CN113614584A - Light diffusion film, method for producing light diffusion film, optical member, display panel for image display device, and image display device - Google Patents

Light diffusion film, method for producing light diffusion film, optical member, display panel for image display device, and image display device Download PDF

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Publication number
CN113614584A
CN113614584A CN202080023415.4A CN202080023415A CN113614584A CN 113614584 A CN113614584 A CN 113614584A CN 202080023415 A CN202080023415 A CN 202080023415A CN 113614584 A CN113614584 A CN 113614584A
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China
Prior art keywords
light diffusion
light
layer
film
diffusion layer
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CN202080023415.4A
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Chinese (zh)
Inventor
茂手木佑辅
足立贵之
济木雄二
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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
    • G02B5/0205Diffusing 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
    • G02B5/0221Diffusing 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 the surface having an irregular structure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02Physical, chemical or physicochemical properties
    • B32B7/023Optical properties
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04Coating
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/04Optical elements characterised by the material of which they are made; Optical coatings for optical elements made of organic materials, e.g. plastics
    • 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
    • G02B5/0236Diffusing 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
    • G02B5/02Diffusing elements; Afocal elements
    • G02B5/0273Diffusing elements; Afocal elements characterized by the use
    • G02B5/0278Diffusing elements; Afocal elements characterized by the use used in transmission
    • 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
    • G02F1/133504Diffusing, scattering, diffracting elements
    • 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

Abstract

Provided is a light-diffusing film which can achieve both light diffusibility and light transmittance. A light diffusion film (10) characterized in that a light diffusion layer (B) (12) is laminated on at least one side of a transparent base material (A) (11), wherein unevenness is formed on the outermost surface of the light diffusion film on the side of the light diffusion layer (B) (12), and the unevenness satisfies the following expressions (1) and (2). Sm (1) is more than or equal to 0.110 and Rsk is more than or equal to 0.200 (2). In the above formula (1), Sm is an average interval (mm) between the irregularities of the above-described concave-convex shape measured in accordance with JIS B0601(1994 version), and in the above formula (2), Rsk is an eccentricity of the above-described concave-convex shape measured in accordance with JIS B0601(1994 version).

Description

Light diffusion film, method for producing light diffusion film, optical member, display panel for image display device, and image display device
Technical Field
The present invention relates to a light diffusion film, a method for manufacturing the light diffusion film, an optical member, a display panel for an image display device, and an image display device.
Background
In an image display device using a backlight, a light diffusion film may be used to make the light amount of the entire screen uniform and reduce display unevenness (patent document 1).
Documents of the prior art
Patent document
Patent document 1: japanese laid-open patent publication No. 10-096922
Disclosure of Invention
Problems to be solved by the invention
The light diffusion film has a problem that if the light diffusion property is intended to be improved, the light transmittance is liable to be lowered.
Accordingly, an object of the present invention is to provide a light diffusion film that can achieve both light diffusibility and light transmittance, a method for producing the light diffusion film, an optical member, a display panel for an image display device, and an image display device.
Means for solving the problems
In order to achieve the above object, the light diffusion film of the present invention is characterized in that,
a light diffusion layer (B) laminated on at least one side of the transparent base material (A),
the light diffusion film has a concave-convex portion formed on the outermost surface thereof on the light diffusion layer (B) side,
the concavo-convex shape satisfies the following formulas (1) and (2).
0.110≤Sm (1)
Rsk≤0.200 (2)
In the above formula (1), Sm is an average interval (mm) of the irregularities of the above-mentioned irregular shape measured in accordance with JIS B0601(1994 version),
in the above formula (2), Rsk is the skewness (skewness) of the above-described uneven shape measured in accordance with JIS B0601(1994 version).
The method for producing a light-diffusing film of the present invention is a method for producing a light-diffusing film of the present invention, and is characterized by comprising:
a light diffusion layer (B) forming step of forming the light diffusion layer (B) on the transparent base material (a); and
a step of forming the irregularities on the outermost surface of the light diffusion film on the light diffusion layer (B) side so as to satisfy the expressions (1) and (2),
the light diffusion layer (B) forming step includes: a coating step of coating the transparent substrate (A) with a coating liquid, and a coating film forming step of drying the coating liquid to form a coating film,
the aforementioned coating liquid contains a resin and a solvent.
The optical member of the present invention is an optical member comprising the light-diffusing film of the present invention.
The display panel for an image display device of the present invention is a display panel for an image display device comprising the light-diffusing film of the present invention, and the light-diffusing film of the present invention is used on the visually recognizable back side of the display panel for an image display device.
The image display device of the present invention is an image display device including the light-diffusing film of the present invention, the optical member of the present invention, or the display panel for an image display device of the present invention.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, a light diffusion film that can achieve both light diffusibility and light transmittance, a method for producing the light diffusion film, an optical member, a display panel for an image display device, and an image display device can be provided.
Drawings
FIG. 1 is a cross-sectional view showing an example of the structure of the light diffusion film of the present invention.
Detailed Description
Next, the present invention will be described more specifically by way of examples. However, the present invention is not limited to the following description.
The light diffusion film of the present invention may have a light transmittance loss ratio of 3.0% or less at a wavelength of 380 to 780nm, for example.
In the light diffusion film of the present invention, for example, another layer may be further laminated on the surface of the light diffusion layer (B) opposite to the transparent base material (a).
The light diffusion film of the present invention may be, for example, a light diffusion film characterized in that,
a light diffusion layer (B) and another layer are laminated on at least one side of a transparent base material (A),
the outermost surface of the other layer is formed with irregularities,
the concavo-convex shape satisfies the following formulas (1) and (2).
0.110≤Sm (1)
Rsk≤0.200 (2)
In the above formula (1), Sm is an average interval (mm) of the irregularities of the above-mentioned irregular shape measured in accordance with JIS B0601(1994 version),
in the above formula (2), Rsk is the skewness of the above-mentioned uneven shape measured in accordance with JIS B0601(1994 version).
In the light diffusing film of the present invention, for example, the transparent substrate (a) may contain an acrylic resin.
In the light diffusing film of the present invention, the transparent substrate (a) may be an acrylic film, for example.
In the light diffusion film of the present invention, for example, the light diffusion layer (B) may contain a binder resin and a filler. In addition, for example, the aforementioned filler may be a particle. For example, the difference in refractive index between the particles and the binder resin may be 0.200 or less.
The light diffusion film of the present invention may have, for example, an intermediate layer between the transparent base material (a) and the light diffusion layer (B), the intermediate layer containing a resin derived from the transparent base material (a) and a resin derived from the light diffusion layer (B).
The light diffusion film of the present invention may be, for example, a light diffusion film used on the back side of a display panel for an image display device for visual recognition.
In the method for producing a light diffusing film of the present invention, for example, the light diffusing layer (B) forming step may further include a curing step of curing the coating film.
In the method for producing a light diffusing film of the present invention, the solvent may contain toluene and cyclopentanone, for example.
In the method for producing a light diffusion film of the present invention, for example, the light diffusion film may be a light diffusion film including the other layer, and the step of forming the unevenness may include a step of forming the other layer on the light diffusion layer (B).
The image display device of the present invention may be, for example, an image display device including the display panel for an image display device and the backlight for an image display device of the present invention.
[1. light-diffusing film ]
The light diffusion film of the present invention is characterized in that a light diffusion layer (B) is laminated on at least one side of a transparent base material (a), and irregularities are formed on the outermost surface of the light diffusion film on the side of the light diffusion layer (B), and the irregularities satisfy the following expressions (1) and (2).
0.110≤Sm (1)
Rsk≤0.200 (2)
In the above formula (1), Sm is an average interval (mm) of the irregularities of the above-mentioned irregular shape measured in accordance with JIS B0601(1994 version),
in the above formula (2), Rsk is the skewness of the above-mentioned uneven shape measured in accordance with JIS B0601(1994 version).
