer composites 40 to 43 are not particularly limited.

(Polarized area)

The polarizing region 11 of the polarizer 10 preferably exhibits absorption dichroism at wavelengths ranging from 380nm to 780nm. The polarizer 10 has the property of absorbing linear polarization having a vibration plane parallel to its absorption axis and transmitting linear polarization having a vibration plane orthogonal to the absorption axis (parallel to the transmission axis), and this property can be mainly obtained by the polarizing region 11.

The polarizing region 11 may be formed by, for example: adsorption/alignment of dichroic substances such as iodine or dichroic dyes on hydrophilic polymer films such as polyvinyl alcohol films, partially formalized polyvinyl alcohol films, and partially saponified films of ethylene/vinyl acetate copolymers; adsorption/alignment of dichroic substances on dehydrated polyvinyl alcohol or dehydrogenated polyvinyl chloride, polyolefin alignment films, or aligned liquid crystal compounds. Among them, the one obtained by dyeing the polyvinyl alcohol film with iodine and uniaxially stretching is preferred in terms of excellent optical properties.

First, the manufacturing method of the polyvinyl alcohol film obtained by dyeing it with iodine and uniaxially stretching it, which will become the preferred polarization region 11, is briefly described.

Dyeing with iodine can be performed, for example, by immersing the polyvinyl alcohol film in an iodine aqueous solution. The stretching ratio of the uniaxial stretching is preferably 3 to 7 times. The stretching can be performed after the dyeing treatment, or while dyeing. In addition, the dyeing can also be performed after stretching.

The polyvinyl alcohol film can be subjected to swelling treatment, crosslinking treatment, cleaning treatment, drying treatment, etc. as needed. For example, by immersing the polyvinyl alcohol film in water and washing it before dyeing, not only can the dirt or anti-caking agent on the surface of the polyvinyl alcohol film be washed away, but the polyvinyl alcohol film can also be swollen to prevent uneven dyeing.

The stretching treatment, dyeing treatment, crosslinking treatment (boric acid treatment), water washing treatment, and drying treatment of the polyvinyl alcohol resin film can be performed, for example, according to the method described in Japanese Patent Publication No. 2012-159778. In the method described in the document, a polyvinyl alcohol resin layer that will become the polarizing area 11 is formed by applying a polyvinyl alcohol resin to a substrate film. At this time, the substrate film used can also be used as the first support layer 25 described later.

Next, the polarization region 11 formed by adsorption/alignment of dichroic dyes on the aligned liquid crystal compound is briefly described. In this case, the polarization region 11 may be, for example, a dichroic dye aligned in a cured film formed by polymerization of a liquid crystal compound as described in Japanese Patent Publication No. 2013-37353, Japanese Patent Publication No. 2013-33249, Japanese Patent Publication No. 2016-170368, Japanese Patent Publication No. 2017-83843, etc. The dichroic dye may be one that has absorption in the wavelength range of 380 to 800 nm, preferably an organic dye. Examples of dichroic dyes include azo compounds. The liquid crystal compound is a liquid crystal compound that can be polymerized in an aligned state and may have a polymerizable group in the molecule. The cured film formed by the polymerization of the liquid crystal compound can be formed on the substrate film. In this case, the substrate film can also be used as the first supporting layer 25 described later.

After the polarizing film used in the polarizing area 11 is made as described above, it is preferred to form the non-polarizing area 12 by perforation to form the polarizer 10. In this specification, the polarizing film formed only by the polarizing area 11 is sometimes referred to as the raw polarizer 20.

The visual sensitivity correction polarization degree (Py) of the polarizing region 11 is preferably 80% or more, more preferably 90% or more, more preferably 95% or more, and particularly preferably 99% or more. The single transmittance (Ts) of the polarizing region 11 is usually less than 50%, and may be less than 46%. The single transmittance (Ts) of the polarizing region 11 is preferably 39% or more, more preferably 39.5% or more, more preferably 40% or more, and particularly preferably 40.5% or more.

The single body transmittance (Ts) is the Y value obtained by measuring the 2-degree field of view (C light source) according to JIS Z8701 and performing sensitivity correction. For example, the sensitivity correction polarization degree (Py) and single body transmittance (Ts) can be measured using an ultraviolet visible light spectrophotometer (manufactured by JASCO Corporation, product name: V7100). The parallel transmittance Tp and orthogonal transmittance Tc after sensitivity correction can be obtained by the following formula.

Py[%]={(Tp-Tc)/(Tp+Tc)} ^1/2 ×100

(Non-polarized area)

Generally speaking, "non-polarized light" refers to light with irregularities that can be observed in the electric field component. In other words, non-polarized light is irregular light in which a specific polarization state that is dominant cannot be observed. In addition, "partially polarized light" refers to light in an intermediate state between polarized light and non-polarized light, and refers to light mixed with non-polarized light and at least one of linear polarized light, circular polarized light, and elliptical polarized light. The non-polarized area 12 of the polarizer 10 means that the light (transmitted light) that transmits the non-polarized area 12 becomes non-polarized light or partially polarized light. It is particularly preferred that the transmitted light is a non-polarized area.

The non-polarizing area 12 of the polarizer 10 is an area surrounded by the polarizing area 11 when viewed from above. The non-polarizing area 12 contains a cured product of a curable resin (X). The non-polarizing area 12 is preferably a cured product of an active energy ray-curable resin composition containing a curable resin (X) described later, which is provided in a through hole provided in a polarizer (raw material polarizer 20) formed only by the polarizing area 11. The non-polarizing area 12 is light-transmissive.

By making the non-polarizing area 12 of the polarizer 10 light-transmissive, a predetermined transparency can be ensured in the non-polarizing area 12. Thus, when the polarizer composites 40 to 43 are applied to a display device, a camera lens, a printed part of an icon or logo, etc. can be arranged corresponding to the non-polarizing area 12, thereby suppressing a reduction in camera sensitivity or a reduction in design.

The planar shape of the non-polarizing area 12 is not particularly limited, but can be set to a circle; an ellipse; an oval; a polygon such as a triangle or a quadrangle; a rounded polygon in which at least one corner of the polygon is rounded (having an R shape), etc.

The diameter of the non-polarizing area 12 is preferably greater than 0.5 mm, and can be greater than 1 mm, greater than 2 mm, or greater than 3 mm. The diameter of the non-polarizing area 12 is preferably less than 20 mm, and can be less than 15 mm, less than 10 mm, or less than 7 mm. The diameter of the non-polarizing area 12 refers to the length of the longest straight line connecting any two points on the periphery of the non-polarizing area 12.

The thickness of the hardened material of the hardening resin (X) disposed in the non-polarizing area 12 may be the same as the thickness of the polarizing area 11, may be less than the thickness of the polarizing area 11, or may be greater than the thickness of the polarizing area 11. As described above, the hardened material of the hardening resin (X) disposed in the non-polarizing area 12 is preferably disposed to fill the entire through hole 22.

The thickness of the hardened material provided in the non-polarizing area 12 can be measured according to the above-described method for measuring the thickness of the hardened material provided in the polarizer composite 40. Specifically, in the above-described measuring method, the second plane is set as "the surface on the opposite side of the surface of the polarizing area 11 of the polarizer 10 that is set to be included in the first plane", and the thickness of the hardened material of the curable resin (X) can be determined.

(Cellular region)

The cell cavity region 55 is the region of the reinforcement material 50 where the cell cavity 51 exists. The cell cavity 51 has a hollow columnar (tube-shaped) structure surrounded by a cell cavity partition wall 53 that divides the cell cavity 51 as shown in FIG1(b), and both ends of the columnar structure in the axial direction are open to form open end faces. The cell cavity 51 has a first open end face arranged at a relatively close side of the polarizer 10 of the polarizer composite 40 to 43, and a second open end face arranged at a relatively far side as open end faces. The cell cavity region 55 can be arranged in a manner opposite to the polarizer 10 if at least one of the first open end face and the second open end face is arranged in a manner opposite to the polarizer 10, and preferably, both the first open end face and the second open end face are arranged in a manner opposite to the polarizer 10.

The opening shape of the cell cavity 51 of the cell cavity region 55 is not particularly limited, but is preferably a polygon, a circle, or an ellipse. The opening shape of the first opening end face and the opening shape of the second opening end face are preferably the same shape with the same size, but may be different shapes, or the same shape with different sizes. In addition, the opening shapes of the plurality of cell cavities 51 of the cell cavity region 55 may be the same or different from each other.

