CN113167940B - Antiglare film, process for producing antiglare film, optical member, and image display - Google Patents

Antiglare film, process for producing antiglare film, optical member, and image display Download PDF

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CN113167940B
CN113167940B CN201980078387.3A CN201980078387A CN113167940B CN 113167940 B CN113167940 B CN 113167940B CN 201980078387 A CN201980078387 A CN 201980078387A CN 113167940 B CN113167940 B CN 113167940B
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antiglare
layer
film
antiglare layer
antiglare film
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CN113167940A (en
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平冈慎哉
桥本尚树
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Nitto Denko Corp
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Nitto Denko Corp
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    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/02Diffusing elements; Afocal elements
    • G02B5/0273Diffusing elements; Afocal elements characterized by the use
    • G02B5/0294Diffusing elements; Afocal elements characterized by the use adapted to provide an additional optical effect, e.g. anti-reflection or filter
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/11Anti-reflection coatings
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/02Diffusing elements; Afocal elements
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/02Diffusing elements; Afocal elements
    • G02B5/0205Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/021Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place at the element's surface, e.g. by means of surface roughening or microprismatic structures
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/02Diffusing elements; Afocal elements
    • G02B5/0205Diffusing elements; Afocal elements characterised by the diffusing properties
    • G02B5/0236Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element
    • G02B5/0242Diffusing elements; Afocal elements characterised by the diffusing properties the diffusion taking place within the volume of the element by means of dispersed particles
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/02Diffusing elements; Afocal elements
    • G02B5/0268Diffusing elements; Afocal elements characterized by the fabrication or manufacturing method
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/30Polarising elements
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/30Polarising elements
    • G02B5/3025Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
    • G02B5/3033Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1335Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133502Antiglare, refractive index matching layers
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1335Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/133528Polarisers
    • GPHYSICS
    • G09EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09FDISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F9/00Indicating arrangements for variable information in which the information is built-up on a support by selection or combination of individual elements

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Nonlinear Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Mathematical Physics (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Dispersion Chemistry (AREA)
  • Theoretical Computer Science (AREA)
  • Optical Elements Other Than Lenses (AREA)
  • Devices For Indicating Variable Information By Combining Individual Elements (AREA)
  • Liquid Crystal (AREA)

Abstract

Provided is an antiglare film capable of suppressing reflection glare. An antiglare film (10) is characterized in that an antiglare layer (B) (12) is laminated on a light-transmitting substrate (A) (11), and a concave-convex pattern satisfying the following expressions (1) and (2) is formed on the outermost surface of the antiglare layer (B) (12) side in the antiglare film (10). Ry is not less than 1 (1) θa is not less than 0.7 (2) in the formula (1), ry is the maximum height [ mu ] m of the convex part of the concave-convex, and in the formula (2), θa is the average inclination angle [ DEG ] of the concave-convex.

Description

Antiglare film, process for producing antiglare film, optical member, and image display
Technical Field
The invention relates to an antiglare film, a method for producing the antiglare film, an optical member, and an image display device.
Background
As various image display devices such as cathode ray tube display devices (CRTs), liquid crystal display devices (LCDs), plasma Display Panels (PDPs), and electroluminescence displays (ELDs), antiglare (anti-glare) treatments for preventing contrast degradation caused by reflection of external light such as fluorescent lamps and sunlight and reflection glare (reflected glare) of images on the surfaces of the image display devices are being carried out, and particularly, as the size of the image display devices increases, image display devices equipped with antiglare films are also increasing.
There are many documents describing antiglare films, for example, patent documents 1 and 2.
Prior art literature
Patent literature
Patent document 1 Japanese patent laid-open No. 2009-109683
Patent document 2 Japanese patent laid-open No. 2003-202416
Disclosure of Invention
Problems to be solved by the invention
From the viewpoint of visual recognition, the antiglare film is required to be capable of suppressing reflection glare caused by reflection of external light.
For example, public Information Displays (PIDs) have been increasingly demanded in recent years. PID is also often used outdoors. When a display (image display device) is used outdoors, reflection glare caused by reflection of external light is more likely to occur than when it is used indoors. When reflection glare occurs, there is a fear that the image becomes difficult to visually recognize.
Accordingly, an object of the present invention is to provide an antiglare film capable of suppressing reflection glare, a method for producing the antiglare film, an optical member, and an image display apparatus.
Solution for solving the problem
In order to achieve the above object, the antiglare film of the present invention is characterized in that an antiglare layer (B) is laminated on a light-transmitting substrate (A),
the antiglare film has irregularities formed on the outermost surface on the antiglare layer (B) side,
The above-mentioned irregularities satisfy the following expressions (1) and (2).
Ry≥1 (1)
θa≥0.7 (2)
In the above formula (1), ry is the maximum height [ μm ] of the convex portion of the concave-convex,
in the above formula (2), θa is an average inclination angle of the irregularities [ ° ].
The method for producing an antiglare film of the present invention is characterized by comprising an antiglare layer (B) forming step of forming the antiglare layer (B) on the light-transmitting substrate (A) so as to satisfy the above-mentioned expressions (1) and (2),
the antiglare layer (B) forming step includes: a coating step of coating the light-transmitting substrate (A) with a coating liquid; and a coating film forming step of forming a coating film by drying the applied coating liquid,
the coating liquid contains a resin and a solvent.
The optical member of the present invention is an optical member comprising the antiglare film of the present invention.
The image display device of the present invention is an image display device comprising the antiglare film of the present invention or the optical member of the present invention.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, an antiglare film, an optical member, and an image display device in which reflection glare is suppressed can be provided.
Drawings
Fig. 1 is a cross-sectional view showing an example of the antiglare film of the present invention.
Fig. 2 is a cross-sectional view showing another example of the antiglare film of the present invention.
Fig. 3 is a cross-sectional view showing an example of an antiglare film.
Detailed Description
The present invention will be described in more detail with reference to examples. However, the present invention is not limited to the following description.
In the antiglare film of the present invention, for example, the antiglare layer (B) may contain fine particles.
In the antiglare film of the present invention, for example, the antiglare layer (B) may have irregularities formed on a surface opposite to the light-transmitting substrate (a), and the weight average particle diameter of the fine particles may be larger than a thickness obtained by subtracting the maximum height of the convex portions of the irregularities from the maximum thickness of the antiglare layer (B).
In the antiglare film of the present invention, for example, the weight average particle diameter of the fine particles may be in the range of 2 to 10. Mu.m.
In the antiglare film of the present invention, for example, another layer may be further laminated on the surface of the antiglare layer (B) on the opposite side from the light-transmitting substrate (a).
The antiglare film of the present invention may be, for example, the following antiglare film: wherein an antiglare layer (B) and another layer are laminated in this order on a light-transmitting substrate (A), and irregularities are formed on the outermost surface of the other layer, and the irregularities satisfy the following expressions (1) and (2).
Ry≥1 (1)
θa≥0.7 (2)
In the above formula (1), ry is the maximum height [ μm ] of the convex portion of the concave-convex,
in the above formula (2), θa is an average inclination angle of the irregularities [ ° ].
In the method for producing an antiglare film of the present invention, for example, the antiglare layer (B) forming step may further include a curing step of curing the coating film.
In the method for producing an antiglare film of the present invention, for example, the coating liquid may contain fine particles.
The optical member of the present invention may be, for example, a polarizing plate.
The optical member of the image display device of the present invention may be, for example, a public information display.
[1. Antiglare film ]
As described above, the antiglare film of the present invention is characterized in that an antiglare layer (B) is laminated on a light-transmitting substrate (a), and irregularities are formed on the outermost surface of the antiglare film on the antiglare layer (B) side, and the irregularities satisfy the following expressions (1) and (2).
Ry≥1 (1)
θa≥0.7 (2)
In the above formula (1), ry is the maximum height [ μm ] of the convex portion of the concave-convex,
in the above formula (2), θa is an average inclination angle of the irregularities [ ° ].