The light diffusion film of the present invention has a large Sm and a small Rsk. That is, the light diffusion film of the present invention has a gentle uneven shape on the outermost surface on the light diffusion layer (B) side. Thus, the light-diffusing film of the present invention can achieve both high light diffusibility and high light transmittance.
In a general light diffusing film, for example, for light diffusing, the interval between peaks in the uneven shape on the surface is short, the valley component is large relative to the center line of the surface height, and the unevenness is large. Thus, the light loss is large and the light transmittance is low. In contrast, the present inventors have found that both light diffusibility and light transmittance can be achieved by setting Sm to be within the range of the above equation (1) and setting Rsk to be within the range of the above equation (2). In the light diffusing film of the present invention, the Sm is as large as 0.110 or more, that is, the interval between peaks in the surface irregularities is large. The Rsk is small and 0.200 or less, which means that the peak and valley components in the surface roughness are nearly uniform, as will be described later. It is considered that by flattening the uneven shape on the outermost surface on the light diffusion layer (B) side in this way, the surface area of the uneven shape can be reduced to suppress back surface reflection, and therefore, light loss is reduced and light transmittance is increased.
Fig. 1 is a cross-sectional view showing an example of the structure of the light diffusion film of the present invention. As shown in the drawing, the light diffusion film 10 is formed by laminating a light diffusion layer (B)12 on one surface of a transparent base (a) 11. The light diffusion layer (B)12 contains particles 12B and a thixotropy-imparting agent 12c in a resin layer 12 a. The resin layer 12a is formed of a binder resin. The particles 12b and the thixotropy imparting agent 12c are fillers. The surface of the light diffusion layer (B)12 opposite to the transparent base material (a)11 is formed with irregularities. The uneven shape satisfies the above formula (1) (0.110. ltoreq. Sm) and the above formula (2) (Rsk. ltoreq.0.200). However, the light diffusing film of the present invention is not limited thereto, and for example, the particles 12b and the thixotropy imparting agent 12c are each optionally present or absent.
In the light diffusion film of the present invention, as described above, another layer may be further laminated on the surface of the light diffusion layer (B) opposite to the transparent base material (a). Wherein the aforementioned other layers are optionally present or absent. When the other layer is present, the other layer may be, for example, an adhesive layer, a low refractive index layer, a high refractive index layer, a conductive layer, a UV absorbing layer, an antifouling layer, a high hardness layer, a stress relaxation layer, a primer layer, or the like. The other layer may be one layer or a plurality of layers, and in the case of a plurality of layers, one layer or a plurality of layers may be provided. For example, the other layer may be an optical film having a strictly controlled thickness and refractive index, or a laminate of two or more layers of the optical film.
In the light diffusion film of the present invention, the "outermost surface on the light diffusion layer (B) side" is the outermost surface on the light diffusion layer (B) side. Specifically, the "outermost surface on the light diffusion layer (B) side" is a surface of the light diffusion layer (B) on the side opposite to the transparent base material (a) when the other layer is not present (for example, fig. 1). In addition, the "outermost surface on the light diffusion layer (B) side" is an outermost surface on the opposite side of the other layer from the transparent base material (a) when the other layer is present (not shown).
In the present invention, Sm in the above formula (1) is an amount representing an average value of the lengths of the contour curve elements in the reference length. Sm of the above formula (1) is an amount measured in accordance with JIS B0601(1994 version), and can be measured, for example, by the method described in examples described later.
In the light diffusion film of the present invention, Sm of the uneven shape on the outermost surface on the light diffusion layer (B) side is 0.110 or more, for example, 0.120 or more, 0.130 or more, or 0.140 or more, as shown in the above formula (1). The upper limit of Sm is not particularly limited, but is, for example, 0.200 or less.
In the present invention, Rsk (skewness) in the above formula (2) represents a cubic average of z (x) over a reference length which is dimensionless by the cube of the root mean square height Rq. Skewness is a skewness indicating symmetry between a crest and a trough around an average line. If Rsk is 0, it is symmetrical (normal distribution) with respect to the average line, if Rsk >0, it is shifted to the lower side with respect to the average line, and if Rsk <0, it is shifted to the upper side with respect to the average line. Rsk in the above formula (2) is an amount measured in accordance with JIS B0601(1994 version), and can be measured, for example, by the method described in examples described later.
In the light diffusion film of the present invention, Rsk of the uneven shape on the outermost surface on the light diffusion layer (B) side is 0.200 or less, for example, 0.180 or less, 0.160 or less, or 0.120 or less, as shown in the above formula (2). The lower limit of Rsk is not particularly limited, but is, for example, -0.200 or more.
In the light diffusion film of the present invention, the height Rz of the microscopic unevenness ten points (also referred to as ten-point average height) of the uneven shape on the outermost surface on the light diffusion layer (B) side may be, for example, 1.700 or less, 1.200 or less, 1.000 or less, or 0.900 or less. The lower limit of Rz is not particularly limited, and may be, for example, 0.200 or more. By making Rz small, higher light transmittance becomes easier to obtain. The Rz can be measured by, for example, the measurement method described in the examples described later. The Rz can be represented by, for example, the sum of the average value from the maximum peak height to the fifth peak height of the profile curve and the average value from the deepest valley depth to the fifth valley depth in the reference length.
In the present invention, the light transmittance of the light diffusion film can be represented by, for example, the above-mentioned light transmittance loss ratio (light transmittance loss ratio at a wavelength of 380 to 780 nm). The light transmittance loss rate can be expressed as a light transmittance loss rate with respect to the light-transmitting substrate. The light-transmitting substrate is, for example, a transparent plastic film substrate, and the light-diffusing film of the present invention is a transparent substrate (a). The light transmittance loss ratio can be calculated based on the following equation, where Y is the light transmittance of only the light-transmitting substrate, Y1, and Y2 is the light transmittance of the light-diffusing film. The light transmittance loss ratio can be measured and calculated by, for example, the measuring method and the calculating method described in the examples described later. The light transmittance loss ratio is not particularly limited, and may be, for example, 3.0% or less, 2.5% or less, or 2.0% or less, as described above. The lower limit of the light transmittance loss rate is not particularly limited, and may be, for example, 0% or a value exceeding 0%.
Light transmittance loss ratio (%) (Y1-Y2)/Y1 × 100
The light diffusing film of the present invention may have a haze value of 10% or more, 15% or more, 18% or more, or 20% or more, for example, 40% or less, 35% or less, 32% or less, or 28% or less. When the overall haze value is high, the light diffusibility tends to be high. When the overall haze value is low, the light transmittance tends to be high. The haze value is an index relating to transparency of an optical film or the like, and indicates haze (haze). The haze value can be calculated from the ratio of the diffuse transmitted light to the total transmitted light, and is affected by the roughness of the surface. In the light diffusing film of the present invention, the overall haze value can be defined by the following formula, for example, and can be measured by the measurement method described in the examples described below, for example.
Integral haze value (%). Td/Tt × 100
Td: diffuse transmittance
Tt: total light transmittance
The transparent substrate (a), the light diffusion layer (B), and the other layers will be described below by way of examples.