The plurality of cells 51 of the cell region 55 are preferably arranged in a manner that the openings of the cells 51 are adjacent to each other when viewed from above the opening end surface. When viewed from above the opening end surface, the plurality of cells 51 can be arranged in a manner that the cells 51 are arranged without gaps, such as when the opening shape of the cell 51 is hexagonal, etc. as shown in FIG. 1(b). Alternatively, when viewed from above the opening end surface, the plurality of cells 51 can be arranged in a manner that a portion of the cell partition walls 53 of the plurality of cells 51 are connected and there are gaps between the plurality of cells 51, such as when the opening shape of the cell 51 is circular, etc.

Preferably, the cell region 55 of the reinforcing material 50 is, for example, as shown in FIG1(b), the opening shape at either the first opening end face or the second opening end face is a hexagon, and in the surface direction of the polarizer composite 40 to 43, it has a honeycomb structure in which a plurality of cells 51 are arranged in a manner such that the openings are adjacent to each other without gaps.

The opening size of the cell cavity 51 is not particularly limited, but preferably has a diameter smaller than the diameter of the non-polarizing region 12. The diameter of the cell cavity 51 is preferably less than 3 mm, less than 2 mm, or less than 1 mm, and usually greater than 0.1 mm, or greater than 0.5 mm. The diameter of the opening of the cell cavity 51 refers to the length of the longest straight line connecting any two points on the periphery of the opening.

The height of the cell cavity 51 (the length in the direction perpendicular to the opening end surface of the cell cavity 51) is usually 0.1 μm or more, can be 0.5 μm or more, can be 1 μm or more, can also be 3 μm or more, and is usually 15 μm or less, can be 13 μm or less, and can also be 10 μm or less.

The cell wall 53 that divides the cell cavity 51 in the cell cavity region 55 is preferably light-transmissive.

The line width of the cell wall 53 of the reinforcing material 50 is, for example, greater than 0.05 mm, greater than 0.1 mm, greater than 0.5 mm, or greater than 1 mm, and is usually less than 5 mm, or less than 3 mm.

The cell wall 53 of the cell region 55 can be formed of, for example, a resin material or an inorganic oxide, and is preferably formed of a resin material. Examples of the resin material include a thermoplastic resin, a thermosetting resin, or a hardening resin such as an active energy ray hardening resin. Examples of the resin material include the hardening resin (X) mentioned above; and the thermoplastic resins exemplified as the thermoplastic resin used as the above-mentioned filler. Examples of the inorganic oxide include silicon oxide (SiO ₂ ), aluminum oxide, and the like.

(Non-luminal area)

The non-cell region 56 is a region of the reinforcing material 50 where there is no cell 51. As described above, it is a region where there is no cell partition wall 53 constituting the cell 51 and a hollow columnar (tube-shaped) space surrounded by the cell partition wall 53. The non-cell region 56 has a through hole 52, which is provided in a manner that the entirety or a portion of the plurality of cells 51 is missing and is provided in a region corresponding to the through hole 22 of the polarizer 10. The non-cell region 56 may contain a hardened material of a hardening resin (X) in the through hole 52.

The planar shape and diameter of the non-cell region 56 are not particularly limited, and the shape and diameter exemplified as the planar shape of the non-polarizing region 12 can be used. The planar shape and diameter of the non-cell region 56 are preferably the same as the planar shape and diameter of the non-polarizing region 12.

(Phase difference area)

The phase difference layer 71 has a phase difference property, and this property can be mainly obtained from the phase difference region 75. At least one of the in-plane phase difference value (R0) and the thickness direction phase difference value (Rth) of the phase difference region 75 at a wavelength of 590nm exceeds 40nm, and can be independently 100nm or more, 500nm or more, or 1000nm or more, and is usually less than 15000nm.

The phase difference region 75 may have a phase difference characteristic that functions as, for example, a 1/4 wavelength plate, a 1/2 wavelength plate, a 1/4 wavelength plate with reverse wavelength dispersion, or a positive C plate. As described above, a plurality of phase difference layers having different phase difference characteristics may be stacked to form the phase difference region 75.

The phase difference region 75 can be a region formed by the raw phase difference layer which is the phase difference region as a whole as described later. When a plurality of phase difference layers having different phase difference characteristics are stacked as the phase difference region 75, the plurality of layers can be set as the raw phase difference layer. Therefore, the phase difference region 75 is formed by the material constituting the raw phase difference layer as described later, and specifically, it can contain a thermoplastic resin. The phase difference region can be formed by, for example, a stretched film formed by uniaxially stretching or biaxially stretching a thermoplastic resin, or a polymerized curing layer of a polymerizable liquid crystal compound.

The thickness of the phase difference region 75 is preferably less than 15μm, can be less than 13μm, can be less than 10μm, can be less than 8μm, can be less than 5μm, and is usually more than 1μm.

(Non-phase difference area)

The non-phase difference region 76 of the phase difference layer 71 is a region surrounded by the phase difference region 75 when viewed from above. The in-plane phase difference value (R0) and the thickness direction phase difference value (Rth) of the non-phase difference region 76 at a wavelength of 590nm are less than 40nm, and can be less than 35nm, less than 30nm, less than 20nm, or 0nm, respectively and independently.

The non-phase difference region 76 may contain a hardened material of a hardening resin (X) in the through hole 72 surrounded by the phase difference region 75 in a top view. The thickness of the hardened material of the hardening resin (X) provided in the non-phase difference region 76 may be the same as the thickness of the phase difference region 75, may be smaller than the thickness of the non-phase difference region 76, or may be larger than the thickness of the non-phase difference region 76. As described above, the hardened material of the hardening resin (X) provided in the non-phase difference region 76 is preferably provided to fill the entire through hole 72. As described later, by arranging such a non-phase difference region 76 in a manner corresponding to the non-polarizing region 12, when the polarizer composites 40 to 43 are applied to a display device, by arranging the camera lens, a printed portion of an icon or logo, etc. in a manner corresponding to the non-polarizing region 12 and the non-phase difference region 76, the reduction in camera sensitivity and the reduction in design can be suppressed.

The thickness of the hardened material provided in the non-phase difference region 76 can be measured according to the above-described method for measuring the thickness of the hardened material provided in the polarizer composite 40. Specifically, in the above-described measuring method, the first plane is set as "the surface on the opposite side of the surface provided in the phase difference region 75 of the phase difference layer 71 to the surface included in the second plane", and the thickness of the hardened material of the curable resin (X) can be determined.

The planar shape and diameter of the non-phase difference region 76 are not particularly limited, and the shape and diameter exemplified as the planar shape of the non-polarizing region 12 can be used. The planar shape and diameter of the non-phase difference region 76 are preferably the same as the planar shape and diameter of the non-polarizing region 12, respectively.

(Active energy ray hardening resin (hardening resin (X)))

As described above, the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76 in the polarizer composites 40 to 43 are regions where a hardened material of an active energy ray-hardening resin (hardening resin (X)) is provided, and are preferably formed by an active energy ray-hardening resin composition (hereinafter, also referred to as a "hardening resin composition") containing the hardening resin (X). The hardening resin (X) contained in the hardening resin composition is hardened by irradiation with active energy rays such as ultraviolet rays, visible light, electron rays, and X-rays. The hardening resin (X) is preferably an ultraviolet-hardening resin that is hardened by irradiation with ultraviolet rays. The curable resin composition containing the curable resin (X) may be an active energy ray curable adhesive, and in this case, it is preferably an ultraviolet ray curable adhesive.

The curable resin composition is preferably a solvent-free type. The so-called solvent-free type means that no solvent is actively added. Specifically, the so-called solvent-free curable resin composition means that the solvent content is 5% by weight or less relative to 100% by weight of the curable resin (X) contained in the curable resin composition.

The curable resin (X) preferably contains an epoxy compound. The so-called epoxy compound refers to a compound having one or more (preferably two or more) epoxy groups in the molecule. Examples of epoxy compounds include alicyclic epoxy compounds, aliphatic epoxy compounds, and hydrogenated epoxy compounds (glycidyl ethers of polyols having alicyclic rings). The epoxy compound contained in the curable resin (X) may be one or more.

The content of the epoxy compound is preferably 40% by weight or more, more preferably 50% by weight or more, and even more preferably 60% by weight or more relative to 100% by weight of the curable resin (X). The content of the epoxy compound may be 100% by weight or less relative to 100% by weight of the curable resin (X), 90% by weight or less, 80% by weight or less, or 75% by weight or less.