Fig. 1 is a cross-sectional view showing an example of the structure of the antiglare film of the present invention. As shown in the figure, the antiglare film 10 has an antiglare layer (B) 12 laminated on one surface of a light-transmitting substrate (a) 11. The antiglare layer (B) 12 includes fine particles 12B and a thixotropic agent 12c in the resin layer 12 a. An uneven surface is formed on the outermost surface of the antiglare film 10 on the antiglare layer (B) 12 side (the surface of the antiglare layer (B) 12 on the opposite side from the light-transmitting substrate (a) 11). The maximum height Ry of the convex portion of the concave-convex is 1 μm or more. The average inclination angle θa (not shown) of the irregularities is 0.7 ° or more. The particle diameter D of the fine particles 12B is larger than the film thickness t obtained by subtracting Ry from the maximum thickness D of the antiglare layer (B). Fig. 1 is an example, and the present invention is not limited thereto. For example, the antiglare film of the present invention may or may not contain each of the fine particles and the thixotropic agent. In fig. 1, the particle diameter D of the fine particles 12B is larger than the film thickness t of the antiglare layer (B), but the present invention is not limited thereto.
Fig. 3 is a cross-sectional view showing an example of the structure of an antiglare film that is not an antiglare film of the present invention. The antiglare film is the same as that of fig. 1 except that the maximum height Ry of the irregularities is less than 1 μm and the average inclination angle θa (not shown) of the irregularities is less than 0.7 °.
Fig. 2 is a cross-sectional view showing another example of the structure of the antiglare film of the present invention. As shown in the drawing, in the antiglare film 10, another layer 13 is further laminated on the surface of the antiglare layer (B) 12 opposite to the light-transmitting substrate (a) 11. The other layer 13 is not particularly limited, and may be, for example, a low refractive index layer, an antireflection layer, a high refractive index layer, a hard coat layer, an adhesive layer, or the like. Except for this, the constitution of the antiglare film 10 of fig. 2 is the same as that of the antiglare film 10 of fig. 1. In fig. 2, irregularities are formed on the outermost surface of the antiglare film 10 on the antiglare layer (B) 12 side (the surface of the other layer 13 on the opposite side from the light-transmitting substrate (a) 11). The maximum height Ry of the convex portion of the concave-convex is 1 μm or more. The average inclination angle θa (not shown) of the irregularities is 0.7 ° or more. The maximum height of the antiglare film 10 in the portion other than the light-transmitting substrate (a) 11 (antiglare layer (B) 12 and other layer 13) is denoted by d in the figure. Further, irregularities are formed on the surface of the antiglare layer (B) 12 on the opposite side (other layer 13 side) from the light-transmitting substrate (a) 11. The film thickness obtained by subtracting the maximum height Ry 'of the irregularities of the antiglare layer (B) 12 from the maximum thickness d' of the antiglare layer (B) 12 is denoted by t in the figure. As shown, t is equal to d '-Ry' and equal to d-Ry. The particle diameter D of the fine particles 12b is larger than the film thickness t as in the case of fig. 1, but the present invention is not limited thereto as described above. In addition, as in the case of fig. 1, the antiglare layer (B) 12 may or may not contain each of the fine particles and the thixotropic agent. In fig. 2, the other layer 13 is one layer, but may be a plurality of layers. When the other layer 13 is not present, ry 'is equal to Ry and d' is equal to d as shown in fig. 1.
Hereinafter, the light-transmitting substrate (a), the antiglare layer (B), and the other layers will be described further by way of examples. In the following, the case where the antiglare layer (B) is an antiglare hard coat layer will be mainly described, but the present invention is not limited to this.
The light-transmitting substrate (a) is not particularly limited, and examples thereof include a transparent plastic film substrate and the like. The transparent plastic film base material is not particularly limited, but is preferably excellent in light transmittance of visible light (preferably, light transmittance of 90% or more) and excellent in transparency (preferably, haze value of 1% or less), and examples thereof include the transparent plastic film base material described in japanese patent application laid-open No. 2008-90263. As the transparent plastic film base material, those having low optical birefringence can be suitably used. The antiglare film of the present invention can be used as a protective film for a polarizing plate, and in this case, a film made of Triacetylcellulose (TAC), polycarbonate, an acrylic polymer, a polyolefin having a cyclic or norbornene structure, or the like is preferable as the transparent plastic film base material. In the present invention, the transparent plastic film base material may be a polarizing material itself, as will be described later. With such a configuration, a protective layer made of TAC or the like is not required, and the structure of the polarizing plate can be simplified, so that the number of manufacturing steps of the polarizing plate or the image display device can be reduced, and improvement in production efficiency can be achieved. In addition, with such a configuration, the polarizing plate can be further thinned. When the transparent plastic film base material is a polarizer, the antiglare layer (B) and the antireflection layer (C) function as protective layers. In addition, with such a configuration, the antiglare film also has a function as a cover sheet when mounted on, for example, the surface of a liquid crystal cell.
In the present invention, the thickness of the light-transmitting substrate (A) is not particularly limited, and is in the range of, for example, 10 to 500. Mu.m, 20 to 300. Mu.m, or 30 to 200. Mu.m, in view of handling properties such as strength and handling properties, and thin layer properties. The refractive index of the light-transmitting substrate (a) is not particularly limited. The refractive index is, for example, in the range of 1.30 to 1.80 or 1.40 to 1.70.
In the antiglare film of the present invention, for example, the resin contained in the light-transmitting substrate (a) may contain an acrylic resin.
In the antiglare film of the present invention, for example, the light-transmitting substrate (a) may be an acrylic film.
In the antiglare film of the present invention, the surface of the antiglare layer (B) is formed with irregularities as described above, and the maximum height Ry of the irregularities is 1 μm or more. The maximum height Ry may be, for example, 1.5 μm or more, and may be, for example, 9 μm or less, 8 μm or less, 7 μm or less, or 6 μm or less. The maximum height Ry may be, for example, 1 to 9. Mu.m, 1 to 8. Mu.m, 1 to 7. Mu.m, or 1.5 to 6. Mu.m. From the viewpoint of suppressing reflection glare, ry is preferably large, and from the viewpoint of haze value described later, it is preferably not too large. In the present invention, the maximum height Ry is set to a value based on JIS B0601 (1994 edition). The method for measuring Ry is not particularly limited, and can be measured by, for example, the measurement method described in examples described below.
In the antiglare film of the present invention, the "outermost surface on the antiglare layer (B)" is the outermost surface on the antiglare layer (B). Specifically, when the other layer is not present (for example, fig. 1), the "outermost surface on the antiglare layer (B) side" is the surface of the antiglare layer (B) on the opposite side from the light-transmitting substrate (a). When the other layer is present (for example, fig. 2), the "outermost surface on the antiglare layer (B) side" is the outermost surface on the opposite side from the light-transmitting substrate (a) in the other layer.
In the antiglare film of the present invention, as described above, the average tilt angle θa (°) is 0.7 or more in the uneven shape of the outermost surface on the antiglare layer (B) side. The average inclination angle θa may be, for example, 0.7 ° or more, 0.8 ° or more, 0.9 ° or more, or 1.0 ° or more, and may be 8 ° or less, 7 ° or less, 6 ° or less, or 5 ° or less. The average inclination angle θa may be, for example, 0.7 to 8 °, 0.7 to 7 °, 0.7 to 6 °, 0.7 to 5 °, 0.8 to 8 °, 0.8 to 7 °, 0.8 to 6 °, 0.8 to 5 °, 0.9 to 8 °, 0.9 to 7 °, 0.9 to 6 °, 0.9 to 5 °, 1.0 to 8 °, 1.0 to 7 °, 1.0 to 6 °, or 1.0 to 5 °. In view of suppressing the reflection glare, θa is preferably large, and in view of a haze value described later, it is preferably not too large. Here, the average inclination angle θa is a value defined by the following equation (3). The average tilt angle θa can be measured, for example, by the method described in examples described below.