The transparent substrate (a) is not particularly limited, and examples thereof include a transparent plastic film substrate. The transparent plastic film substrate is not particularly limited, and a transparent plastic film substrate having excellent visible light transmittance (preferably, light transmittance of 90% or more) and excellent transparency (preferably, a transparent plastic film substrate having a haze value of 1% or less) is preferable, and examples thereof include the transparent plastic film substrate described in jp 2008-90263 a. Specific examples of the material for forming the transparent plastic film substrate include polyester polymers such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), cellulose polymers such as cellulose Diacetate (DAC) and cellulose Triacetate (TAC), polycarbonate polymers, and acrylic polymers such as polymethyl methacrylate. Examples of the material for forming the transparent plastic film substrate include styrene polymers such as polystyrene and acrylonitrile-styrene copolymer, olefin polymers such as polyethylene, polypropylene, polyolefin having a cyclic and/or norbornene structure, and ethylene-propylene copolymer, vinyl chloride polymers, and amide polymers such as nylon and aromatic polyamide. Further, examples of the material for forming the transparent plastic film substrate include imide polymers, sulfone polymers, polyethersulfone polymers, polyether ether ketone polymers, polyphenylene sulfide polymers, vinyl alcohol polymers, vinylidene chloride polymers, vinyl butyral polymers, acrylate polymers, polyoxymethylene polymers, epoxy polymers, and blends of the above polymers. As the transparent plastic film substrate, a transparent plastic film substrate having little optical birefringence can be suitably used. The light diffusion film of the present invention can be used as a protective film for a polarizing plate, and in this case, a film made of polyethylene terephthalate (PET), cellulose Triacetate (TAC), polycarbonate, an acrylic polymer, polyolefin having a cyclic and/or norbornene structure, or the like is preferable as the transparent plastic film substrate. In the present invention, the transparent plastic film substrate may be a polarizer itself, as described later. In such a configuration, since a protective layer made of TAC or the like is not required and the structure of the polarizing plate can be simplified, the number of manufacturing processes of the polarizing plate and the image display device can be reduced, and the production efficiency can be improved. In addition, with such a configuration, the polarizing plate can be made thinner. In the case where the transparent plastic film base material is a polarizer, the light diffusion layer (B) and the low reflection layer (C) function as protective layers. In the case of such a configuration, the light diffusion film also functions as a cover plate when mounted on the surface of a liquid crystal cell, for example.
In the present invention, the thickness of the transparent substrate (A) is not particularly limited, but is, for example, in the range of 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 transparent 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 light diffusing film of the present invention, for example, as described above, the transparent substrate (a) may contain an acrylic resin.
In the light diffusing film of the present invention, the transparent substrate (a) may be an acrylic film, for example, as described above. In this case, the acrylic film forming the transparent substrate (a) may contain a resin other than an acrylic resin. The content of the acrylic resin contained in the transparent substrate (a) is not particularly limited, but may be, for example, 80 mass% or more, 85 mass% or more, or 90 mass% or more, and the upper limit value is not particularly limited, but may be, for example, 100 mass% or less, or 95 mass% or less.
With regard to the light diffusion film of the present invention, for example, the light diffusion layer (B) may contain a resin (binder resin) and a filler. The aforementioned filler may comprise at least one of particles and a thixotropy-imparting agent (thixotropic agent).
For example, by including a thixotropy-imparting agent in the light diffusion layer (B) without including particles, the light diffusion film of the present invention in which Sm and Rsk are small and the unevenness of the outermost surface is gentle can be produced. Further, by including the thixotropy-imparting agent and the particles having a small particle diameter in the light diffusion layer (B), the light diffusion film of the present invention having small Sm and Rsk and having gentle irregularities on the outermost surface can be similarly produced.
In the light diffusion film of the present invention, for example, the resin contained in the light diffusion layer (B) may contain an acrylate resin (also referred to as an acrylic resin).
In the light diffusion film of the present invention, for example, the resin contained in the light diffusion layer (B) may contain a urethane acrylate resin.
In the light diffusion film of the present invention, for example, the resin contained in the light diffusion layer (B) may be a copolymer of a curable urethane acrylate resin and a polyfunctional acrylate.
In the light diffusion film of the present invention, for example, the light diffusion layer (B) is formed using a light diffusion layer forming material containing a resin and a filler, and the light diffusion layer (B) can have a gathered portion forming a convex portion on the surface of the light diffusion layer (B) by gathering the filler. In the light diffusing layer (B), the filler may be present in a plurality of collected states in one direction of the plane direction of the light diffusing layer (B). In the image display device of the present invention, for example, the light diffusion film of the present invention may be disposed such that one direction in which the plurality of fillers are collected coincides with the longitudinal direction of the black matrix pattern.
In the light diffusion film of the present invention, the aforementioned thixotropy-imparting agent may be, for example, at least one selected from the group consisting of organoclays, oxidized polyolefins, and modified ureas. In addition, the aforementioned thixotropy imparting agent may be, for example, a thickener.
The light diffusion film of the present invention may contain the thixotropy-imparting agent in an amount of, for example, 0.2 to 5 parts by weight based on 100 parts by weight (mass) of the resin of the light diffusion layer (B).
The light diffusion film of the present invention may contain the particles in an amount of, for example, 0.2 to 12 parts by weight or 0.5 to 12 parts by weight based on 100 parts by weight of the resin of the light diffusion layer (B).
In the method for producing a light diffusion film of the present invention, the surface shape of the light diffusion film may be adjusted by adjusting the weight part of the particles in the light diffusion layer-forming material with respect to 100 parts by weight of the resin.
By providing the aggregation portion formed by aggregating the particles, for example, the light diffusion film of the present invention having a gentle uneven shape can be obtained. For example, by providing the light collecting portion, the average interval sm (mm) between the irregularities on the surface of the light diffusion layer (B) is increased. The light diffusion film having such a surface shape can effectively prevent reflection of fluorescent lamps and the like. However, the light diffusion film of the present invention is not limited thereto.
The light diffusion layer (B) is formed, for example, as described below, in the following manner: the coating liquid is prepared by applying a coating liquid containing the resin, the filler and a solvent to at least one surface of the transparent substrate (a) to form a coating film, and then removing the solvent from the coating film. Examples of the resin include thermosetting resins and ionizing radiation curable resins that are cured by ultraviolet rays or light. As the resin, commercially available thermosetting resins, ultraviolet curable resins, and the like can be used.
As the thermosetting resin and the ultraviolet curable resin, for example, a curable compound having at least one group of an acrylate group and a methacrylate group, which is cured by heat, light (ultraviolet rays, etc.) or an electron beam, can be used, and examples thereof include oligomers or prepolymers such as acrylates and methacrylates of polyfunctional compounds such as silicone resins, polyester resins, polyether resins, epoxy resins, urethane resins, alkyd resins, spiroacetal resins, polybutadiene resins, polythiol polyene resins, and polyols. These may be used alone in 1 kind, or may be used in combination of 2 or more kinds.
The aforementioned resin may also contain a reactive diluent having at least one group selected from an acrylate group and a methacrylate group. The reactive diluent may be, for example, one described in Japanese patent application laid-open No. 2008-88309, and may include, for example, 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 hardness of the light diffusion layer (B) can be made excellent. Examples of the reactive diluent include butanediol glyceryl ether diacrylate, isocyanuric acid acrylate, and isocyanuric acid methacrylate. These may be used alone in 1 kind, or may be used in combination of 2 or more kinds.
The particles for forming the light diffusion layer (B) provide light diffusion properties by forming the surface of the formed light diffusion layer (B) into a concavo-convex shape, and mainly function to control the haze value of the light diffusion layer (B). The haze value of the light diffusion layer (B) can be designed by controlling the difference in refractive index between the particles and the resin. The difference in refractive index between the particles and the resin is not particularly limited, and may be, for example, 0.200 or less, 0.150 or less, 0.100 or less, or 0.050 or less, as described above, and may be, for example, 0 or more, a numerical value exceeding 0, or 0.010 or more, 0.020 or more, or 0.030 or more. Examples of the particles include inorganic particles and organic particles. The inorganic 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 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 particles and organic particles may be used alone or in combination of two or more.