The epoxy equivalent of the epoxy compound is usually 40 to 3000 g/equivalent, preferably 50 to 1500 g/equivalent. If the epoxy equivalent exceeds 3000 g/equivalent, the compatibility with other components contained in the curable resin (X) may be reduced.

The epoxy compound contained in the curable resin (X) is preferably an alicyclic epoxy compound. An alicyclic epoxy compound is an epoxy compound having one or more epoxy groups bonded to an alicyclic ring in the molecule. The so-called "epoxy group bonded to an alicyclic ring" means the bridging oxygen atom -O- in the structure shown in the following formula. In the following formula, m is an integer from 2 to 5.

In the above formula, a compound in which one or more hydrogen atoms in (CH ₂ ) _m are removed and bonded to other chemical structures can become an alicyclic epoxy compound. One or more hydrogen atoms in (CH ₂ ) _m can also be appropriately substituted by a linear alkyl group such as a methyl group or an ethyl group. Among the alicyclic epoxy compounds, an epoxy compound having an oxygen-doped bicyclohexane ring (where m=3 in the above formula) or an oxygen-doped bicycloheptane ring (where m=4 in the above formula) is preferably used because it can provide excellent adhesion between the polarizing region 11 of the polarizer 10, the phase difference region 75 of the phase difference layer 71, the cell region 55 of the reinforcing material 50, and the cured product of the curable resin (X) forming the non-polarizing region 12, the non-phase difference region 76, and the non-cell region 56. The alicyclic epoxy compounds that can be preferably used are specifically exemplified below, but are not limited to these compounds.

[a] Epoxycyclohexanecarboxylic acid epoxycyclohexylmethyl esters represented by the following formula (IV):

[In formula (IV), R ⁸ and R ⁹ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms].

[b] Epoxycyclohexane carboxylic acid esters of alkanediol represented by the following formula (V):

[In formula (V), R ¹⁰ and R ¹¹ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and n represents an integer of 2 to 20].

[c] Epoxycyclohexylmethyl esters of dicarboxylic acids represented by the following formula (VI):

[In formula (VI), R ¹² and R ¹³ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and p represents an integer of 2 to 20].

[d] Epoxycyclohexyl methyl ethers of polyethylene glycol represented by the following formula (VII):

[In formula (VII), R ¹⁴ and R ¹⁵ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and q represents an integer of 2 to 10].

[e] Epoxycyclohexyl methyl ethers of alkanediols represented by the following formula (VIII):

[In formula (VIII), R ¹⁶ and R ¹⁷ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms, and r represents an integer of 2 to 20].

[f] A diepoxy trispiro compound represented by the following formula (IX):

[In formula (IX), R ¹⁸ and R ¹⁹ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms].

[g] A diepoxy monospiro compound represented by the following formula (X):

[In formula (X), R ²⁰ and R ²¹ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms].

[h] Vinylcyclohexene diene oxides represented by the following formula (XI):

[In formula (XI), R ²² represents a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms].

[i] Epoxycyclopentyl ethers represented by the following formula (XII):

[In formula (XII), R ²³ and R ²⁴ independently represent a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms].

[j] Bicyclic oxytricyclic decanes represented by the following formula (XIII):

[In formula (XIII), R ²⁵ represents a hydrogen atom or a linear alkyl group having 1 to 5 carbon atoms].

Aliphatic epoxy compounds include polyglycidyl ethers of aliphatic polyols or their alkylene oxide adducts. More specifically, examples include: diglycidyl ether of 1,4-butanediol; diglycidyl ether of 1,6-hexanediol; triglycidyl ether of glycerol; triglycidyl ether of trihydroxymethylpropane; diglycidyl ether of polyethylene glycol; diglycidyl ether of propylene glycol; polyglycidyl ether of polyether polyols obtained by adding one or more alkylene oxides (ethylene oxide or propylene oxide) to aliphatic polyols such as ethylene glycol, propylene glycol or glycerol, etc.

Hydrogenated epoxy compounds are obtained by reacting alicyclic polyols obtained by hydrogenating aromatic rings of aromatic polyols with epichlorohydrin. Examples of aromatic polyols include bisphenol-type compounds such as bisphenol A, bisphenol F, and bisphenol S; phenolic novolac resins such as phenol novolac resins, cresol novolac resins, and hydroxybenzaldehyde phenol novolac resins; and polyfunctional compounds such as tetrahydroxydiphenylmethane, tetrahydroxydiphenyl ketone, and polyvinylphenol. Preferred examples of hydrogenated epoxy compounds include diglycidyl ether of hydrogenated bisphenol A.

The curable resin (X) may also contain (meth) acrylic compounds and the like while containing active energy line curable compounds such as epoxy compounds. By using (meth) acrylic compounds together, it is expected that the adhesion between the polarizing region 11 of the polarizer 10, the phase difference region 75 of the phase difference layer 71, and the cell region 55 of the reinforcing material 50 and the curable resin (X) forming the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76, the hardness and mechanical strength of the cured product of the curable resin (X) can be improved, and the viscosity and curing speed of the curable resin (X) can be adjusted more easily. "(Meth) acrylic acid" means at least one selected from the group consisting of acrylic acid and methacrylic acid.

The curable resin composition containing the curable resin (X) preferably contains a polymerization initiator. The polymerization initiator may be, for example, a cationic polymerization initiator such as a photo-cationic polymerization initiator or a free radical polymerization initiator. The photo-cationic polymerization initiator is a polymer that generates cationic species or Lewis acid by irradiation with active energy rays such as visible light, ultraviolet rays, X-rays, electron rays, etc., and initiates the polymerization reaction of the epoxy group. As described above, the curable resin (X) is preferably a UV-curable resin that is cured by irradiation with ultraviolet rays. Since the curable resin (X) preferably contains an alicyclic epoxy compound, the polymerization initiator in this case is preferably one that generates cationic species or Lewis acid by irradiation with ultraviolet rays.

The curable resin composition may further contain additives such as photosensitizers, polymerization accelerators, ion scavengers, antioxidants, chain transfer agents, thickeners, thermoplastic resins, fillers, flow regulators, plasticizers, defoamers, antistatic agents, and leveling agents.

(Filling material)

The filler material that can be provided in the reinforcing material 50 is not particularly limited as long as it is light-transmissive and can fill the internal space of the cell cavity 51 of the reinforcing material 50. The filler material is preferably a material different from the material constituting the cell cavity partition 53 of the reinforcing material 50, and more preferably contains a resin material. The resin material can be, for example, one or more selected from the group consisting of thermoplastic resins, thermosetting resins, active energy ray-curing resins, and other curable resins, and can also be an adhesive (pressure-sensitive adhesive) or a bonding agent.

Examples of thermoplastic resins include: polyolefin resins such as chain polyolefin resins (such as polypropylene resins) and cyclic polyolefin resins (such as norbornene resins); cellulose ester resins such as cellulose triacetate and cellulose diacetate; polyester resins such as polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate; polycarbonate resins; (meth) acrylic resins; polystyrene resins; polyether resins; polyurethane resins; polyamide resins, polyimide resins; fluorine resins, etc.

The hardening resin may be, for example, the hardening resin (X) mentioned above.

Adhesives are those that exhibit adhesion by attaching themselves to the adherend, that is, so-called pressure-sensitive adhesives. Adhesives may contain, for example, (meth)acrylic polymers, silicone polymers, polyester polymers, polyurethane polymers, polyether polymers, or rubber polymers as main components. In this specification, the so-called main component refers to a component that contains 50% by mass or more of the total solid content of the adhesive. Adhesives can be active energy ray-curing type or heat-curing type, and the degree of crosslinking or adhesion can be adjusted by active energy ray irradiation or heating.

Adhesives are adhesives other than pressure-sensitive adhesives (adhesives) that contain a curable resin component. Examples of adhesives include water-based adhesives made by dissolving or dispersing a curable resin component in water, active energy ray-curable adhesives containing active energy ray-curable compounds, and thermosetting adhesives.

Adhesives may also use water-based adhesives commonly used in the technical field of polarizing plates. Examples of resin components contained in water-based adhesives include polyvinyl alcohol resins and amine resins. Examples of active energy ray-curable adhesives include compositions that are cured by irradiation with active energy rays such as ultraviolet rays, visible light, electron rays, and X-rays. Active energy ray-curable adhesives may also use the above-mentioned curable resin composition containing the curable resin (X). Examples of thermosetting adhesives include those containing epoxy resins, silicone resins, phenolic resins, melamine resins, etc. as main components.