Average tilt angle θa=tan -1 Δa (3)
In the above expression (3), Δa is a value obtained by dividing the sum (h1+h2+h3··h+hn) of the differences (height h) between adjacent peaks and valleys in the reference length L of the roughness curve defined in JIS B0601 (1994 edition) by the reference length L, as shown in the following expression (4). The roughness curve is a curve obtained by removing a surface waviness component longer than a predetermined wavelength from a cross-sectional curve by a phase difference compensation type high-pass filter. The cross-sectional curve is a contour that appears in a notch when the object surface is cut by a plane perpendicular to the object surface.
Δa=(h1+h2+h3···+hn)/L (4)
In the antiglare film of the present invention, the haze value may be, for example, 4% or more, 6% or more, 10% or more, or 15% or more, and may be, for example, 50% or less, 40% or less, 35% or less, or less than 30%. The haze value may be, for example, 4 to 50%, 6 to 40%, 10 to 40%, further 15 to 40%, or 15 to 35%. The haze value is the haze value (opacity) of the entire antiglare film according to JIS K7136 (2000 edition). In general, in the antiglare film, a large haze value tends to suppress reflection glare. However, if the haze value is too large, display characteristics are liable to be degraded, such as an image becoming unclear, a contrast in a dark place being degraded, and the like. However, according to the present invention, by satisfying the above-described expressions (1) and (2) with Ry and θa, even if the haze value is reduced to, for example, 50% or less, 40% or less, 35% or less, or less than 30%, reflection glare can be suppressed. In order to minimize the haze value, the fine particles and the resin may be selected so as to minimize the refractive index difference (for example, in the range of 0.001 to 0.02) between the resin and the fine particles, which will be described later, in addition to the adjustment of Ry and θa.
In the antiglare film of the present invention, for example, the antiglare layer (B) may contain a resin and a filler. The filler may contain at least one of fine particles and a thixotropic agent (thixotropic agent).
In the antiglare film of the present invention, for example, the resin contained in the antiglare layer (B) may contain an acrylate resin (also referred to as an acrylic resin).
In the antiglare film of the present invention, for example, the resin contained in the antiglare layer (B) may contain a urethane acrylate resin.
In the antiglare film of the present invention, for example, the resin contained in the antiglare layer (B) may be a copolymer of a curable urethane acrylate resin and a polyfunctional acrylate.
The antiglare film of the present invention may be, for example: the antiglare layer (B) is formed by using an antiglare layer forming material comprising a resin and a filler, and the antiglare layer (B) has an aggregation portion forming a convex portion on the surface of the antiglare layer (B) due to aggregation of the filler. In the above-described aggregation portion where the convex portion is formed, the filler may be present in a state where a plurality of fillers are concentrated in one direction of the surface direction of the antiglare layer (B). In the image display device of the present invention, the antiglare film of the present invention may be arranged such that, for example, one direction in which the plurality of fillers are gathered coincides with a longitudinal direction of the black matrix pattern.
In the antiglare film of the present invention, the thixotropic agent may be at least one selected from the group consisting of organoclay, oxidized polyolefin and modified urea. The thixotropic agent may be, for example, a thickener.
In the antiglare film of the present invention, the thixotropic agent may be contained in an amount of, for example, 0.2 to 5 parts by weight based on 100 parts by weight of the resin of the antiglare layer (B).
The antiglare film of the present invention may contain the fine particles in a range of, for example, 0.2 to 12 parts by weight or 0.5 to 12 parts by weight relative to 100 parts by weight of the resin of the antiglare layer (B).
In the method for producing an antiglare film of the present invention, the surface shape of the antiglare film can be adjusted by further adjusting the parts by weight of the fine particles in the antiglare layer-forming material relative to 100 parts by weight of the resin.
The antiglare layer (B) may be formed, for example, as follows: as described later, a coating liquid containing the resin, the filler, and a solvent is applied to at least one surface of the light-transmitting substrate (a) to form a coating film, and the solvent is removed from the coating film. Examples of the resin include thermosetting resins and ionizing radiation curable resins cured by ultraviolet rays and/or light. As the resin, a commercially available thermosetting resin, an ultraviolet curable resin, or the like can be used.
As the thermosetting resin and the ultraviolet curable resin, for example, a curable compound having at least one of an acrylate group and a methacrylate group, which is cured by heat, light (ultraviolet rays or the like), electron beam or the like, may be used, and examples thereof include an oligomer or prepolymer of an acrylate, a methacrylate or the like of a polyfunctional compound such as a silicone resin, a polyester resin, a polyether resin, an epoxy resin, a urethane resin, an alkyd resin, a spiroacetal resin, a polybutadiene resin, a polythiol polyene resin, or a polyol. One kind of these may be used alone, or two or more kinds may be used in combination.
Among the above resins, for example, a reactive diluent having at least one of an acrylate group and a methacrylate group can also be used. The reactive diluent may be, for example, a reactive diluent described in Japanese patent application laid-open No. 2008-88309, and examples thereof include monofunctional acrylates, monofunctional methacrylates, polyfunctional acrylates, polyfunctional methacrylates, and the like. The reactive diluent is preferably an acrylate having 3 or more functions or a methacrylate having 3 or more functions. This is because the antiglare layer (B) can be made excellent in hardness. Examples of the reactive diluent include butanediol glycerol ether diacrylate, isocyanuric acid acrylate, and isocyanuric acid methacrylate. One kind of these may be used alone, or two or more kinds may be used in combination.
The fine particles for forming the antiglare layer (B) have a main function of imparting antiglare properties by making the surface of the antiglare layer (B) formed into a concave-convex shape and controlling the haze value of the antiglare layer (B). The haze value of the antiglare layer (B) can be designed by controlling the refractive index difference between the fine particles and the resin. Examples of the fine particles include inorganic fine particles and organic fine particles. The inorganic fine particles are not particularly limited, and examples thereof include silicon oxide particles, titanium oxide particles, aluminum oxide particles, zinc oxide particles, tin oxide particles, calcium carbonate particles, barium sulfate particles, talc particles, kaolin particles, and calcium sulfate particles. The organic fine particles are not particularly limited, and examples thereof include polymethyl methacrylate resin powder (PMMA particles), silicone resin powder, polystyrene resin powder, polycarbonate resin powder, acrylic-styrene resin powder, benzoguanamine resin powder, melamine resin powder, polyolefin resin powder, polyester resin powder, polyamide resin powder, polyimide resin powder, and polyvinyl fluoride resin powder. These inorganic fine particles and organic fine particles may be used singly or in combination of two or more kinds.
The particle diameter (D) (weight average particle diameter) of the fine particles is not particularly limited, and is, for example, in the range of 2 to 10. Mu.m. By setting the weight average particle diameter of the fine particles to be within the above range, for example, an antiglare film having more excellent antiglare properties and capable of suppressing reflection glare can be produced. From the viewpoint of suppressing reflection glare from an oblique direction, the weight average particle diameter of the fine particles is preferably not too small. From the viewpoint of suppressing reflection glare from the front direction, it is preferable that the weight average particle diameter of the fine particles is not excessively large. The weight average particle diameter of the fine particles may be, for example, 2 μm or more and 3 μm or more, and may be, for example, 10 μm or less, 9 μm or less, or 8 μm or less. The weight average particle diameter of the fine particles may be, for example, 2 to 10. Mu.m, 2 to 9. Mu.m, or 3 to 8. Mu.m. The weight average particle diameter of the fine particles can be measured by, for example, the coulter counter method. For example, the number and volume of the fine particles are measured by measuring the resistance of an electrolyte corresponding to the volume of the fine particles when the fine particles pass through the fine pores using a particle size distribution measuring device (trade name: coulter Multisizer, manufactured by Beckman Coulter, inc.), and the weight average particle diameter is calculated.