The particle diameter (D) (weight average particle diameter) of the particles is not particularly limited, and is, for example, in the range of 2 to 10 μm. By setting the weight average particle diameter of the particles to the above range, for example, a light diffusing film having more excellent light diffusing properties and suppressed reflection can be obtained. From the viewpoint of suppressing the reflection from the oblique direction, it is preferable that the weight average particle diameter of the particles is not too small. From the viewpoint of suppressing reflection from the front direction, the weight average particle diameter of the particles is preferably not too large. The weight average particle diameter of the particles may be, for example, 2.2 μm or more, 2.3 μm or more, 2.5 μm or more, or 3.0 μm or more, or may be 9.0 μm or less, 8.0 μm or less, 7.0 μm or less, or 6.0 μm or less. The weight average particle diameter of the particles may be, for example, 2.2 to 9.0 μm, 2.2 to 8.0 μm, 2.2 to 7.0 μm, 2.2 to 6.0 μm, 2.3 to 9.0 μm, 2.3 to 8.0 μm, 2.3 to 7.0 μm, 2.3 to 6.0 μm, 2.5 to 9.0 μm, 2.5 to 8.0 μm, 2.5 to 7.0 μm, 2.5 to 6.0 μm, 3.0 to 9.0 μm, 3.0 to 8.0 μm, 3.0 to 7.0 μm, or 6.0 to 3.0 μm. The weight average particle diameter of the particles can be measured by, for example, the coulter counter method. For example, the number and volume of the particles are measured and the weight average particle diameter is calculated by measuring the resistance of the electrolyte corresponding to the volume of the particles when the particles pass through the pores using a particle size distribution measuring apparatus (trade name: Coulter Multisizer, Beckman Coulter, Inc.) using a pore resistance method.
The shape of the particles is not particularly limited, and may be, for example, roughly spherical in the form of microspheres, or irregularly shaped such as powder, and roughly spherical particles are preferred, roughly spherical particles having an aspect ratio of 1.5 or less are more preferred, and spherical particles are most preferred.
The proportion of the particles in the light diffusion layer (B) may be, for example, 0.1 part by weight or more, 0.2 part by weight or more, 0.3 part by weight or more, or 0.5 part by weight or more, or 10 parts by weight or less, 8 parts by weight or less, 7 parts by weight or less, or 6 parts by weight or less, relative to 100 parts by weight of the resin. The proportion of the particles may be, for example, 0.1 part by weight or more and 10 parts by weight or less, 0.1 part by weight or more and 8 parts by weight or less, 0.1 part by weight or more and 7 parts by weight or less, 0.1 part by weight or more and 6 parts by weight or less, 0.2 part by weight or more and 10 parts by weight or less, 0.2 part by weight or more and 8 parts by weight or less, 0.2 part by weight or more and 7 parts by weight or less, 0.2 part by weight or more and 6 parts by weight or less, 0.3 part by weight or more and 10 parts by weight or less, 0.3 part by weight or more and 8 parts by weight or less, 0.3 part by weight or more and 7 parts by weight or less, 0.3 part by weight or more and 6 parts by weight or less, 0.5 part by weight or more and 10 parts by weight or less, 0.5 part by weight or more and 8 parts by weight or less, 0.5 part by weight or more and 7 parts by weight or less with respect to 100 parts by weight or less of the resin. By setting the ratio of the particles to the above range, for example, the aggregated portion can be formed appropriately, and a light diffusing film having more excellent light diffusion and suppressed reflection can be obtained.
In the aforementioned light diffusion layer (B), the aforementioned filler may be a particle and a thixotropy-imparting agent. The aforementioned thixotropy-imparting agent may be contained alone, or the aforementioned thixotropy-imparting agent may be further contained on the basis of the aforementioned particles. By containing the aforementioned thixotropy-imparting agent, control of the aggregation state of the aforementioned particles can be easily performed. Examples of the thixotropy-imparting agent include organoclays, oxidized polyolefins, and modified ureas.
The organoclay is preferably an organically treated layered clay in order to improve the affinity with the resin. The organoclay may be prepared by itself or may be commercially available. Examples of the commercially available products include: lucentite SAN, Lucentite STN, Lucentite SEN, Lucentite SPN, Somasif ME-100, Somasif MAE, Somasif MTE, Somasif MEE, Somasif MPE (trade name, all Co-op Chemical Co., manufactured by 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, ORGANITE D, ORGANITE T (trade name, HOJUN Co., manufactured by Ltd.); kunipia F, Kunipia G4 (trade name, both kuunimine INDUSTRIES co., ltd.); TIXOGEL VZ, CLAYTONE HT, CLAYTONE 40 (trade name, manufactured by Rockwood Additives Ltd.) and the like.
The oxidized polyolefin may be prepared by itself, or a commercially available product may be used. Examples of the commercially available products include DISPARLON 4200-20 (trade name, manufactured by NAKANGCHENJIU Co., Ltd.), FLOWNON SA300 (trade name, manufactured by Kyoho chemical Co., Ltd.), and the like.
The modified urea is a reaction product of isocyanate monomer or adduct thereof and organic amine. The modified urea may be prepared by itself or a commercially available product may be used. Examples of the commercially available product include BYK410 (manufactured by BYK corporation).
The thixotropy-imparting agent may be used singly or in combination of two or more.
The thixotropic agent in the light diffusion layer (B) is preferably contained in an amount of 0.2 to 5 parts by weight, more preferably 0.4 to 4 parts by weight, based on 100 parts by weight of the resin.
The maximum thickness (d') of the light diffusion layer (B) is not particularly limited, but is preferably in the range of 3 to 12 μm. By setting the maximum thickness (d') of the light diffusion layer (B) to the above range, it is possible to prevent occurrence of curling in the light diffusion film, and to avoid a problem of lowering of productivity such as poor transportability. When the thickness (D) is in the above range, the weight average particle diameter (D) of the particles is preferably in the range of 2 to 10 μm as described above. By setting the maximum thickness (D') of the light diffusion layer (B) and the weight-average particle diameter (D) of the particles to the above combinations, a light diffusion film having excellent light diffusibility can be produced. The maximum thickness (d') of the light diffusion layer (B) is more preferably in the range of 3 to 8 μm.
The ratio D/D of the thickness (D') of the light diffusion layer (B) to the weight-average particle diameter (D) of the particles may be, for example, 1 or less, 0.9 or less, 0.8 or less, 0.7 or less, or 0.6 or less, and may be 0.1 or more, 0.2 or more, 0.3 or more, or 0.4 or more. The D/D may be, for example, 0.1 or more and 1 or less, 0.2 or more and 1 or less, 0.3 or more and 1 or less, 0.4 or more and 1 or less, 0.1 or more and 0.9 or less, 0.2 or more and 0.9 or less, 0.3 or more and 0.9 or less, 0.4 or more and 0.9 or less, 0.1 or more and 0.8 or less, 0.2 or more and 0.8 or less, 0.3 or more and 0.8 or less, 0.4 or more and 0.8 or less, 0.1 or more and 0.7 or less, 0.2 or more and 0.7 or less, 0.4 or more and 0.7 or less, 0.1 or more and 0.6 or less, 0.2 or more and 0.6 or less, 0.3 or more and 0.6 or less. By having such a relationship, a light diffusion film having more excellent light diffusion properties and suppressed reflection can be obtained.
In the light diffusion film of the present invention, for example, the light diffusion layer (B) may have a plurality of collecting portions forming convex portions on the surface of the light diffusion layer (B) by collecting the filler, and the filler may be present in a state of being collected in a plurality in one direction of the surface direction of the light diffusion layer (B) in the collecting portions forming convex portions. This can prevent, for example, reflection of the fluorescent lamp. However, the light diffusion film of the present invention is not limited thereto.
The light diffusion film of the present invention may have, for example, an intermediate layer between the transparent substrate (a) and the light diffusion layer (B), the intermediate layer containing a resin derived from the transparent substrate (a) and a resin derived from the light diffusion layer (B). By controlling the thickness of the intermediate layer, the surface shape of the light diffusion layer (B) can be controlled. For example, when the thickness of the interlayer is increased, Sm and Rsk tend to be increased, and when the thickness of the interlayer is decreased, Sm and Rsk tend to be decreased. The presence of the intermediate layer can be confirmed by observing the cross section of the light diffusion film with a microscope, for example. The thicknesses of the intermediate layer, the transparent substrate (a), and the light diffusion layer (B) can be measured by observing the cross section of the light diffusion film with a microscope to determine the interfaces between the transparent substrate (a), the intermediate layer, and the light diffusion layer (B). Examples of the Microscope include a Transmission Electron Microscope (TEM). For example, time-of-flight secondary ion mass spectrometry or the like can be used to determine the interface. Such a method may be used, for example, where the interface is difficult to determine using a microscope.