(Manufacturing method of polarizer composite (1))

Figures 7 and 8 are schematic cross-sectional views schematically showing an example of a method for manufacturing a polarizer composite of the present embodiment. Although Figures 7 and 8 show the situation of manufacturing the polarizer composite 40 shown in Figure 1 (a), the polarizer composite 40 shown in Figures 2 (b) and 2 (d) can also be manufactured by the method described below. The polarizer composite 40 can be manufactured, for example, using "a raw polarizer 20 (FIG. 7(a)) having the same visual sensitivity correction polarization (Py) as a whole and having no non-polarization area 12, a polymerized hardened layer 85 (FIG. 7(b)) as a raw phase difference layer and having a phase difference area as a whole, and a reinforcing material forming structure 58 (hereinafter sometimes referred to as "structure 58") formed on either the raw polarizer 20 or the polymerized hardened layer 85, which is composed of only the cell area 55 and has no non-cell area 56." In the following, although the structure 58 is formed on the raw polarizer 20 as an example for explanation, the structure 58 can also be formed on the polymerized hardened layer 85 belonging to the raw phase difference layer.

Since the raw polarizer 20 is formed only by the polarization region 11 of the polarizer 10, the thickness of the raw polarizer 20 is preferably the same thickness as the polarization region 11 of the polarizer 10, that is, less than 15μm. Since the polymerized hardened layer 85 will become the phase difference region 75 of the phase difference layer 71, the thickness of the polymerized hardened layer 85 is preferably the same thickness as the phase difference region 75 of the phase difference layer 71. Since the structure 58 will become the cell region 55 of the reinforcing material 50, the thickness of the structure 58 (the height of the cell 51) is preferably the same as the thickness of the cell region 55 of the reinforcing material 50 (the height of the cell 51).

The polarizer composite 40 can be manufactured, for example, by the following steps. First, a first support layer 25 is provided on one side of the raw polarizer 20 in a manner that is removable from the raw polarizer 20, and then a structure 58 is formed on the other side of the raw polarizer 20 to prepare the first laminate 31 (FIG. 7(a)). The structure 58 can be manufactured, for example, by using a resin material or an inorganic oxide to form a cell wall 53 that divides the cell 51 on the surface of the raw polarizer 20.

The method of using the resin material to form the cell cavity wall 53 is not particularly limited, and examples thereof include: printing methods such as inkjet printing, screen printing, and gravure printing; photoetching methods; coating methods using a nozzle or a mold, etc. In the above methods, a resin composition formed by mixing the resin material with a solvent, an additive, etc. can also be used. Additives can include: leveling agents, antioxidants, plasticizers, thickeners, organic or inorganic fillers, pigments, anti-aging agents, ultraviolet absorbers, antioxidants, etc. The cell cavity wall 53 can also be formed by curing or hardening the printed or coated resin composition as needed.

The method of using inorganic oxide to form the cell wall 53 is not particularly limited, and it can be formed, for example, by evaporating inorganic oxide.

The polymerizable liquid crystal compound is polymerized and cured on the substrate layer 84, and a polymerized cured layer 80 attached to the substrate layer is prepared to be formed on the substrate layer 84, with a polymerized cured layer 85 which is a phase difference region as a whole (Figure 7(b)).

The polymerized hardened layer 85 of the polymerized hardened layer 80 of the substrate layer is laminated on the structure 58 side of the prepared first laminate 31 through a bonding layer not shown in the figure (FIG. 7(c)). At this time, the bonding layer is preferably arranged in a manner that enters the inner space of the cell 51 of the structure 58 and the gaps between the plurality of cells 51. In this way, the second laminate 32 having the substrate layer 84, the polymerized hardened layer 85, the structure 58, the raw material polarizer 20, and the first support layer 25 laminated in sequence is obtained (FIG. 7(c)). For the second laminate 32, a through hole 33 (FIG. 7(d)) is formed in the lamination direction by punching, cutting, cutting, or laser cutting, and the first support layer 25 is peeled off to obtain a third laminate 34 (FIG. 8(a)). Thus, a polarizer 21 with an opening formed with a through hole 22 in the raw polarizer 20, a structure 59 with an opening formed with a through hole 52 in the structure 58, and a phase difference layer 81 with an opening formed with a through hole 72 in the polymerized hardening layer 85 are obtained.

Next, the second support layer 26 is stacked on the side of the polarizer 21 with openings of the third laminate 34 ( FIG. 8( b )), and the substrate layer 84 is peeled off ( FIG. 8( c )). The second support layer 26 is provided in a manner to seal one side of the through hole 22 of the polarizer 21 with openings. Then, a curable resin composition containing a curable resin (X) is filled in the through hole 22 of the polarizer 21 with openings, the through hole 52 of the structure 59 with openings, and the through hole 72 of the phase difference layer 81 with openings, and the curable resin (X) in the through hole 22, 52, 72 is cured by irradiating active energy rays, and a cured product of the curable resin (X) is formed in the through hole 22 of the polarizer 21 with openings, the through hole 52 of the structure 59 with openings, and the through hole 72 of the phase difference layer 81 with openings (FIG. 8(d)). Thus, a polarizer composite 40 is obtained on the second support layer 26. The polarizer composite 40 is formed by sequentially stacking the polarizer 10, the reinforcing material 50 and the phase difference layer 71 on the second support layer 26. The second support layer 26 can also be peeled off after the hardened material is formed. In the obtained polarizer 10, the area other than the through hole 22 of the polarizer 21 with an opening becomes the polarizing area 11, and the area with the through hole 22 of the hardened material becomes the non-polarizing area 12. In the obtained reinforcing material 50, the area other than the through hole 52 of the structure 59 with an opening becomes the cell area 55, and the area with the through hole 52 of the hardened material becomes the non-cell area 56. In the obtained phase difference layer 71, the area other than the through hole 72 of the phase difference layer 81 with opening becomes the phase difference area 75, and the area where the through hole 72 with the hardened material is provided becomes the non-phase difference area 76.

The polarizer composite 40 shown in FIG. 1 can be manufactured, for example, in the following manner, instead of the above method. Below, although the situation of obtaining the polarizer composite 40 shown in FIG. 1(a) is shown, the polarizer composite 40 shown in FIG. 2(a) and FIG. 2(c) can also be manufactured by the method described below. As shown in FIG. 7(c) and FIG. 7(d), for the second laminate 32, after forming a through hole 33 penetrating in the lamination direction by punching, cutting, cutting, or laser cutting, the substrate layer 84 is peeled off. Then, the third support layer is laminated on the side exposed by peeling off the substrate layer 84 (the side of the phase difference layer 81 with an opening), and the first support layer 25 is peeled off. Then, a curable resin composition containing a curable resin (X) is filled in the through hole 22 of the polarizer 21 with openings, the through hole 52 of the structure 59 with openings, and the through hole 72 of the phase difference layer 81 with openings, and the curable resin (X) in the through hole 22, 52, 72 is cured by irradiating active energy rays, and a cured product of the curable resin (X) is formed in the through hole 22 of the polarizer 21 with openings, the through hole 52 of the structure 59 with openings, and the through hole 72 of the phase difference layer 81 with openings. In this way, a polarizer composite 40 is obtained on the third support layer. The polarizer composite 40 is formed by sequentially stacking the phase difference layer 71, the reinforcing material 50, and the polarizer 10 on the third support layer. The third support layer can also be peeled off after the hardened material is formed.

The method of filling the through hole 22 of the polarizer 21 with openings, the through hole 52 of the structure 59 with openings, and the through hole 72 of the phase difference layer 81 with openings with the curable resin composition is not particularly limited. For example, the curable resin composition may be injected into the through hole 22, 52, 72 using a dispenser or a distributor, or the curable resin composition may be applied on the surface of the phase difference layer 81 with openings or on the surface of the polarizer 21 with openings while filling the through hole 22, 52, 72 with the curable resin composition. When the curable resin composition is applied on the surface of the polarizer 21 with openings and the through holes 22, 52, 72 are filled with the curable resin composition, the cured layer of the curable resin composition applied on the surface of the polarizer 21 with openings can be used as a protective layer described later. When the curable resin composition is applied, a base film can also be provided in a manner to cover the surface of the coating layer formed by the application. The base film can also be used as the protective layer described later. In this case, the cured layer of the curable resin (X) can also be used as a bonding layer for bonding the protective layer described later. The base film can also be peeled off after the curable resin (X) contained in the curable resin composition has hardened.