The shape of the fine particles is not particularly limited, and may be, for example, a substantially spherical shape such as a bead, or an amorphous shape such as a powder, and preferably a substantially spherical fine particle, more preferably a substantially spherical fine particle having an aspect ratio of 1.5 or less, and most preferably a spherical fine particle.
The content of the fine particles in the antiglare layer (B) is not particularly limited, and may be appropriately set in consideration of, for example, the surface shape of the antiglare layer (B). The relationship between the content (parts by weight relative to the resin) of the fine particles and the weight average particle diameter and the surface shape of the antiglare layer (B) will be described later.
In the antiglare layer (B), the filler may be fine particles or a thixotropic agent. The thixotropic agent may be contained alone or may be further contained in addition to the fine particles. By including the thixotropic agent, the aggregation state of the microparticles can be easily controlled. Examples of the thixotropic agent include organoclay, oxidized polyolefin, and modified urea.
In order to improve the affinity with the resin, the organoclay is preferably an organized layered clay. The organoclay may be prepared by itself or commercially available ones may be used. Examples of the commercial products include: LUCENTITE SAN, LUCENTITE STN, LUCENTITE SEN, LUCENTITE SPN, SOMASIF ME-100, SOMASIF MAE, SOMASIF MTE, SOMASIF MEE, SOMASIF MPE (trade names, all manufactured by CO-OP CHEMICAL Co.Ltd.); S-BEN, S-BEN C, S-BEN E, S-BEN W, S-BEN P, S-BEN WX, S-BEN-400, S-BEN NX80, S-BEN NO12S, S-BEN NEZ, S-BEN NO12, S-BEN NE, S-BEN NZ70, ORGANAIT D, ORGANAIT T (trade names, all HOJUN Co., manufactured by Ltd.); KUNIPIAF, KUNIPIAG, KUNIPIAG4 (trade name, kunimine Industries, manufactured by co.ltd.); TIXOGEL VZ, CLAYTONE HT, CLAYTONE 40 (trade name, manufactured by Rockwood Additives Limited).
The oxidized polyolefin may be prepared by itself or commercially available products may be used. Examples of the commercial products include DISPARON 4200-20 (trade name, manufactured by Nanyu chemical Co., ltd.), FLOWNON SA300 (trade name, manufactured by Kyowa chemical Co., ltd.), and the like.
The modified urea is a reactant of isocyanate monomer or an adduct thereof and organic amine. The modified urea may be prepared by itself or commercially available urea may be used. Examples of the commercial products include BYK410 (BYK-Chemie Corporation).
The thixotropic agent may be used singly or in combination of two or more.
The proportion of the thixotropic agent in the antiglare layer (B) is preferably in the range of 0.2 to 5 parts by weight, more preferably in the range of 0.4 to 4 parts by weight, based on 100 parts by weight of the resin.
The maximum thickness (d') of the antiglare layer (B) is not particularly limited, but is preferably in the range of 3 to 12. Mu.m. By setting the maximum thickness (d') of the antiglare layer (B) to the above range, curling of the antiglare film can be prevented, and the problem of productivity degradation such as poor transportation can be avoided. When the thickness (D) is within the above range, the weight average particle diameter (D) of the fine particles is preferably within the range of 2 to 10 μm as described above. By combining the maximum thickness (D') of the antiglare layer (B) and the weight average particle diameter (D) of the fine particles, an antiglare film excellent in antiglare property can be produced. The maximum thickness (d') of the antiglare layer (B) is more preferably in the range of 3 to 8. Mu.m.
The ratio D/D 'of the thickness (D') of the antiglare layer (B) to the weight average particle diameter (D) of the fine particles may be, for example, 1 or less, less than 1, 0.98 or less, 0.96 or less, 0.93 or less, or 0.90 or less, and may be 0.5 or more, 0.6 or more, 0.7 or more, or 0.8 or more. By having such a relationship, an antiglare film having more excellent antiglare properties and capable of suppressing reflection glare can be produced. For example, when D/D' is large, ry and θa tend to easily increase.
The antiglare film of the present invention may, for example: the antiglare layer (B) has an aggregation part in which convex parts are formed on the surface of the antiglare layer (B) due to aggregation of the filler, and the filler is present in a state in which a plurality of fillers are concentrated in one direction of the surface directions of the antiglare layer (B) in the aggregation part in which the convex parts are formed. This can prevent, for example, reflection glare of the fluorescent lamp. However, the antiglare film of the present invention is not limited thereto.
The surface shape of the antiglare layer (B) can be designed by adjusting, for example, a film thickness t obtained by subtracting the maximum height Ry 'of the irregularities of the antiglare layer (B) from the maximum thickness D' of the antiglare layer (B), and the weight average particle diameter D of the fine particles. Specifically, for example, if the weight average particle diameter D of the fine particles is relatively large with respect to the film thickness t of the antiglare layer (B), the Ry and θa tend to increase. The film thickness t can be adjusted by, for example, the coating thickness of the resin. Further, the surface shape of the antiglare layer (B) can be designed by adjusting the weight fraction of the fine particles in the antiglare layer forming material relative to 100 parts by weight of the resin. For example, when the weight fraction of the fine particles is relatively large relative to the resin, θa tends to be easily increased.
The antiglare film of the present invention may have an intermediate layer between the light-transmitting substrate (a) and the antiglare layer (B), for example, the intermediate layer including a resin derived from the light-transmitting substrate (a) and a resin derived from the antiglare layer (B). By controlling the thickness of the intermediate layer, the surface shape of the antiglare layer (B) can be controlled. For example, if the thickness of the intermediate layer is increased, the Ry and θa tend to be large, and if the thickness of the intermediate layer is reduced, the Ry and θa tend to be small.
In the present invention, the mechanism of forming the intermediate layer (also referred to as a permeation layer or a compatible layer) is not particularly limited, and it is formed, for example, by the drying step in the method for producing an antiglare hard coat film of the present inventors. Specifically, for example, in the drying step, the coating liquid for forming the antiglare layer (B) permeates into the light-transmitting substrate (a), and the intermediate layer including the resin from the light-transmitting substrate (a) and the resin from the antiglare layer (B) is formed. The resin contained in the intermediate layer is not particularly limited, and may be, for example, a resin obtained by simply mixing (compatibilizing) the resin contained in the light-transmitting substrate (a) and the resin contained in the antiglare layer (B). In addition, among the resins contained in the intermediate layer, at least one of the resin contained in the light-transmitting substrate (a) and the resin contained in the antiglare layer (B) may be chemically changed by heating, light irradiation, or the like, for example.
The thickness ratio R of the intermediate layer defined by the following formula (5) is not particularly limited, and may be, for example, 0.10 to 0.80, for example, 0.15 or more, 0.20 or more, 0.25 or more, 0.30 or more, 0.40 or more, or 0.45 or more, and may be, for example, 0.75 or less, 0.70 or less, 0.65 or less, 0.60 or less, 0.50 or less, 0.40 or less, 0.45 or less, or 0.30 or less. The thickness ratio R of the intermediate layer may be, for example, 0.15 to 0.75, 0.20 to 0.70, 0.25 to 0.65, 0.30 to 0.60, 0.40 to 0.50, 0.45 to 0.50, 0.15 to 0.45, 0.15 to 0.40, 0.15 to 0.30, or 0.20 to 0.30. The intermediate layer can be confirmed by, for example, observing the cross section of the antiglare hard coat film with a Transmission Electron Microscope (TEM), and measuring the thickness.
R=[D C /(D C +D B )] (5)
In the above formula (5), D B Thickness [ mu ] m of the antiglare layer (B)],D C Thickness [ mu ] m of the intermediate layer]。
The surface shape of the antiglare layer (B) may be designed by controlling the aggregation state of the filler contained in the antiglare layer forming material. The aggregation state of the filler may be controlled by, for example, the material of the filler (e.g., the chemically modified state of the surface of the fine particles, the affinity for a solvent and/or a resin, etc.), the resin (binder), the kind and combination of solvents, and the like. In addition, the thixotropic agent can precisely control the aggregation state of the fine particles.