In the present invention, the mechanism for forming the intermediate layer (also referred to as a penetration layer or a compatibility layer) is not particularly limited, and is formed, for example, by the drying step in the method for producing a light diffusion film of the present invention. Specifically, for example, in the drying step, the coating liquid for forming the light diffusion layer (B) permeates into the transparent base material (a), and the intermediate layer including the resin derived from the transparent base material (a) and the resin derived from the light diffusion 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 transparent base material (a) and the resin contained in the light diffusion layer (B). In addition, as for the resin contained in the intermediate layer, for example, at least one of the resin contained in the transparent base material (a) and the resin contained in the light diffusion layer (B) may be chemically changed by heating, light irradiation, or the like.
The thickness ratio R of the intermediate layer defined by the following formula (5) is not particularly limited, and is, for example, 0.10 to 0.80, and may be, 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 intermediate layer can be confirmed by observing a cross section of the light diffusion film with a Transmission Electron Microscope (TEM), for example, and the thickness can be measured.
R=[DC/(DC+DB)] (5)
In the above formula (5), DBThe thickness of the light diffusion layer (B) [ mu m ]],DCThe thickness of the intermediate layer [ mu ] m]。
In the light diffusion film of the present invention, for example, as described above, the light diffusion layer (B) may have a concentration portion forming a convex portion on the surface of the light diffusion layer (B) by the filler being concentrated, and the filler may be present in a plurality of concentration portions forming the convex portion in one direction in the plane direction of the light diffusion layer (B). Thereby, the convex portion has a gentle shape having anisotropy. However, the light diffusion film of the present invention is not limited thereto.
The surface shape of the light diffusion layer (B) can be arbitrarily designed by controlling the aggregation state of the filler contained in the light diffusion layer forming material. The aggregation state of the filler can be controlled by, for example, the material of the filler (for example, the chemical modification state of the particle surface, the affinity for a solvent or a resin, or the like), the kind or combination of a resin (binder) and a solvent, or the like. In addition, the aggregation state of the particles can be precisely controlled by the thixotropy-imparting agent. As a result, in the present invention, the surface shape of the light diffusion film can be controlled (adjusted) in a wide range, and for example, the convex portion can be made to have a gentle shape by setting the aggregation state of the filler as described above. Further, as described above, by adjusting the weight part of the particles in the light diffusion layer forming material with respect to 100 parts by weight of the resin, the surface shape of the light diffusion film can be controlled (adjusted) in a wider range.
The convex portion of the light diffusion film of the present invention may have a gentle shape to prevent the formation of a protrusion on the surface of the light diffusion layer (B) which is an appearance defect, but the present invention is not limited thereto. In addition, the light diffusion film of the present invention may have some of the aforementioned particles at positions directly or indirectly overlapping with the thickness direction of the light diffusion layer (B), for example.
The other layer is not particularly limited, and may be, for example, a pressure-sensitive adhesive layer, an adhesive layer, a low refractive index layer, a high refractive index layer, a conductive layer, a UV absorbing layer, an antifouling layer, a high hardness layer, a stress relaxation layer, a primer layer, or the like, as described above. The other layer may be one layer or a plurality of layers, and in the case of a plurality of layers, one layer or a plurality of layers may be provided. For example, the other layer may be an optical film having a strictly controlled thickness and refractive index, or a laminate of two or more optical films.
[2. method for producing light-diffusing film ]
The method for producing the light diffusion film of the present invention is not particularly limited, and the light diffusion film can be produced by any method, and is preferably produced by the method for producing the light diffusion film of the present invention.
The method for producing the light diffusion film can be performed, for example, as follows.
First, the light diffusion layer (B) is formed on the transparent base material (a) so as to satisfy the above formulae (1) and (2) (light diffusion layer (B) forming step). Thus, a laminate of the transparent base material (a) and the light diffusion layer (B) was produced. The light diffusion layer (B) forming step includes, as described above: a coating step of coating the transparent substrate (a) with a coating liquid, and a coating film forming step of drying the coating liquid to form a coating film. For example, as described above, the light diffusion layer (B) forming step may further include a curing step of curing the coating film. The curing may be performed after the drying, but is not limited thereto. The curing may be performed by, for example, heating, light irradiation, or the like. The light is not particularly limited, and may be, for example, ultraviolet light. 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, a light diffusion layer forming material (coating liquid) containing the resin, the particles, the thixotropy imparting agent, and the solvent.
The coating liquid preferably exhibits thixotropy, 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 still more preferably in the range of 1.5 to 3.
Ti value of beta 1/beta 2
In the above formula,. beta.1 is a viscosity measured at a shear rate of 20(1/s) using RheoStress RS6000 manufactured by HAAKE, and. beta.2 is a viscosity measured at a shear rate of 200(1/s) using RheoStress RS6000 manufactured by HAAKE.
When the Ti value is 1.3 or more, appearance defects are less likely to occur, and characteristics related to light diffusibility and white turbidity are less likely to be deteriorated. When the Ti value is 3.5 or less, the particles are not easily aggregated and dispersed.
In addition, the aforementioned coating liquid may or may not contain a thixotropy-imparting agent, but is preferred because it easily exhibits thixotropy when containing a thixotropy-imparting agent. In addition, as described above, by including the thixotropy-imparting agent in the coating liquid, an effect of preventing the sedimentation of the particles (thixotropy effect) can be obtained. Further, the surface shape of the light diffusing film can be freely controlled in a wide range by shear aggregation of the thixotropy imparting agent itself. For example, by including the thixotropy-imparting agent in the coating liquid without containing particles, the light diffusing film of the present invention in which Sm and Rsk are small and the irregularities on the outermost surface are gentle can be produced as described above. Further, by including the thixotropy-imparting agent and the particles having a small particle diameter in the coating liquid, the light diffusion film of the present invention having the small Sm and Rsk and the gentle unevenness of the outermost surface can be similarly produced.
The solvent is not particularly limited, and various solvents can be used, and one solvent may be used alone, or two or more solvents may be used in combination. Depending on the composition of the resin, the types and contents of the particles and the thixotropy imparting agent, and the like, there are optimum solvent types and solvent ratios for obtaining the light diffusion film of the present invention. The solvent is not particularly limited, and examples thereof include: alcohols such as methanol, ethanol, isopropanol, butanol, and 2-methoxyethanol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, and cyclopentanone; 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 and octane; aromatic hydrocarbons such as benzene, toluene, and xylene. In addition, for example, the aforementioned solvent may contain a hydrocarbon solvent and a ketone solvent. 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, and acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, acetophenone. The solvent may be, for example, a mixture of the hydrocarbon solvent and the ketone solvent in a ratio of 90: 10-10: 90 in a mass ratio of 90. 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, the hydrocarbon solvent may be toluene, and the ketone solvent may be cyclopentanone.
When the intermediate layer (penetration layer) is formed using an acrylic film, for example, as the transparent substrate (a), a good solvent for the acrylic film (acrylic resin) can be suitably used. As the solvent, for example, as described above, a solvent including a hydrocarbon solvent and a ketone solvent may be used. 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 aforementioned 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, a mixture of the hydrocarbon solvent and the ketone solvent in a ratio of 90: 10-10: 90 in a mass ratio of 90. 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, the hydrocarbon solvent may be toluene, and the ketone solvent may be cyclopentanone.
In addition, by appropriately selecting the solvent, the thixotropy of the light diffusion layer forming material (coating liquid) can be favorably exhibited when the thixotropy imparting agent is contained. For example, in the case of using organoclay, toluene and xylene may be suitably used alone or in combination, for example, in the case of using oxidized polyolefin, methyl ethyl ketone, ethyl acetate, propylene glycol monomethyl ether may be suitably used alone or in combination, for example, in the case of using modified urea, butyl acetate and methyl isobutyl ketone may be suitably used alone or in combination.