The first support layer 25 may be a support layer used in the manufacture of the raw polarizer 20 described later, or the above-mentioned substrate film used when applying the curable resin composition. Alternatively, it may be a removable support layer attached to the raw polarizer 20 by a volatile liquid such as water, or a removable adhesive sheet for the raw polarizer 20. The second support layer 26 may be a removable support layer attached to the polarizer 21 with an opening by a volatile liquid such as water, or a removable adhesive sheet for the polarizer 21 with an opening. The method of setting the third support layer and the fourth support layer may be listed as the method exemplified as the method of setting the first support layer 25 and the second support layer 26.

As described above, by making the thickness of the raw material polarizer 20 less than 15 μm, the depth of the through hole 22 provided in the polarizer 21 with an opening can also be made less than 15 μm. As described for the polarizer composite 40, the thickness of the layered structure portion of the polarizer composite 40 including the polarization region 11, the cell region 55, and the phase difference region 75 is preferably less than 30 μm, so the total thickness of the structure 58 and the polymerized hardened layer 85 belonging to the raw material phase difference layer is also preferably less than 15 μm. In this way, the total depth of the through holes 22, 52, and 72 can be set to less than 30 μm. Therefore, the filling of the curable resin composition in the through hole 22 of the polarizer 21 with openings, the through hole 52 of the structure 59 with openings, and the through hole 72 of the phase difference layer 81 with openings, and the curing treatment of the curable resin (X) contained in the curable resin composition filled in the through holes 22, 52, 72 can be performed in a short time, so the reduction of workability can be suppressed.

(Manufacturing method of polarizer composite (2))

FIG9 and FIG10 are schematic cross-sectional views schematically showing another example of the method for manufacturing the polarizer composite of the present embodiment. FIG9 and FIG10 show the situation in which the polarizer composite 41 shown in FIG4 is manufactured. The polarizer composite 41 can be manufactured using the second laminate 32 (FIG. 7(c)) obtained by the method for manufacturing the polarizer composite 40. First, the first support layer 25 (FIG. 9(a)) is peeled off from the second laminate 32 shown in FIG7(c), and a structure 58 is formed on the exposed surface (the surface on the polarizer 10 side) exposed by the peeling. The structure 58 can be formed by the method described above. Thus, a fourth laminate 35 (FIG. 9(b)) is obtained, which is sequentially laminated with a substrate layer 84, a polymerized hardened layer 85, a structure 58, a raw polarizer 20, and a structure 58. For the fourth laminate 35, a through hole 36 is formed in the lamination direction by punching, cutting, cutting, or laser cutting (FIG. 9(c)). Thus, a polarizer 21 with an opening having a through hole 22 formed in the raw polarizer 20, a structure 59 with an opening having a through hole 52 formed in two structures 58, and a phase difference layer 81 with an opening having a through hole 72 formed in the polymerized hardened layer 85 are obtained.

The fourth support layer 27 is laminated on the side of the structure 59 with openings (the side opposite to the phase difference layer 81 with openings) of the fourth laminate 35 having the through hole 36 ( FIG. 10( a )). The fourth support layer 27 is provided to seal one side of the through hole 52 of the structure 59 with openings. Then, the substrate layer 84 is peeled off (FIG. 10(b)), and a curable resin composition containing a curable resin (X) is filled in the through hole 22 of the polarizer 21 with openings, the through holes 52 of the two structures 59 with openings, and the through holes 72 of the phase difference layer 81 with openings, and the curable resin (X) in the through holes 22, 52, 72 is cured by irradiating active energy rays, thereby forming a cured product of the curable resin (X) in the through holes 22 of the polarizer 21 with openings, the through holes 52 of the two structures 59 with openings, and the through holes 72 of the phase difference layer 81 with openings (FIG. 10(c)). Thus, a polarizer composite 41 is obtained on the fourth support layer 27. The polarizer composite 41 is formed by sequentially stacking a reinforcing material 50, a polarizer 10, a reinforcing material 50, and a phase difference layer 71 on a fourth support layer 27. The fourth support layer 27 may be peeled off after forming a hardened material. In the obtained polarizer 10, the region other than the through hole 22 of the polarizer 21 with an opening becomes the polarizing region 11, and the region with the through hole 22 provided with the hardened material becomes the non-polarizing region 12. In the obtained reinforcing material 50, the region other than the through hole 52 of the structure 59 with an opening becomes the cell region 55, and the region with the through hole 52 provided with the hardened material becomes the non-cell region 56. In the obtained phase difference layer 71, the area other than the through hole 72 of the phase difference layer 81 with openings becomes the phase difference area 75, and the area with the through hole 72 provided with the hardened material becomes the non-phase difference area 76. Then, the non-polarizing area 12 located in the polarizer 10, the non-cell area 56 located in the reinforcement material 50, and the non-phase difference area 76 located in the phase difference layer 71 are interconnected.

The method of filling the through hole 22 of the polarizer 21 with openings, the through hole 52 of the two structures 59 with openings, and the through hole 72 of the phase difference layer 81 with openings with the curable resin composition can be listed as the filling method described in the manufacturing method of the polarizer composite 40. The method of setting the fourth support layer 27 can be listed as the method exemplified as the method of setting the first support layer 25 and the second support layer 26.

(Manufacturing method of polarizer composite (3))

FIG. 11 and FIG. 12 are schematic cross-sectional views schematically showing another example of the manufacturing method of the polarizer composite of the present embodiment. FIG. 11 and FIG. 12 show the situation of manufacturing the polarizer composite 42 shown in FIG. 5. The polarizer composite 42 can be manufactured, for example, using a raw material polarizer 20 (FIG. 11(a)) having the same visual sensitivity correction polarization degree (Py) as a whole and having no non-polarizing area 12, and a polymerized hardened layer 85 (FIG. 11(b)) as a raw material phase difference layer having a phase difference area as a whole. The raw material polarizer 20, the polymerized hardened layer 85, and the structure 58 are as described above.

The polarizer composite 42 can be manufactured, for example, by the following steps. First, a first support layer 25 is provided on one side of a raw polarizer 20 in a manner that is removable from the raw polarizer 20 (FIG. 11(a)). A polymerizable liquid crystal compound is polymerized and cured on a substrate layer 84, and a substrate-attached polymerized cured layer 80 is prepared in which a polymerized cured layer 85 that is a phase difference region as a whole is formed on the substrate layer 84 (FIG. 11(b)). On the side of the polymerized cured layer 85 of the substrate-attached polymerized cured layer 80, which is laminated on the raw polarizer 20 on the first support layer 25 via a bonding layer not shown in the figure (FIG. 11(c)), the substrate layer 84 is peeled off (FIG. 11(d)). The structure 58 is formed on the surface exposed by peeling off the substrate layer 84 (the surface on the polymerized hardened layer 85 side) (Figure 11 (e)). The structure 58 can be formed by the method described above. In this way, the fifth laminate 37 (Figure 11 (e)) is obtained, which is laminated with the structure 58, the polymerized hardened layer 85, the raw material polarizer 20, and the first support layer 25 in sequence.

For the fifth laminate 37, a through hole 38 is formed in the lamination direction by punching, cutting, cutting, or laser cutting (Fig. 12(a)). Thus, a polarizer 21 with an opening having a through hole 22 formed in the raw polarizer 20, a phase difference layer 81 with an opening having a through hole 72 formed in the polymerized hardening layer 85, and a structure 59 with an opening having a through hole 52 formed in the structure 58 are obtained. The fifth support layer 28 is laminated on the side of the structure 59 with an opening of the fifth laminate 37 with the through hole 38 formed therein (the opposite side of the phase difference layer 81 with an opening) (Fig. 12(b)). The fifth support layer 28 is provided in a manner to seal one side of the through hole 72 of the phase difference layer 81 having an opening.