The antiglare film of the present invention may be a film in which the convex portion has a gentle shape and the occurrence of a protrusion on the surface of the antiglare layer (B) which is an appearance defect can be prevented, but is not limited thereto. The antiglare film of the present invention may contain a plurality of the fine particles at positions which directly or indirectly overlap with the thickness direction of the antiglare layer (B), for example.
The other layers are not particularly limited, and may be, for example, a low refractive index layer, an antireflection layer, a high refractive index layer, a hard coat layer, an adhesive layer, and the like as described above. The other layers may be one layer or a plurality of layers, and when the layers are a plurality of layers, the layers may be one or a plurality of layers. For example, the other layers may be optical films having strictly controlled thickness and refractive index, or may be formed by laminating two or more layers of the optical films.
[2 ] method for producing antiglare film ]
The method for producing the antiglare film of the present invention is not particularly limited, and the antiglare film can be produced by any method, and is preferably produced by the above-described method for producing an antiglare film of the present invention.
The method for producing the antiglare film can be carried out, for example, as follows.
First, the antiglare layer (B) is formed on the light-transmitting substrate (a) so as to satisfy the above-described expressions (1) and (2) (antiglare layer (B) forming step). Thereby producing a laminate of the light-transmitting substrate (a) and the antiglare layer (B). The antiglare layer (B) forming step includes a coating step of coating the light-transmitting substrate (a) with a coating liquid and a coating film forming step of drying the coated coating liquid to form a coating film, as described above. In addition, for example, the antiglare layer (B) forming step may further include a curing step of curing the coating film as described above. The curing may be performed, for example, after the drying, but is not limited thereto. The curing may be performed by heating, light irradiation, or the like, for example. The light is not particularly limited, and may be ultraviolet light, for example. The light source for the light irradiation is not particularly limited, and may be, for example, a high-pressure mercury lamp.
The coating liquid contains a resin and a solvent as described above. The coating liquid may be, for example, an antiglare layer forming material (coating liquid) containing the resin, the particles, the thixotropic agent, and the solvent.
The coating liquid preferably exhibits thixotropic properties, and the Ti value defined by the following formula is preferably in the range of 1.3 to 3.5, more preferably in the range of 1.4 to 3.2, and even more preferably in the range of 1.5 to 3.
Ti value = β1/β2
In the above formula, β1 is the viscosity measured using RHEOSTES RS6000 manufactured by HAAKE company under the condition of a shear rate of 20 (1/s), and β2 is the viscosity measured using RHEOSTES RS6000 manufactured by HAAKE company under the condition of a shear rate of 200 (1/s).
If the Ti value is 1.3 or more, problems such as appearance defects, deterioration of antiglare properties and blushing characteristics are less likely to occur. If the Ti value is 3.5 or less, the above-mentioned problems such as the particles not aggregating and being in a dispersed state are less likely to occur.
The coating liquid may or may not contain a thixotropic agent, and it is preferable that the coating liquid contains a thixotropic agent because it easily shows thixotropic properties. In addition, as described above, by including the thixotropic agent in the coating liquid, an effect of preventing sedimentation of the particles (thixotropic effect) can be obtained. In addition, the surface shape of the antiglare film can be freely controlled in a wider range by the shear aggregation of the thixotropic agent itself.
The solvent is not particularly limited, and various solvents may be used, and one may be used alone, or two or more may be used in combination. In order to obtain the antiglare film of the present invention, the most suitable solvent type and solvent ratio may be appropriately selected according to the composition of the resin, the type and content of the particles and the thixotropic agent, and the like. The solvent is not particularly limited, and examples thereof include: alcohols such as methanol, ethanol, isopropyl alcohol (IPA), butanol, t-butanol (TBA), and 2-methoxyethanol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclopentanone, and the like; esters such as methyl acetate, ethyl acetate, and butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellosolves such as ethyl cellosolve and butyl cellosolve; aliphatic hydrocarbons such as hexane, heptane, octane, etc.; aromatic hydrocarbons such as benzene, toluene and xylene. In addition, for example, the above-mentioned solvents may include hydrocarbon solvents and ketone solvents. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene, for example. The ketone solvent may be, for example, at least one selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. For example, in order to dissolve the thixotropy imparting agent (e.g., thickener), the above solvent preferably contains the above hydrocarbon solvent (e.g., toluene). The solvent may be, for example, 90% of the hydrocarbon solvent and the ketone solvent: 10-10: 90 mass ratio of the solvent obtained by mixing. The mass ratio of the hydrocarbon solvent to the ketone solvent may be, for example, 80: 20-20: 80. 70: 30-30: 70. or 40: 60-60: 40, etc. In this case, for example, toluene may be used as the hydrocarbon solvent and methyl ethyl ketone may be used as the ketone solvent. The solvent may contain, for example, toluene and at least one selected from the group consisting of ethyl acetate, butyl acetate, IPA, methyl isobutyl ketone, methyl ethyl ketone, methanol, ethanol, and TBA.
For example, when an acrylic film is used as the light-transmitting substrate (a), a good solvent for the acrylic film (acrylic resin) can be suitably used in forming the intermediate layer (permeation layer). As the solvent, for example, a solvent including a hydrocarbon solvent and a ketone solvent may be mentioned above. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be at least one selected from the group consisting of toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene, for example. The ketone solvent may be, for example, at least one selected from the group consisting of cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and acetophenone. The solvent may be, for example, 90% of the hydrocarbon solvent and the ketone solvent: 10-10: 90 mass ratio of the solvent obtained by mixing. The mass ratio of the hydrocarbon solvent to the ketone solvent may be, for example, 80: 20-20: 80. 70: 30-30: 70. or 40: 60-60: 40, etc. In this case, for example, toluene may be used as the hydrocarbon solvent and methyl ethyl ketone may be used as the ketone solvent.
For example, when cellulose Triacetate (TAC) is used as the light-transmitting substrate (a), a good solvent for TAC can be suitably used to form the intermediate layer (permeation layer). Examples of the solvent include ethyl acetate, methyl ethyl ketone, and cyclopentanone.
In addition, by appropriately selecting the solvent, thixotropic properties to the antiglare layer forming material (coating liquid) can be well exhibited when the thixotropic agent is contained. For example, when organoclay is used, toluene and xylene may be suitably used alone or in combination, for example, when oxidized polyolefin is used, methyl ethyl ketone, ethyl acetate, propylene glycol monomethyl ether may be suitably used alone or in combination, for example, when modified urea is used, butyl acetate and methyl isobutyl ketone may be suitably used alone or in combination.
Various leveling agents may be added to the antiglare layer forming material. As the leveling agent, for example, a fluorine-based or silicone-based leveling agent can be used for the purpose of preventing uneven coating (leveling of the coated surface). In the present invention, the leveling agent may be appropriately selected depending on the case where antifouling property is required for the surface of the antiglare layer (B), the case where an antireflection layer (low refractive index layer) or a layer containing an interlayer filler is formed on the antiglare layer (B) as described later, or the like. In the present invention, for example, by containing the thixotropic agent, the coating liquid can be made thixotropic, and thus coating unevenness is less likely to occur. In this case, for example, there is an advantage that the alternative of the leveling agent described above can be added.
The amount of the leveling agent to be blended is, for example, 5 parts by weight or less, preferably 0.01 to 5 parts by weight, based on 100 parts by weight of the resin.
In the antiglare layer forming material, a pigment, a filler, a dispersant, a plasticizer, an ultraviolet absorber, a surfactant, an antifouling agent, an antioxidant, and the like may be added as necessary within a range that does not impair the performance. These additives may be used singly or in combination of two or more.