Various leveling agents may be added to the light diffusion 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 coating unevenness (uniformity of the coated surface). In the present invention, when antifouling property is required for the surface of the light diffusion layer (B), or when a layer containing a low reflection layer (low refractive index layer) and an interlayer filler is formed on the light diffusion layer (B) as described later, the leveling agent can be appropriately selected according to the above-mentioned case. In the present invention, for example, the thixotropic property imparting agent is contained, whereby the coating liquid can exhibit thixotropy, and thus coating unevenness is less likely to occur. In this case, for example, there is an advantage that the selection range of the leveling agent can be widened.
The amount of the leveling agent is not particularly limited, but is preferably in the range of 0.3 to 5 parts by weight, more preferably 0.5 to 5 parts by weight, based on 100 parts by weight of the resin.
The light diffusion layer-forming material may contain, as necessary, a pigment, a filler, a dispersant, a plasticizer, an ultraviolet absorber, a surfactant, an antifouling agent, an antioxidant, and the like, as long as the performance is not impaired. These additives may be used alone or in combination of two or more.
For the light diffusion layer-forming material, a conventionally known photopolymerization initiator such as that described in jp 2008-88309 a can be used.
As a method for forming a coating film by applying the coating liquid onto the transparent base material (a), for example, a coating method such as a fountain 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.
Next, as described above, the coating film is dried and cured to form the light diffusion layer (B). The drying may be, for example, natural drying, air drying by blowing, heat drying, or a combination thereof.
The drying temperature of the coating liquid for forming the light diffusion layer (B) may be, for example, in the range of 30 to 200 ℃. The drying temperature may be, for example, 40 ℃ or higher, 50 ℃ or higher, 60 ℃ or higher, 70 ℃ or higher, 80 ℃ or higher, 90 ℃ or higher, or 100 ℃ or higher, and may be 190 ℃ or lower, 180 ℃ or lower, 170 ℃ or lower, 160 ℃ or lower, 150 ℃ or lower, 140 ℃ or lower, 135 ℃ or lower, 130 ℃ or lower, 120 ℃ or lower, or 110 ℃ or lower. 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, or 150 seconds or less, 130 seconds or less, 110 seconds or less, or 90 seconds or less.
The method for curing the coating film is not particularly limited, and ultraviolet curing is preferred. The irradiation amount of the energy ray source is preferably 50-500 mJ/cm in terms of the cumulative exposure amount under the ultraviolet wavelength of 365nm2. The irradiation dose was 50mJ/cm2In the above case, the curing is easily sufficiently advanced, and the hardness of the formed light diffusion layer (B) is easily increasedBecomes high. Further, it was 500mJ/cm2In the following case, the formed light diffusion layer (B) can be prevented from being colored.
In the above manner, a laminate of the transparent base material (a) and the light diffusion layer (B) can be produced. The laminate may be used as it is as the light diffusion film of the present invention, or the light diffusion film of the present invention may be produced by forming the other layer on the light diffusion layer (B), for example. The method for forming the other layer is not particularly limited, and for example, the other layer can be formed by the same method as or a method based on the formation method of a general optical layer or the like.
In the above-described manner, the light diffusion film of the present invention in which the light diffusion layer (B) is laminated on at least one surface of the transparent base material (a) can be produced. As described above, the light diffusion film of the present invention may contain other layers than the transparent substrate (a) and the light diffusion layer (B).
In the process for producing the antireflection film of the present invention, at least one of the transparent substrate (a) and the light diffusion layer (B) is preferably subjected to a surface treatment. When the surface of the transparent substrate (A) is treated, the adhesion to the light diffusion layer (B) or to a polarizer or a polarizing plate is further improved. Further, if the surface of the light diffusion layer (B) is subjected to surface treatment, for example, the adhesion to the other layer is further improved.
[ 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 the light diffusing film and the polarizer of the present invention, and may further include other components. The respective components of the polarizing plate may be bonded to each other with an adhesive or a bonding agent, 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, a quantum dot display device, and the like.
The light diffusing film of the present invention can be used, for example, as described above, on the back side of a display panel for an image display device for visual recognition. Specifically, for example, the light diffusing film of the present invention may be attached to the visually recognizable back side of the display panel for an image display device by an adhesive or a bonding agent. In this case, the light diffusing film of the present invention may be used alone, or may be used in the form of an optical member of the present invention (for example, the polarizing plate or the like) including other components. The image display device of the present invention may include, for example, the display panel for an image display device and the backlight for an image display device. Specifically, for example, the light diffusion film of the present invention or the optical member of the present invention may be attached to the visually recognizable back side of the display panel for image display device, and the backlight for image display device may be disposed on the visually recognizable back side of the display panel for image display device. In the light diffusion film of the present invention, as described above, the uneven shape of the outermost surface on the light diffusion layer (B) side is gentle. Therefore, the light diffusion film of the present invention can suppress or prevent damage to the surface of the backlight for an image display device due to the uneven shape, for example. However, the image display device of the present invention is not limited to this.
The image display device of the present invention is, for example, an image display device having the light diffusion film of the present invention on a side surface for visual recognition, and the image display device may have a black matrix pattern.
The light diffusing film of the present invention can be produced by, for example, bonding the transparent substrate (a) side to an optical member for LCD with an adhesive or a bonding agent. In the bonding, the surface of the transparent substrate (a) may be subjected to various surface treatments as described above. As described above, according to the method for manufacturing a light diffusion film of the present invention, the surface shape of the light diffusion film can be freely controlled in a wide range. Therefore, the optical properties obtained by laminating the light diffusion film and another optical member using an adhesive, a pressure-sensitive adhesive, or the like can be in a wide range corresponding to the surface shape of the light diffusion 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 side or both sides of a polarizer. In the case where transparent protective films are provided on both surfaces of the polarizer, the transparent protective films on the front surface and the back surface may be made of the same material or different materials. The polarizing plates are generally disposed on both sides of the liquid crystal cell. The polarizing plates were arranged so that the absorption axes of the 2 polarizing plates were substantially orthogonal to each other.
The structure of the polarizing plate in which the light diffusion film is laminated is not particularly limited, and for example, a structure in which a transparent protective film, the polarizing material, and the transparent protective film are laminated in this order on the light diffusion film, or a structure in which the polarizing material and the transparent protective film are laminated in this order on the light diffusion film may be used.
The image display device of the present invention has the same configuration as the conventional image display device except that the light diffusion film is disposed. For example, in the case of an LCD, it can be manufactured by appropriately assembling and mounting a driving circuit and the like to each component such as an optical member such as a liquid crystal cell and a polarizing plate and, if necessary, an illumination system (backlight and the like).
The image display device of the present invention is used for any appropriate purpose. Examples of the applications of the devices include OA devices such as computer monitors, notebook computers and copiers, portable devices such as mobile phones, clocks, digital cameras, Personal Digital Assistants (PDAs) and portable game machines, home appliances such as video cameras, television sets and microwave ovens, vehicle-mounted devices such as back monitors, vehicle-mounted navigation system monitors and car audio systems, display devices such as information monitors for commercial stores, police devices such as monitors, nursing/medical devices such as nursing monitors and 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.
[ example 1]
60 parts by weight of pentaerythritol triacrylate (PETA; manufactured by Osaka organic chemical Co., Ltd., trade name "VISCOAT # 300") as a binder resin, 40 parts by weight of a urethane acrylate prepolymer (manufactured by NONGZHONG Chemicals K.K., trade name "UA-53H-80 BK"), 4 parts by weight of silicone particles (manufactured by Momentive Performance Materials Japan LLC, trade name "Tospearl 130", weight-average particle diameter: 3 μm, | D90-D50 |: 2.5 μm), 2.5 parts by weight of synthetic montmorillonite (KUNIMINE INDUSTRIES CO., LTD. manufactured by SAN, trade name "Sumecton"), 5 parts by weight of a photopolymerization initiator (manufactured by BASF, trade name "IRGACURE 907") as an organoclay, and 1.0 part by weight of a leveling agent (manufactured by BASF, trade name "PC 4100", solid content: 3910%) were mixed and diluted with a toluene/Cyclopentanone (CPP) solvent (toluene/cyclopentanone) (trade name: 70/30), a light diffusion layer-forming composition I having a solid content of 31.5 wt% was prepared. The organoclay was diluted with toluene until the solid content became 6 wt%.