Then, the first support layer 25 is peeled off (FIG. 12(c)), and a hardening resin composition containing a hardening resin (X) is filled in the through hole 22 of the polarizer 21 with openings, the through hole 72 of the phase difference layer 81 with openings, and the through hole 52 of the structure 59 with openings, and the hardening resin (X) in the through hole 22, 72, 52 is hardened by irradiating active energy rays, and a hardened material of the hardening resin (X) is formed in the through hole 22 of the polarizer 21 with openings, the through hole 72 of the phase difference layer 81 with openings, and the through hole 52 of the structure 59 with openings (FIG. 12(d)). Thus, a polarizer composite 42 is obtained on the fifth support layer 28. The polarizer composite 42 is formed by sequentially stacking a reinforcing material 50, a phase difference layer 71, and a polarizer 10 on a fifth support layer 28. The fifth support layer 28 may be peeled off after forming a hardened material. In the obtained polarizer 10, the region other than the through hole 22 of the polarizer 21 with an opening becomes the polarizing region 11, and the region with the through hole 22 provided with the hardened material becomes the non-polarizing region 12. In the obtained reinforcing material 50, the region other than the through hole 52 of the structure 59 with an opening becomes the cell region 55, and the region with the through hole 52 provided with the hardened material becomes the non-cell region 56. In the obtained phase difference layer 71, the area other than the through hole 72 of the phase difference layer 81 with opening becomes the phase difference area 75, and the area where the through hole 72 with the hardened material is provided becomes the non-phase difference area 76.

The method of filling the through hole 22 of the polarizer 21 with openings, the through hole 72 of the phase difference layer 81 with openings, and the through hole 52 of the structure 59 with openings with the curable resin composition can be listed as the filling method described in the manufacturing method of the polarizer composite (1). The method of setting the fifth support layer 28 can be listed as the method exemplified as the method of setting the first support layer 25 and the second support layer 26.

(Manufacturing method of polarizer composite (4))

FIG. 13 and FIG. 14 are schematic cross-sectional views schematically showing another example of the method for manufacturing the polarizer composite of the present embodiment. FIG. 13 and FIG. 14 show the situation in which the polarizer composite 43 shown in FIG. 6 is manufactured. The polarizer composite 43 can be manufactured using the fifth laminate 37 (FIG. 11(e)) obtained by the method for manufacturing the polarizer composite 42. First, the sixth support layer 29 is laminated on the side of the structure 58 of the fifth support layer 28 shown in FIG. 11(e) (FIG. 13(a)), and then the first support layer 25 is peeled off (FIG. 13(b)). The structure 58 is formed on the exposed surface (the surface on the polarizer 10 side) exposed by this peeling. The structure 58 can be formed by the method described above. Thus, a sixth laminate 39 (FIG. 13(c)) is obtained, which is sequentially laminated with a sixth support layer 29, a structure 58, a polymerized hardened layer 85, a raw polarizer 20, and a structure 58. A through hole 91 is formed in the lamination direction by punching, cutting, cutting, or laser cutting (FIG. 13(d)). Thus, a structure 59 with openings having through holes 52 formed in two structures 58, a polarizer 21 with openings having through holes 22 formed in the raw polarizer 20, and a phase difference layer 81 with openings having through holes 72 formed in the polymerized hardened layer 85 is obtained.

In the sixth laminate 39 formed with the through hole 91, the seventh support layer 92 is laminated on the side of the structure 59 with the opening which is arranged on the side of the polarizer 21 with the opening opposite to the phase difference layer 81 with the opening (FIG. 14(a)). The seventh support layer 92 is arranged in a manner to seal one side of the through hole 52 of the structure 59 with the opening. Then, the sixth support layer 29 is peeled off (FIG. 14(b)), and a hardening resin composition containing a hardening resin (X) is filled in the through holes 52 of the two structures 59 with openings, the through holes 22 of the polarizer 21 with openings, and the through holes 72 of the phase difference layer 81 with openings, and the hardening resin (X) in the through holes 52, 22, 72 is hardened by irradiating active energy rays, and a hardened material of the hardening resin (X) is formed in the through holes 52 of the two structures 59 with openings, the through holes 22 of the polarizer 21 with openings, and the through holes 72 of the phase difference layer 81 with openings (FIG. 14(c)). Thus, a polarizer composite 43 is obtained on the seventh support layer 92. The polarizer composite 43 is a composite of a reinforcing material 50, a polarizer 10, a phase difference layer 71, and a reinforcing material 50 stacked in sequence on a seventh support layer 92. The seventh support layer 92 may be peeled off after forming a hardened material. In the obtained polarizer 10, the area other than the through hole 22 of the polarizer 21 with an opening becomes the polarizing area 11, and the area with the through hole 22 provided with the hardened material becomes the non-polarizing area 12. In the obtained two reinforcing materials 50, the area other than the through hole 52 of the structure 59 with an opening becomes the cell area 55, and the area with the through hole 52 provided with the hardened material becomes the non-cell area 56. In the obtained phase difference layer 71, the area other than the through hole 72 of the phase difference layer 81 with opening becomes the phase difference area 75, and the area where the through hole 72 with the hardened material is provided becomes the non-phase difference area 76.

The method of filling the through holes 52 of the two structures 59 with openings, the through holes 22 of the polarizer 21 with openings, and the through holes 72 of the phase difference layer 81 with openings with the curable resin composition can be listed as the filling method described in the method for manufacturing the polarizer composite (1). The method of setting the sixth support layer 29 and the seventh support layer 92 can be listed as the method exemplified as the method for setting the first support layer 25 and the second support layer 26.

(Raw polarizer)

The raw polarizer 20 is preferably one that is not easily deteriorated significantly by the active energy rays irradiated to cure the curable resin (X) in the curable resin composition filled in the through hole 22. Such a raw polarizer 20 is, for example, a film formed by adsorbing and aligning a dichroic pigment on a polyvinyl alcohol resin film, or a film formed by aligning a dichroic pigment in a curing layer of a polymerizable liquid crystal compound. The manufacturing method of these is as described in the above-mentioned polarization region 11.

(Raw material phase difference layer)

The raw phase difference layer is composed of a phase difference region having a phase difference characteristic as a whole. The raw phase difference layer may have, for example, the phase difference characteristic of the phase difference region 75 described above. The raw phase difference layer may have, for example, a phase difference characteristic that functions as a 1/4 wavelength plate, a 1/2 wavelength plate, a 1/4 wavelength plate with reverse wavelength dispersion, or a positive C plate.

The raw material phase difference layer is, for example, a stretched film formed by uniaxially stretching or biaxially stretching a thermoplastic resin, or a polymerized and cured layer of a polymerizable liquid crystal compound.

The thermoplastic resin constituting the stretched film is preferably a light-transmitting (preferably optically transparent) thermoplastic resin. Specifically, the following can be cited: polyolefin resins such as chain polyolefin resins (polyethylene resins, polypropylene resins, etc.), cyclic polyolefin resins (norbornene resins, etc.); cellulose ester resins such as cellulose triacetate, cellulose diacetate, cellulose acetate propionate, cellulose acetate butyrate; polyethylene terephthalate, polyethylene glycol ester, polyisocyanate ... Polyester resins such as butylene phthalate, polyethylene naphthalate, polybutylene naphthalate, polytrimethylene terephthalate, polytrimethylene naphthalate, polycyclohexane dimethyl terephthalate, polycyclohexane dimethyl naphthalate; polycarbonate resins; (meth) acrylic resins; polystyrene resins; or mixtures and copolymers thereof.

The polymerizable liquid crystal compound constituting the polymerized curing layer is a compound having a polymerizable reactive group and exhibiting liquid crystal properties. The polymerizable reactive group can be exemplified by the polymerizable reactive groups exemplified in the raw material polarizer. The type of polymerizable liquid crystal compound is not particularly limited, and rod-shaped liquid crystal compounds, disc-shaped liquid crystal compounds, and mixtures thereof can be used. The liquid crystal properties of the polymerizable liquid crystal compound can be thermotropic liquid crystal or lyotropic liquid crystal; in terms of phase regular structure, it can be nematic liquid crystal or lamellar liquid crystal.

The raw phase difference layer can be formed by the following methods: [v] For example, a phase difference layer forming composition containing a polymerizable liquid crystal compound is applied on an alignment layer formed on a substrate film, and the polymerizable liquid crystal compound is polymerized and hardened; [vi] A phase difference layer forming composition is applied on a substrate layer to form a coating film, and the coating film is extended together with the substrate layer. The substrate layer can be the substrate film used in the above [ii] described in the raw polarizer.

The stretched film and polymerized hardened layer constituting the raw phase difference layer may be, for example, the phase difference layer described in International Publication No. 2018/003416.

(Structural body for forming reinforcement material (structural body))

The structure 58 is a structure composed only of the cell cavity region 55 and does not have the non-cell cavity region 56. The structure 58 can be obtained by using a resin material or an inorganic oxide to form a cell cavity partition 53 that divides the cell cavity 51 as described above. The materials that can be used as the resin material and the inorganic oxide, and the method of forming the cell cavity partition 53 using the same, can be exemplified by the materials and methods exemplified above.