For the antiglare layer-forming material, a conventionally known photopolymerization initiator, for example, as described in japanese unexamined patent publication No. 2008-88309, can be used.
As a method of forming a coating film by applying the coating liquid to the light-transmitting substrate (a), for example, a coating method such as a spray coating method, a die coating method, a spin coating method, a spray coating method, a gravure coating method, a roll coating method, or a bar coating method can be used.
Subsequently, the coating film is dried and cured as described above to form the antiglare layer (B). The drying may be, for example, natural drying, air-drying by blowing, heating drying, or a combination thereof.
The drying temperature of the coating liquid for forming the antiglare layer (B) may be, for example, 30 to 200 ℃. The drying temperature may be, for example, 40℃or more, 50℃or more, 60℃or more, 70℃or more, 80℃or more, 90℃or more, or 100℃or more, and may be 190℃or less, 180℃or less, 170℃or less, 160℃or less, 150℃or less, 140℃or less, 135℃or less, 130℃or less, 120℃or less, or 110℃or less. The drying time is not particularly limited, and may be, for example, 30 seconds or more, 40 seconds or more, 50 seconds or more, or 60 seconds or more, and may be 150 seconds or less, 130 seconds or less, 110 seconds or less, or 90 seconds or less.
The curing means of the coating film is not particularly limited, and ultraviolet curing is preferable. The irradiation amount of the energy ray source is preferably 50 to 500mJ/cm in terms of cumulative exposure amount at 365nm ultraviolet wavelength 2 . The irradiation amount is 50mJ/cm 2 As described above, the curing is easily and sufficiently performed, and the hardness of the antiglare layer (B) to be formed is easily increased. In addition, if it is 500mJ/cm 2 The antiglare layer (B) thus formed can be prevented from being colored.
In this way, a laminate of the light-transmitting substrate (a) and the antiglare layer (B) can be produced. The laminate may be used as the antiglare film of the present invention as it is, or may be used as the antiglare film of the present invention by forming the other layer on the antiglare layer (B). The method for forming the other layers is not particularly limited, and may be performed in the same manner as or by a method based on a conventional method for forming a low refractive index layer, an antireflection layer, a high refractive index layer, a hard coat layer, an adhesive layer, or the like
[3 ] optical Member and image display device ]
The optical member of the present invention is not particularly limited, and may be, for example, a polarizing plate. The polarizing plate is not particularly limited, and may include, for example, the antiglare film and the polarizing material of the present invention, and may further include other components. The respective constituent elements of the polarizing plate may be bonded by an adhesive or an adhesive, for example.
The image display device of the present invention is not particularly limited, and may be any image display device, and examples thereof include a liquid crystal display device, an organic EL display device, and the like.
The image display device of the present invention may be, for example, an image display device having the antiglare film of the present invention on a visual recognition side surface, and the image display device may have a black matrix pattern.
The antiglare film of the present invention can be used for an optical member for an LCD by bonding the light-transmitting substrate (a) side to the film with an adhesive or an adhesive. In the bonding, the surface of the light-transmitting substrate (a) may be subjected to various surface treatments as described above. As described above, according to the method for producing an antiglare film of the present invention, the surface shape of the antiglare film can be freely controlled in a wider range. Therefore, the optical characteristics obtained by laminating the antiglare film and other optical members using an adhesive, a binder, or the like can cover a wide range corresponding to the surface shape of the antiglare film.
Examples of the optical member include a polarizer and a polarizing plate. The polarizing plate is generally configured to have a transparent protective film on one or both sides of a polarizer. In the case where transparent protective films are provided on both sides of the polarizer, the transparent protective films on the front and rear surfaces may be the same material or may be different materials. Polarizing plates are generally disposed on both sides of the liquid crystal cell. The polarizing plates were arranged such that the absorption axes of the 2 polarizing plates were substantially orthogonal to each other.
The structure of the polarizing plate in which the antiglare film is laminated is not particularly limited, and for example, a transparent protective film, the polarizing material, and the transparent protective film may be laminated in this order on the antiglare film, or the polarizing material and the transparent protective film may be laminated in this order on the antiglare film.
The image display device of the present invention has the same configuration as the conventional image display device except that the antiglare film is disposed in a specific direction. For example, in the case of an LCD, the LCD can be manufactured by appropriately assembling optical members such as a liquid crystal cell and a polarizing plate, and constituent members such as an illumination system (backlight or the like) used as needed, and incorporating a driving circuit or the like.
The antiglare film of the present invention can scatter strong external light and suppress reflection, and thus can suppress reflection glare even outdoors. Therefore, the image display device of the present invention can be suitably used as, for example, a public information display for outdoor use, or the like. However, the image display device of the present invention is not limited to this application, and can be used for any other application. Examples of other applications include OA equipment such as personal computer monitors, notebook computers, and copiers, cellular phones, watches, digital cameras, portable information terminals (PDAs), portable equipment such as portable game machines, home electric equipment such as video cameras, televisions, and microwave ovens, rear view monitors, car navigation system monitors, car-mounted equipment such as car stereos, display equipment such as information monitors for commercial stores, police equipment such as monitor monitors, care monitors, and care and medical equipment such as medical monitors.
Examples
Next, examples of the present invention will be described together with comparative examples. However, the present invention is not limited to the following examples and comparative examples.
In the following examples and comparative examples, the parts of the substances are parts by mass (parts by weight) unless otherwise specified.
Production example 1 > production of base film A
First, an imidized polymethyl methacrylate resin was produced by the same method as in production example 1 of japanese patent application laid-open No. 2010-284840 using a tandem reaction extruder in which 2 extrusion reactors were arranged in tandem. The tandem reaction extruder used was a co-rotating twin screw extruder having a diameter of 75mm and an L/D (ratio of length L to diameter D) of 74 in each of the extruder 1 and extruder 2. For supplying the raw material resin to the raw material supply port of the 1 st extruder, a quantitative feeder (manufactured by KUBOTA corporation) was used. The decompression degree of each vent hole in the 1 st extruder and the 2 nd extruder was set to-0.095 MPa. A pipe having a diameter of 38mm and a length of 2m was used for connection between the 1 st extruder and the 2 nd extruder. As the part internal pressure control mechanism connecting the resin discharge port of the 1 st extruder and the raw material supply port of the 2 nd extruder, a constant flow pressure valve was used. Further, a resin pressure gauge is provided at each of the 1 st extruder outlet, the central portion of the connecting member between the 1 st extruder and the 2 nd extruder, and the 2 nd extruder outlet. The resin pressure gauge can be used for adjusting the pressure in a member connecting the resin discharge port of the 1 st extruder and the raw material supply port of the 2 nd extruder, or for confirming extrusion fluctuation.
The imidized polymethyl methacrylate resin is produced as follows. First, a polymethyl methacrylate resin (Mw: 10.5 ten thousand) as a raw material resin and a monomethylamine as an imidizing agent were charged into a 1 st extruder to produce an imide resin intermediate 1. At this time, the highest temperature part temperature of the extruder was 280 ℃, the screw rotation speed was 55rpm, the raw material resin supply amount was 150 kg/hr, and the addition amount of monomethylamine was 2.0 parts with respect to 100 parts of the raw material resin. The pressure of the monomethylamine press-in portion of the 1 st extruder was adjusted to 8MPa by a constant flow pressure valve provided in front of the raw material supply port of the 2 nd extruder. Next, the imide resin intermediate 1 was transferred to the 2 nd extruder, and the remaining imidizing reagent and by-products were devolatilized through the rear vent and the vacuum vent. Then, a mixed solution of dimethyl carbonate and triethylamine as an esterifying agent was added to produce an imide resin intermediate 2. At this time, the barrel temperature of the 2 nd extruder was 260 ℃, the screw rotation speed was 55rpm, the amount of dimethyl carbonate added was 3.2 parts per 100 parts of the raw material resin, and the amount of triethylamine added was 0.8 part per 100 parts of the raw material resin. Further, after the esterifying agent was removed through the vent hole, the resultant was extruded from the strand die, cooled in a water tank, and pelletized by a pelletizer, whereby an imidized polymethyl methacrylate resin as a target product was obtained. The imidization ratio of the imidized polymethyl methacrylate resin was 3.7% and the acid value was 0.29mmol/g.