Further, the composition I for forming a light diffusion layer was coated on a transparent plastic film substrate (acrylic film, manufactured by Toyo Steel plate Co., Ltd., trade name "HX-40 UC", thickness: 40 μm, refractive index: 1.50, and light transmittance of monomer: 94.0%) using a wire bar, heated at 90 ℃ for 1 minute, and irradiated with a high-pressure mercury lamp with a cumulative light amount of 300mJ/cm2Ultraviolet rays of (1). In this manner, a light diffusion film was obtained in which a light diffusion layer (B) (having a thickness of 5.7 μm) was laminated on one surface of a transparent base material (a), and an intermediate layer including a resin derived from the transparent base material (a) and a resin derived from the light diffusion layer (B) was formed between the transparent base material (a) and the light diffusion layer (B). In the present example and all of the following examples and comparative examples, the formation of the intermediate layer was confirmed by observing the cross section of the light-diffusing thin film with a Transmission Electron Microscope (TEM).
[ example 2]
A light diffusion film was obtained in the same manner as in example 1, except that the light diffusion layer was formed to have a thickness of 6.3 μm.
[ example 3]
A light diffusion film was obtained in the same manner as in example 1, except that the light diffusion layer was formed to have a thickness of 6.9 μm.
[ example 4]
A light diffusion film was obtained in the same manner as in example 1, except that the light diffusion layer was formed to have a thickness of 7.3 μm.
[ example 5]
A light diffusion film was obtained in the same manner as in example 1, except that the heating time after coating with the light diffusion layer-forming composition I was changed from 1 minute to 30 seconds.
[ example 6]
A light diffusion film was obtained in the same manner as in example 5, except that the light diffusion layer was formed to have a thickness of 6.3 μm.
[ example 7]
A light diffusion film was obtained in the same manner as in example 5, except that the light diffusion layer was formed to have a thickness of 6.9 μm.
[ example 8]
A light diffusion film was obtained in the same manner as in example 5, except that the light diffusion layer was formed to have a thickness of 7.3 μm.
[ example 9]
A light diffusing film was obtained in the same manner as in example 1 except that a PET film (trade name "ASTROL CE 900", thickness: 38 μm, refractive index: 1.64, and light transmittance of monomer: 88.3%) was used as the transparent plastic film substrate (transparent substrate (A)) in place of the acrylic film of example 1.
[ example 10]
A light diffusing film was obtained in the same manner as in example 1 except that TAC (manufactured by KONICA MINOLTA, INC., trade name: KC4 UY; thickness: 40 μm, refractive index: 1.50, and light transmittance of monomer: 92.4%) was used as the transparent plastic film substrate (transparent substrate (A)) in place of the acrylic film described in example 1.
Comparative example 1
Pentaerythritol triacrylate (PETA; product name "VISCOAT # 300" available from Osaka organic chemical Co., Ltd.) as a binder resin 60 parts by weight and urethane acrylate prepolymer (product name "UA-53H-80 BK" available from Ningmura chemical Co., Ltd.), 4 parts by weight of organic particles (product name "SSX 1055 QXE" available from Ningmura chemical Co., Ltd., product name "5.5 μm), 2.5 parts by weight of synthetic montmorillonite (product name" Sumecton SAN "available from KUNIMINE INDUSTRIES CO., LTD. available from Sumecton SAN") as an organoclay, 5 parts by weight of a photopolymerization initiator (product name "IRGACURE 907" available from BASF Co., Ltd.) and 1.0 part by weight of a leveling agent (product name "PC 4100" available from DIC Co., Ltd., product name "10%) were mixed, and diluted with toluene/mixed solvent (weight ratio toluene/methyl ethyl ketone 70/30), a light diffusion layer-forming composition II having a solid content concentration of 32 wt% was prepared. The organoclay was diluted with toluene until the solid content became 6 wt%.
Further, the composition II for forming a light diffusion layer was coated on the same transparent plastic film substrate as in example 1 using a wire bar, heated at 90 ℃ for 1 minute, and then irradiated with a high pressure mercury lamp with a cumulative light amount of 300mJ/cm2Ultraviolet rays of (1). In this manner, a light diffusion film having a transparent base material layer and a light diffusion layer (thickness 5.7 μm) and further having an intermediate layer formed therebetween was obtained.
Comparative example 2
A light diffusion film was obtained in the same manner as in comparative example 1, except that the light diffusion layer was formed to have a thickness of 5.9 μm.
Comparative example 3
A light diffusion film was obtained in the same manner as in comparative example 1, except that the light diffusion layer was formed to have a thickness of 6.2 μm.
Comparative example 4
A light diffusion film was obtained in the same manner as in comparative example 1, except that the light diffusion layer was formed to have a thickness of 6.3 μm.
Comparative example 5
A light diffusion film was obtained in the same manner as in comparative example 1, except that the light diffusion layer was formed to have a thickness of 6.5 μm.
Comparative example 6
50 parts by weight of pentaerythritol triacrylate (PETA; manufactured by Osaka Chemical Co., Ltd., trade name "VISCOAT # 300") as a binder resin, 50 parts by weight of a urethane acrylate prepolymer (manufactured by NONGZHONG Chemical Co., Ltd., trade name "UA-53H-80 BK"), 3.5 parts by weight of silicone particles (manufactured by Momentive Performance Materials LLC, trade name "Tospearl 130", weight-average particle diameter: 3 μm, | D90-D50 |: 2.5 μm, refractive index: 1.42), 3.5 parts by weight of a synthetic montmorillonite (Co-op Chemical Co., manufactured by Ltd., trade name "LucentSAN") as an organoclay), 3 parts by weight of a photopolymerization initiator (manufactured by BASF, trade name "IRGACURE 907") as an organoclay, and 0.2 parts by weight of a leveling agent (manufactured by BASF corporation, trade name "PC 4100.2 parts by weight of a solid content") as an organoclay solvent were mixed and diluted with 0.2 parts by toluene/Cyclopentanone (CPN) as a solvent at a toluene/ring mixing ratio 70/30, a light diffusion layer-forming composition III having a solid content concentration of 33 wt% was prepared. The organoclay was diluted with toluene until the solid content became 6 wt%.
Next, the composition III for forming a light diffusion layer was coated on a Triacetylcellulose (TAC) film (manufactured by KONICA MINOLTA OPTO, INC., trade name "KC 4 UA", thickness: 40 μm) by using a Comma Coater (registered trademark), heated at 80 ℃ for 1 minute, and irradiated with a high-pressure mercury lamp with a cumulative light amount of 300mJ/cm2Ultraviolet rays of (1). In this manner, a light diffusion film having a transparent base layer and a light diffusion layer (thickness: 6.3 μm) and an intermediate layer formed between the transparent base layer and the light diffusion layer was obtained.
The characteristics of the light diffusion films of the examples and comparative examples produced as described above were measured as follows.
[ irregular shapes (Sm, Rsk, Rz) of the surface of the light diffusion layer ]
The average interval Sm (mm) of irregularities, skewness Rsk, and microscopic unevenness ten-point height Rz (. mu.m) were measured in accordance with JIS B0601(1994 version). Specifically, first, a glass plate (model S, MICRO SLIDE GLASS, thickness 1.3mm, 45 × 50mm, manufactured by MATSUNAMI corporation) was bonded to the surface of the transparent substrate opposite to the light diffusion layer of the light diffusion film in each of the above examples and comparative examples with an adhesive to prepare a sample. Next, the surface shape of the light diffusion layer of the sample was measured in a fixed direction at a scanning speed of 1 mm/sec, a cutoff value of 0.8mm, and a measurement length of 12mm using a stylus type surface roughness measuring instrument (product name "surfcore ET 4000") having a measuring tip with a radius of curvature R of 2 μm of the tip (diamond), and an average distance sm (mm) between irregularities, a microscopic unevenness ten-point height Rz (μm), and an offset Rsk were calculated. The high-precision fine-shape measuring device automatically calculates the respective measured values.