<Optical layered body>

Figures 15 to 18 are schematic cross-sectional views schematically showing an example of an optical laminate of the present embodiment. The optical laminate is a laminate having a protective layer on one side or both sides of the polarizer complex 40 to 43 shown in Figures 1 and 4 to 5.

(Optical layered structure (1))

The optical laminate 45 shown in FIG15 has protective layers 17 and 18 on both sides of the polarizer composite 40 shown in FIG1(a). The optical laminate 45 may also have the protective layer 17 (or 18) only on one side of the polarizer composite 40. The polarizer composite 40 included in the optical laminate 45 may also be the polarizer composite 40 shown in FIG2(a) or FIG2(d). The protective layers 17 and 18 may be provided on the polarizer composite 40 via a bonding layer such as an adhesive layer or a bonding agent layer. In this case, for example, a thin film-like protective layer may be laminated on the polarizer composite 40 via a bonding layer. The protective layers 17 and 18 can also be directly connected to the polarizer composite 40 without passing through the bonding layer. In this case, for example, the protective layers 17 and 18 can be formed by coating a composition containing a resin material constituting the protective layers 17 and 18 on the polarizer composite 40 and curing or hardening the coating layer.

When the optical laminate 45 is a laminate in which the protective layer 17 is disposed on the polarizer 10 side of the polarizer composite 40 shown in FIG. 2(a) or FIG. 2(c) via a bonding layer, it is preferred to provide the protective layer 17 by providing the bonding layer in a manner that fills the thickness difference between the polarizing region 11 and the non-polarizing region 12 of the polarizer 10. When the optical laminate 45 is a laminate in which the protective layer 18 is disposed on the polarizer 10 side of the polarizer composite 40 shown in FIG. 2(b) or FIG. 2(d) via a bonding layer, it is preferred to provide the protective layer 18 by providing the bonding layer in a manner that fills the thickness difference between the polarizing region 11 and the non-polarizing region 12 of the polarizer 10.

When the optical laminate 45 is a structure in which the protective layer 18 is directly disposed on the phase difference layer 71 side of the polarizer composite 40 shown in Figure 2(a) or 2(c), it is preferred to form the protective layer 18 by disposing a composition containing a resin material constituting the protective layer 18 in a manner that fills the thickness difference between the phase difference region 75 and the non-phase difference region 76 of the phase difference layer 71. When the optical laminate 45 is a structure in which the protective layer 18 is directly disposed on the phase difference layer 71 side of the polarizer composite 40 shown in FIG. 2(b) or FIG. 2(d), it is preferred to form the protective layer 18 by disposing a composition containing a resin material constituting the protective layer 18 in a manner that fills the thickness difference between the phase difference region 75 and the non-phase difference region 76 of the phase difference layer 71.

In the optical laminate 45, the protective layer 17 may also be a hardened material layer of a hardening resin (X) directly disposed on the polarizer 10. The hardening resin (X) constituting the protective layer 17 belonging to the hardening material layer may be a resin that can be hardened by irradiation with active energy rays such as ultraviolet rays, visible light, electron rays, and X-rays, and is not particularly limited, and may be, for example, the hardening resin (X) described above. The protective layer 17 is preferably a hardening material layer of the same hardening resin (X) as the hardening material contained in the non-polarizing region 12, the non-cell region 56, and the non-phase difference region 76.

When the protective layer 17 is a cured material layer of the same curable resin (X) as the cured material (X) constituting the polarizer 10, the reinforcing material 50, and the phase difference layer 71, the protective layer 17 preferably covers at least the non-polarizing area 12 of the polarizer 10. Although the protective layer 17 only needs to cover at least a portion of a single surface of the polarizer 10, it is preferred to cover the entire single surface of the polarizer 10.

In order to manufacture the optical laminate 45, for example, a curable resin composition is applied to the polarizer 10 side of the polarizer composite 40, and the curable resin (X) (together with the curable resin (X) filled in the through hole 22 of the polarizer 21 with openings, the through hole 52 of the structure 59 with openings, and the through hole 72 of the phase difference layer 81 with openings) is cured by irradiating active energy rays. In this way, a protective layer 17 belonging to the cured material layer of the curable resin (X) can be formed on the polarizer 10 to obtain the optical laminate 45.

Alternatively, in the step of manufacturing the polarizer composite 40, a curable resin (X) is coated on the surface of the polarizer 21 with an opening, thereby filling the through holes 72 of the phase difference layer 81 with an opening, the through holes 52 of the structure 59 with an opening, and the through holes 22 of the polarizer 21 with an opening with the curable resin composition, and also forming a coating layer of the curable resin composition on the surface of the polarizer 21 with an opening. Afterwards, the curable resin (X) contained in the curable resin composition in the through hole 72 of the phase difference layer 81 with openings, the through hole 52 of the structure 59 with openings, the through hole 22 of the polarizer 21 with openings, and on the polarizer 21 with openings can be cured by irradiation with active energy rays to form a cured product and a protective layer 17 belonging to the cured product layer, thereby obtaining an optical laminate 45. In this case, the hardened material contained in the non-phase difference region 76, the non-polarization region 12, and the non-cell region 56 can be integrated with the hardened material layer constituting the protective layer 17, and the hardened material of the curable resin (X) constituting the protective layer 17 can be set to be the same as the hardened material contained in the non-phase difference region 76, the non-polarization region 12, and the non-cell region 56.

(Optical layered structure (2))

The optical laminate 46 shown in FIG16 has protective layers 17 and 18 on both sides of the polarizer composite 41 shown in FIG4. The optical laminate 46 may also have the protective layer 17 (or 18) on only one side of the polarizer composite 41. The protective layers 17 and 18 may be disposed on the polarizer composite 41 via a bonding layer such as an adhesive layer or a bonding agent layer, or may be disposed on the polarizer composite 41 in a directly connected manner without a bonding layer. The method of setting the protective layers 17 and 18 on the polarizer composite 41 can be carried out in the same manner as the method of setting the protective layers 17 and 18 on the polarizer composite 40 in the optical laminate 45 shown in FIG. 15 above.

When the optical laminate 46 is a laminate in which the protective layer 17 is disposed on the side of the reinforcing material 50 of the polarizer composite 41 via a bonding layer, it is preferred to form the protective layer 17 by disposing the bonding layer in a manner such that the internal space of the cell cavity 51 of the reinforcing material 50 and the gaps between the plurality of cell cavities 51 are filled. When the optical laminate 46 is a laminate in which the protective layer 17 is disposed on the side of the reinforcing material 50 of the polarizer composite 40 in a directly connected manner, it is preferred to form the protective layer 17 by disposing a composition containing a resin material constituting the protective layer 17 in a manner such that the internal space of the cell cavity 51 of the reinforcing material 50 and the gaps between the plurality of cell cavities 51 are filled.

(Optical layered structure (3))

The optical laminate 47 shown in FIG. 17 has protective layers 17 and 18 on both sides of the polarizer composite 42 shown in FIG. 5. The optical laminate 47 may also have the protective layer 17 (or 18) on only one side of the polarizer composite 42. The protective layers 17 and 18 may be disposed on the polarizer composite 42 via a bonding layer such as an adhesive layer or a bonding agent layer, or may be disposed on the polarizer composite 42 in a directly connected manner without a bonding layer. The method of setting the protective layers 17 and 18 on the polarizer composite 42 can be carried out in the same steps as the method of setting the protective layers 17 and 18 on the polarizer composites 40 and 41 in the optical laminates 45 and 46 shown in the above-mentioned Figures 15 and 16.

(Optical layered structure (4))

The optical laminate 48 shown in FIG18 has protective layers 17 and 18 on both sides of the polarizer composite 43 shown in FIG6. The optical laminate 48 may also have the protective layer 17 (or 18) on only one side of the polarizer composite 43. The protective layers 17 and 18 may be disposed on the polarizer composite 43 via a bonding layer such as an adhesive layer or a bonding agent layer, or may be disposed on the polarizer composite 43 in a directly connected manner without a bonding layer. The method of setting the protective layers 17 and 18 on the polarizer composite 43 can be carried out in the same manner as the method of setting the protective layers 17 and 18 on the polarizer composites 40 to 42 in the optical laminates 45 to 47 shown in FIGS. 15 to 17 above.