Next, 100 parts by weight of the imidized polymethyl methacrylate resin and 0.62 parts by weight of a triazine-based ultraviolet absorber (trade name: T-712, manufactured by ADEKA Co., ltd.) were mixed together by a twin-screw kneader at 220℃to prepare resin pellets. The resin pellets were dried at 100.5kPa and 100℃for 12 hours, and extruded from a T die at a die temperature of 270℃using a single screw extruder to form a film (thickness: 160 μm). Further, the film was conveyed in the conveying direction of the film at 150 ℃Stretching to a thickness of 80 μm. Subsequently, the film was stretched in a direction perpendicular to the transport direction of the film at 150℃to obtain a base film A ((meth) acrylic resin film) having a thickness of 40. Mu.m. The substrate film A obtained had a transmittance of light having a wavelength of 380nm of 8.5%, an in-plane retardation Re of 0.4nm and a retardation Rth in the thickness direction of 0.78nm. In addition, the substrate film A obtained had a moisture permeability of 61g/m 2 24hr. The transmittance was measured by using a spectrophotometer (device name; U-4100) manufactured by HITACHI HIGH-TECH Co., ltd.) in a wavelength range of 200nm to 800nm, and the transmittance at 380nm was read. The phase difference value was measured at a wavelength of 590nm and a temperature of 23℃using a product name "KOBRA21-ADH" manufactured by prince measuring instruments. The moisture permeability was measured by a method based on JIS K0208 under conditions of a temperature of 40℃and a relative humidity of 92%.
[ coating liquid 1]
Pentaerythritol triacrylate (PETA) (trade name: viscoat #300, concentration 80%) 60 parts, 15 functional urethane acrylic oligomer (trade name: NK OLIGO UA-53H, weight average molecular weight: 2300, concentration 100%) 40 parts, 4-hydroxybutyl acrylate (trade name: 4-HBA, concentration 100%) 20 parts, leveling agent (trade name: GRANDIC PC-4100, manufactured by DIC corporation), photopolymerization initiator (trade name: IRGACURE 907, manufactured by BASF japan), crosslinked acrylic-styrene copolymer resin microparticles (water-logging finished product company, trade name: SSX1055QXE, weight average particle size: 5.5 μm) 8 parts, thickener (thixotropy imparting agent, manufactured by KUNIMINE INDUSTRIES CO, LTD: methyl ethyl ketone: seme on is adjusted to 6% SAN toluene concentration) 2.5 parts, and the total concentration of toluene is 7% by mixing the above components: 3, to prepare a coating liquid 1 (composition for forming an antiglare layer).
[ coating liquid 2]
Coating liquid 2 (antiglare layer-forming composition) was prepared in the same manner as coating liquid 1 except that the fine particles of the crosslinked acrylic-styrene copolymer resin of coating liquid 1 were changed to 6 parts of fine particles of the crosslinked acrylic-styrene copolymer resin having a weight average particle diameter of 3.0 μm.
[ coating liquid 3]
Coating liquid 3 (antiglare layer-forming composition) was prepared in the same manner as coating liquid 1 except that the fine particles of the crosslinked acrylic-styrene copolymer resin of coating liquid 1 were changed to 20 parts by weight of the fine particles of the crosslinked acrylic-styrene copolymer resin having a weight average particle diameter of 8.0 μm.
< measurement method >)
[ surface shape measurement ]
A glass plate (thickness: 1.3 mm) manufactured by Song Nitro Co., ltd was bonded to the surface of the antiglare film on which the antiglare layer was not formed with an adhesive, and the surface shape of the antiglare layer (B) was measured under the condition of a cutoff value of 0.8mm by using a high-precision fine shape measuring instrument (trade name; SURFCORDER ET4000, manufactured by Seiki Seisaku-ku-Mitsui, ltd.), and the maximum height and average tilt angle were calculated. Further, the average value obtained by measuring the maximum height and the average inclination angle at any 10 points is referred to as the maximum height Ry and the average inclination angle θa, respectively. The high-precision fine shape measuring device may automatically calculate the maximum height Ry and the average inclination angle θa. The measurement method and calculation method of the maximum height Ry and the average inclination angle θa are based on JIS B0601 (1994 edition).
[ reflection glare ]
(1) A black acrylic plate (thickness 2.0mm, manufactured by mitsubishi positive, inc.) was attached to the surface of the antiglare film on which the antiglare layer was not formed by an adhesive, and a sample having no back reflection was produced.
(2) In an office environment (about 1000 Lx) in which a display is generally used, the sample is irradiated with a fluorescent lamp (three-wavelength light source), and the antiglare property of the sample is determined by visual observation based on the following criteria.
Determination criterion
And (2) the following steps: the glare-proof property is excellent, and the reflection glare of the fluorescent lamp wheel Guo Yingxiang does not remain.
Delta: the antiglare property is inferior to good but reflection glare can be prevented without any problem.
X: the pinwheel of the fluorescent lamp is not blurred and clearly reflected.
[ film thickness t ]
The maximum thickness of the antiglare layer (B) was measured at the same 10 points as the maximum height Ry measurement point by the high-precision fine shape measuring instrument (trade name; SURFCORDER ET4000, manufactured by Xiao Ban research, inc.). The average value of the measured values of the maximum thickness at the 10 points was used as the maximum thickness d of the antiglare layer (B). The maximum height Ry is subtracted from the maximum thickness d to obtain a value as the film thickness t of the antiglare layer (B). The high-precision fine shape measuring device may automatically calculate the maximum thickness d and the film thickness t. In the present example and the comparative example, the maximum thickness d is substantially equal to the weight average particle diameter of the fine particles, and therefore, a value obtained by subtracting the maximum height Ry from the weight average particle diameter can be approximately used as the film thickness t.
[ haze value ]
In the method of measuring haze value, haze (opacity) based on JIS K7136 (2000 edition) was measured by providing an antiglare film alone using a haze meter (trade name "HM-150" manufactured by the institute of color technology, inc.).
Example 1
A coating layer (coating layer) was formed by applying (coating) a coating liquid 1 to one surface of the substrate (light-transmitting substrate (a)) of production example 1. Then, the above coating layer was dried by heating at 90 ℃ for 1 minute to form a coating film. Then, the film was irradiated with a high-pressure mercury lamp with an integrated light quantity of 300mJ/cm 2 The ultraviolet ray of (a) is cured to form an antiglare layer (B), thereby obtaining an antiglare film as an object. The maximum height Ry value of the antiglare layer (B) was 4.6. Mu.m. In this embodiment, the antiglare layer (B) is an antiglare hard coat layer. The same applies to each of the following examples and comparative examples.
Example 2
An antiglare film was obtained in the same manner as in example 1, except that the thickness of the coating film was changed and the maximum height Ry value of the antiglare layer (B) was set to 2.6 μm.
Example 3
An antiglare film was obtained in the same manner as in example 1, except that the thickness of the coating film was changed and the maximum height Ry value of the antiglare layer (B) was 1.8 μm.
Example 4
An antiglare film was obtained in the same manner as in example 1, except that the thickness of the coating film was changed and the maximum height Ry value of the antiglare layer (B) was 1.1 μm.
Example 5
An antiglare film was obtained in the same manner as in example 1 except that the coating liquid 1 was changed to the coating liquid 2 and the maximum height Ry value of the antiglare layer (B) was set to 2.4 μm.
Example 6
An antiglare film was obtained in the same manner as in example 5, except that the thickness of the coating film was changed and the maximum height Ry value of the antiglare layer (B) was 1.5 μm.
Example 7
An antiglare film was obtained in the same manner as in example 5, except that the thickness of the coating film was changed and the maximum height Ry value of the antiglare layer (B) was 1.1 μm.
Example 8
An antiglare film was obtained in the same manner as in example 1 except that the coating liquid 1 was changed to the coating liquid 3 and the maximum height Ry value of the antiglare layer (B) was 6.9 μm.
Example 9
An antiglare film was obtained in the same manner as in example 1 except that the coating liquid 1 was changed to the coating liquid 3 and the maximum height Ry value of the antiglare layer (B) was set to 4.5 μm.
Example 10
An antiglare film was obtained in the same manner as in example 1 except that the coating liquid 1 was changed to the coating liquid 3 and the maximum height Ry value of the antiglare layer (B) was set to 2.6 μm.
Example 11
An antiglare film was obtained in the same manner as in example 5, except that the thickness of the coating film was changed and the maximum height Ry value of the antiglare layer (B) was 1.8 μm.
Example 12
An antiglare film was obtained in the same manner as in example 5, except that the thickness of the coating film was changed and the maximum height Ry value of the antiglare layer (B) was set to 1.2 μ.
Comparative example 1
On the antiglare layer (a) in the antiglare film of example 2, 8 parts of a coating liquid obtained by removing fine particles of a crosslinked acrylic-styrene copolymer resin (trade name: SSX1055QXE, average particle diameter: 5.5 μm, manufactured by water-accumulating finished product company) from the coating liquid 1 was coated again. Then, the top coat layer was dried and cured in the same manner as in example 1 to form an antiglare layer. The maximum height Ry value of the antiglare layer is less than 1.0 μm.
Comparative example 2
The antiglare layer (A) in the antiglare film of example 5 was coated with a coating liquid prepared by removing 8 parts of fine particles of the crosslinked acrylic-styrene copolymer resin (trade name: SSX1055QXE, average particle diameter: 5.5 μm, manufactured by water-logging finished product Co., ltd.) from the coating liquid 1. Then, the top coat layer was dried and cured in the same manner as in example 1 to form an antiglare layer. The maximum height Ry value of the antiglare layer is less than 1.0 μm.
Comparative example 3
The antiglare layer (A) in the antiglare film of example 10 was coated with a coating liquid prepared by removing 8 parts of fine particles of the crosslinked acrylic-styrene copolymer resin (trade name: SSX1055QXE, average particle diameter: 5.5 μm, manufactured by water-logging finished product Co., ltd.) from the coating liquid 1. Then, the top coat layer was dried and cured in the same manner as in example 1 to form an antiglare layer. The maximum height Ry value of the antiglare layer is less than 1.0 μm.
Comparative example 4
An antiglare film was obtained in the same manner as in example 8, except that the addition amount of the microparticles was changed to 0.3 part without adding SUMECTON SAN (addition amount of 0 part). The average inclination angle thetaa of the irregularities of the antiglare layer in the antiglare film is less than 0.7 degrees.
Comparative example 5
An antiglare film was obtained in the same manner as in example 1, except that the addition amount of the microparticles was changed to 0.1 part without adding SUMECTON SAN (addition amount of 0 parts). The average inclination angle thetaa of the irregularities of the antiglare layer in the antiglare film is less than 0.7 degrees.
The film thicknesses t (thicknesses obtained by subtracting the maximum heights of the convex portions of the irregularities from the maximum thickness of the antiglare layer (B)), the maximum heights Ry of the convex portions of the irregularities on the outermost surface, the average inclination angle θa of the irregularities on the outermost surface, the haze values, and the reflection glare test results of examples 1 to 12 and comparative examples 1 to 5 are summarized in the following table 1.
TABLE 1
As shown in table 1 above, examples 1 to 12 in which Ry and θa satisfy the conditions of the present invention suppressed reflection glare. In contrast, comparative examples 1 to 3 in which Ry and θa were outside the range of the present invention were remarkable in reflection glare. In addition, although Ry satisfies the conditions of the present invention, the reflection glare of comparative examples 4 and 5 in which θa is outside the range of the present invention is also significant.
Industrial applicability
As described above, according to the present invention, an antiglare film, an optical member, and an image display device in which reflection glare is suppressed can be provided. The antiglare film of the present invention can scatter strong external light and suppress reflection, for example, and thus can suppress reflection glare even outdoors. Therefore, the present invention can be suitably used for an image display device such as an outdoor public information display. However, the present invention is not limited to this application, and can be used in a wide range of applications.
This application claims priority based on japanese patent application publication No. 2018-223536, filed on publication No. 29 at 11/2018, the entire disclosure of which is incorporated herein by reference.
Description of the reference numerals
10. Antiglare film
11. Light-transmitting base material (A)
12. Antiglare layer (B)
12a resin layer
12b particles
12c thixotropic imparting agent
13. Other layers
Maximum height of convex part of Ry outermost surface concave-convex
d maximum thickness other than the light-transmitting substrate (A)
Particle diameter of D particles
Maximum height of convex part of concave-convex part of Ry' anti-dazzle layer (B)
Maximum thickness of d' antiglare layer (B)
Film thickness (d '-Ry') of t antiglare layer (B)

Claims (13)

1. An antiglare film comprising a light-transmitting substrate (A) and an antiglare layer (B) laminated on the light-transmitting substrate,
an uneven portion is formed on the outermost surface of the antiglare film on the antiglare layer (B) side,
the irregularities satisfy the following expressions (1) and (2),
9≥Ry≥1 (1)
8.0≥θa≥2.9 (2)
in the above formula (1), ry is the maximum height [ μm ] of the convex portion of the concave-convex,
in the above formula (2), θa is an average inclination angle of the irregularities [ ° ].
2. The antiglare film according to claim 1, wherein the antiglare layer (B) comprises fine particles.
3. The antiglare film according to claim 2, wherein the antiglare layer (B) has irregularities formed on a surface opposite to the light-transmitting substrate (A),
the weight average particle diameter of the fine particles is larger than the thickness obtained by subtracting the maximum height of the convex portions of the irregularities from the maximum thickness of the antiglare layer (B).
4. The antiglare film according to claim 2 or 3, wherein the fine particles have a weight average particle diameter in the range of 2 to 10 μm.
5. The antiglare film according to any one of claims 1 to 3, wherein a further layer is laminated on a surface of the antiglare layer (B) on the opposite side from the light-transmitting substrate (a).
6. An antiglare film comprising a light-transmitting substrate (A) and, laminated thereon, an antiglare layer (B) and another layer in this order,
on the outermost surface of the other layer is formed a relief,
the irregularities satisfy the following expressions (1) and (2),
9≥Ry≥1 (1)
8.0≥θa≥2.9 (2)
in the above formula (1), ry is the maximum height [ μm ] of the convex portion of the concave-convex,
in the above formula (2), θa is an average inclination angle of the irregularities [ ° ].
7. The method for producing an antiglare film according to any one of claims 1 to 6, comprising an antiglare layer (B) forming step of forming the antiglare layer (B) on the light-transmitting substrate (A) so as to satisfy the numerical formulas (1) and (2),
the antiglare layer (B) forming step includes: a coating step of coating the light-transmitting substrate (A) with a coating liquid; and a coating film forming step of forming a coating film by drying the applied coating liquid,
the coating liquid contains a resin and a solvent.
8. The production method according to claim 7, wherein the antiglare layer (B) forming step further comprises a curing step of curing the coating film.
9. The manufacturing method according to claim 7 or 8, wherein the coating liquid contains fine particles.
10. An optical member comprising the antiglare film according to any one of claims 1 to 6.
11. The optical member according to claim 10, which is a polarizing plate.
12. An image display device comprising the antiglare film according to any one of claims 1 to 6, or the optical member according to claim 10 or 11.
13. The image display device of claim 12, being a public information display.
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