When the protective layer 17 (or 18) disposed on a single side of the polarizer composite 40 to 43 is a layer disposed in direct contact with the polarizer composite 40 to 43, the protective layer 17 (or 18) can be set as a hardened material layer of the same hardened resin (X) as the hardened material contained in the non-phase difference area 76, the non-polarizing area 12 and the non-cell cavity area 56 constituting the polarizer composite 40 to 43. In this case, when manufacturing the polarizer composites 40 to 43, if the curable resin composition is filled in the through holes 72 of the phase difference layer with an opening 81, the through holes 52 of the structure with an opening 59, and the through holes 22 of the polarizer 21 with an opening, and the curable resin composition coated on the surface of the phase difference layer with an opening 81, the polarizer 21 with an opening, and the structure with an opening 59 is cured to form a cured layer, the cured layer can be used as the protective layer 17 (or 18). Thus, the hardened material contained in the non-phase difference region 76, the non-polarization region 12, and the non-cell region 56 can be integrated with the hardened material layer constituting the protective layer 17 (or 18), and the hardening resin (X) constituting the protective layer 17 (or 18) can be the same as the hardening resin (X) constituting the non-phase difference region 76, the non-polarization region 12, and the non-cell region 56.

In the optical laminates 45 to 48 shown in FIGS. 15 to 18 , one of the protective layers 17 and 18 may be a protective layer provided via a bonding layer, and the other may be a protective layer provided without a bonding layer. The protective layers 17 and 18 included in the optical laminates 45 to 48 may be the same as each other or different from each other.

When applying the curable resin (X), a base film can be provided to cover the surface of the coating layer formed by the application. In this case, the base film can also be used as the protective layer 17, 18, and the cured layer of the curable resin (X) can be used as a bonding layer for bonding the protective layer 17, 18 to the polarizer composite 40 to 43. The base film can also be peeled off after the curable resin (X) is cured.

(Protective layer)

The protective layers 17 and 18 are preferably light-transmissive resin layers, resin films, or coating layers formed by coating a composition containing a resin material. The resin used in the resin layer is preferably a thermoplastic resin with excellent transparency, mechanical strength, thermal stability, moisture barrier, isotropy, and elongation. Thermoplastic resins can be, for example, thermoplastic resins that can be used to form a substrate film in the manufacture of the above-mentioned raw polarizer 20. When the optical laminates 45 to 48 have protective layers 17 and 18 on both sides, the resin compositions of the protective layers 17 and 18 can be the same or different from each other.

From the perspective of thinning, the thickness of the protective layers 17 and 18 is usually less than 200 μm, preferably less than 150 μm, more preferably less than 100 μm, less than 80 μm, or less than 60 μm. The thickness of the protective layers 17 and 18 is usually more than 5 μm, more than 10 μm, or more than 20 μm. The protective layers 17 and 18 may have a phase difference or may not have a phase difference. When the optical laminates 45 to 48 have the protective layers 17 and 18 on both sides, the thickness of the protective layers 17 and 18 may be the same or different.

(bonding layer)

The bonding layer is an adhesive layer or a bonding agent layer. The adhesive used to form the adhesive layer and the bonding agent used to form the bonding agent layer can be, for example, the adhesive and bonding agent used to form the above-mentioned filler.

<Laminated body with bonding layer for optical display element>

The polarizer complexes 40 to 43 shown in FIGS. 1 to 6 and the optical laminates 45 to 48 shown in FIGS. 15 to 18 may further have a bonding layer for an optical display element, and the bonding layer for an optical display element is used to bond to an optical display element (liquid crystal panel, organic EL element) of a display device such as a liquid crystal display device or an organic EL display device.

When a bonding layer for an optical display element is provided on a surface where a thickness difference is generated between the polarizing region 11 and the non-polarizing region 12, or between the phase difference region 75 and the non-phase difference region 76, as in the polarizer composite 40 shown in FIG. 2(a) to FIG. 2(d), it is preferred to provide the bonding layer for an optical display element in a manner that fills the thickness difference.

In the polarizer complexes 41 to 43 and the optical laminates 46 to 48, when the bonding layer for the optical display element is set on the surface of the reinforcing material 50, the material constituting the bonding layer for the optical display element can be used as the filling material set on the reinforcing material 50, and the filling of the filling material in the internal space of the cell cavity 51 of the reinforcing material 50 and the formation of the bonding layer for the optical display element are performed at the same time.

10: Polarizer

11: Polarization area

12: Non-polarized area

22: Perforation

40: Polarizer composite

50: Reinforcement material

51:Cell cavity

52: Perforation

53: Cell wall

55:Cellular region

56: Non-luminal region

71: Phase difference layer

72: Perforation

75: Phase difference area

76: Non-phase difference area

Claims (19)

A polarizer composite comprises a polarizer, a phase difference layer and a reinforcing material, wherein the polarizer has a polarizing region with a thickness of less than 15 μm and a non-polarizing region surrounded by the polarizing region when viewed from above, the phase difference layer has a phase difference region and a non-phase difference region, the phase difference region has a phase difference characteristic and exists in a region corresponding to the polarizing region, and the non-phase difference region does not have a phase difference characteristic and exists in a region corresponding to the non-polarizing region; the reinforcing material has a plurality of cavities with open end faces, and each open end face is arranged in a manner opposite to the surface of the polarizer, and ... The reinforcing material has a cell region and a non-cell region, the cell region has the aforementioned cell and the cell region exists in a region corresponding to the aforementioned polarization region, the non-cell region does not have the aforementioned cell and the non-cell region exists in a region corresponding to the aforementioned non-polarization region, the aforementioned non-polarization region, the aforementioned non-phase difference region and the aforementioned non-cell region contain a hardened material of an active energy ray hardening resin, the aforementioned hardened material contained in the aforementioned non-polarization region is provided with a through hole surrounded by the aforementioned polarization region when viewed from above, and the aforementioned hardened material contained in the aforementioned non-phase difference region is provided with a through hole surrounded by the aforementioned phase difference region when viewed from above. The polarizer composite as described in claim 1, wherein the reinforcing material is disposed on one side of the polarizer, and the phase difference layer is provided on the side of the reinforcing material opposite to the polarizer. The polarizer composite as described in claim 1, wherein the phase difference layer is disposed on one side of the polarizer, and the reinforcing material is provided on the side of the phase difference layer opposite to the polarizer. The polarizer composite as described in claim 2 or 3 further has the aforementioned reinforcing material on the other side of the aforementioned polarizer. A polarizer composite as described in any one of claims 1 to 3, wherein the thickness of the hardened material is the same as the thickness of the layered structure portion of the polarizer composite including the polarization region, the phase difference region, and the cell region. A polarizer composite as described in any one of claims 1 to 3, wherein the thickness of the cured product is less than the thickness of the layered structure portion of the polarizer composite including the polarization region, the phase difference region, and the cell region. A polarizer composite as described in any one of claims 1 to 3, wherein the thickness of the cured product is greater than the thickness of the layered structure portion of the polarizer composite including the polarization region, the phase difference region, and the cell region. A polarizer composite as described in any one of claims 1 to 3, wherein the phase difference region is a polymerized hardened layer of a polymerizable liquid crystal compound. A polarizer composite as described in any one of claims 1 to 3, wherein the non-polarizing area is light-transmissive. A polarizer composite as described in any one of claims 1 to 3, wherein the diameter of the non-polarizing area when viewed from above is greater than 0.5 mm and less than 20 mm. A polarizer composite as described in any one of claims 1 to 3, wherein the active energy ray-curable resin contains an epoxy compound. The polarizer composite as described in claim 11, wherein the epoxy compound comprises an alicyclic epoxy compound. A polarizer composite as described in any one of claims 1 to 3, wherein the shape of the opening of the aforementioned open end face of the aforementioned cell cavity is polygonal, circular or elliptical. The polarizer composite as described in any one of claims 1 to 3 further has a light-transmitting filling material disposed in the internal space of the aforementioned cell cavity. An optical laminate having a protective layer on one or both sides of the polarizer composite described in any one of claims 1 to 14. The optical laminate as described in claim 15, wherein the protective layer disposed on one side of the polarizer composite is an active energy ray-curable resin, and the active energy ray-curable resin is the same as the active energy ray-curable resin of the aforementioned cured product included in the aforementioned non-polarizing region, the aforementioned non-phase difference region, and the aforementioned non-cell region. The optical laminate as described in claim 15, wherein the protective layer is a resin film. The optical laminate as described in claim 15, wherein the protective layer covers the entire single surface of the polarizer. The optical laminate as described in claim 15, wherein the protective layer is laminated on the polarizer only through an adhesive layer or laminated on the polarizer only through a bonding agent layer.

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