[ light transmittance loss Rate ]
The transmittance spectrum of the light diffusion film of each of the above examples or comparative examples was measured in a wavelength range of 380nm to 780nm using a spectrophotometer manufactured by Hitachi High-Tech corporation (trade name U-4100), and the light transmittance Y was automatically calculated. The transmittance spectrum was measured similarly only for the transparent plastic film substrate (without forming the light diffusion layer and the intermediate layer), and the light transmittance Y was automatically calculated. The light transmittance loss rate was calculated based on the following equation, where Y is the light transmittance of only the transparent plastic film substrate as Y1, and Y is the light transmittance of the light diffusion film of each of the above examples or comparative examples as Y2.
Light transmittance loss ratio (%) (Y1-Y2)/Y1 × 100
[ Overall haze ]
The haze (haze) was measured according to JIS K7136 (2000 edition) using a haze meter (trade name "HM-150" manufactured by village color technology research).
The properties of the light diffusion films of the examples and comparative examples measured as described above are shown in table 1 below. In table 1 below, the unit of the average interval Sm of irregularities is mm, the unit of skewness Rsk is nothing, the unit of the microscopic unevenness ten-point height Rz is μm, and the unit of the overall haze is%.
[ Table 1]
Base material Sm Rsk Rate of loss of light transmittance Rz Overall haze
Example 1 Acrylic acid series 0.141 0.161 1.60% 0.832 22.8
Example 2 Acrylic acid series 0.139 0.1819 2.20% 0.993 24.3
Example 3 Acrylic acid series 0.149 0.086 1.50% 0.980 25.1
Example 4 Acrylic acid series 0.159 0.050 1.80% 1.140 26.8
Example 5 Acrylic acid series 0.121 0.154 2.20% 0.806 23.9
Example 6 Acrylic acid series 0.128 0.160 2.70% 0.823 24.7
Example 7 Acrylic acid series 0.128 0.161 2.70% 0.853 25.4
Example 8 Acrylic acid series 0.139 0.126 2.80% 0.871 26.4
Example 9 PET 0.251 0.1263 0.00% 0.768 31.0
Example 10 TAC 0.198 0.1577 1.95% 0.674 24.2
Comparative example 1 Acrylic acid series 0.095 0.488 4.20% 2.861 31.0
Comparative example 2 Acrylic acid series 0.094 0.343 4.00% 2.418 28.4
Comparative example 3 Acrylic acid series 0.098 0.306 3.70% 2.171 23.1
Comparative example 4 Acrylic acid series 0.098 0.236 3.50% 1.969 20.9
Comparative example 5 Acrylic acid series 0.102 0.148 3.40% 1.857 18.2
Comparative example 6 TAC 0.247 0.390 3.60% 0.822 30.0
As shown in Table 1, the light diffusing films of examples 1 to 10 satisfy both of 0.110. ltoreq. Sm and Rsk. ltoreq.0.200. In contrast, the light diffusing films of comparative examples 1 to 5 did not satisfy 0.110. ltoreq. Sm. The light-diffusing films of comparative examples 1 to 4 also did not satisfy Rsk ≦ 0.200. The light-diffusing film of comparative example 6 satisfied 0.110. ltoreq. Sm, but did not satisfy Rsk. ltoreq.0.200.
The light diffusing films of examples 1 to 10 all had a light transmittance loss ratio of 3.0% or less, and it was confirmed that the light transmittance was high. The light-diffusing films of examples 1 to 10 were confirmed to have light diffusibility suitable for practical use because the haze value of the entire films was of an appropriate size (height).
In contrast, the light diffusing films of comparative examples 1 to 6 all had a light transmittance loss ratio exceeding 3.0% and a low light transmittance.
Industrial applicability
As described above, according to the present invention, it is possible to provide a light diffusion film that can achieve both light diffusibility and light transmittance, a method for producing the light diffusion film, an optical member, a display panel for an image display device, and an image display device. The application of the present invention is not particularly limited, and the present invention can be applied to a wide range of applications, for example, to any image display device.
The present application claims priority based on Japanese application laid-open at 4/3/2019, application number 2019-071238, the disclosure of which is incorporated herein in its entirety.
Description of the reference numerals
10 light diffusing film
11 transparent substrate (A)
12 light diffusion layer (B)
12a resin layer
12b particles
12c thixotropy imparting agent

Claims (19)

1. A light diffusion film characterized in that a light diffusion layer (B) is laminated on at least one side of a transparent substrate (A),
wherein the light diffusion film has a concave-convex portion formed on the outermost surface thereof on the light diffusion layer (B) side,
the concavo-convex shape satisfies the following mathematical expressions (1) and (2),
0.110≤Sm (1)
Rsk≤0.200 (2)
in the above formula (1), Sm is an average interval (mm) of the irregularities of the above-described irregular shape measured in accordance with JIS B0601(1994 version),
in the above formula (2), Rsk is the skewness of the above-described concave-convex shape measured in accordance with JIS B0601(1994 version).
2. The light diffusing film according to claim 1, wherein a light transmittance loss ratio at a wavelength of 380 to 780nm is 3.0% or less.
3. The light diffusing film according to claim 1 or 2, wherein another layer is further laminated on a surface of the light diffusing layer (B) opposite to the transparent base material (a).
4. A light diffusion film characterized in that a light diffusion layer (B) and other layers are laminated on at least one side of a transparent substrate (A),
the outermost surface of the other layer is formed with irregularities,
the concavo-convex shape satisfies the following mathematical expressions (1) and (2),
0.110≤Sm (1)
Rsk≤0.200 (2)
in the above formula (1), Sm is an average interval (mm) of the irregularities of the above-described irregular shape measured in accordance with JIS B0601(1994 version),
in the above formula (2), Rsk is the skewness of the above-described concave-convex shape measured in accordance with JIS B0601(1994 version).
5. The light diffusing film according to any one of claims 1 to 4, wherein the transparent substrate (A) comprises an acrylic resin.
6. The light diffusing film according to any one of claims 1 to 5, wherein the transparent substrate (A) is an acrylic film.
7. The light diffusing film according to any one of claims 1 to 6, wherein the light diffusing layer (B) contains a binder resin and a filler.
8. The light diffusing film of claim 7 wherein the filler is particulate.
9. The light diffusing film according to claim 8, wherein a difference in refractive index between the particles and the binder resin is 0.200 or less.
10. The light diffusing film according to any one of claims 1 to 9, wherein an intermediate layer comprising a resin derived from the transparent substrate (a) and a resin derived from the light diffusing layer (B) is provided between the transparent substrate (a) and the light diffusing layer (B).
11. The light-diffusing film according to any one of claims 1 to 10, which is used for a visually recognizable back side of a display panel for an image display device.
12. The method for producing a light-diffusing film according to any one of claims 1 to 11, comprising:
a light diffusion layer (B) forming step of forming the light diffusion layer (B) on the transparent base material (a); and
a step of forming the irregularities on the outermost surface of the light diffusion film on the light diffusion layer (B) side so as to satisfy the expressions (1) and (2),
the light diffusion layer (B) forming step includes: a coating step of coating the transparent substrate (A) with a coating liquid, and a coating film forming step of drying the coating liquid to form a coating film,
the coating liquid contains a resin and a solvent.
13. The production method according to claim 12, wherein the light diffusion layer (B) forming step further comprises a curing step of curing the coating film.
14. The production method according to claim 12 or 13, wherein the solvent comprises toluene and cyclopentanone.
15. The production method according to any one of claims 12 to 14, wherein the light diffusion film is the light diffusion film according to claim 3 or 4,
the step of forming the unevenness includes a step of forming another layer on the light diffusion layer (B).
16. An optical member comprising the light-diffusing film according to any one of claims 1 to 11.
17. A display panel for an image display device, comprising the light-diffusing film according to claim 11.
18. An image display device comprising the light-diffusing film according to any one of claims 1 to 11, the optical member according to claim 16, or the display panel for an image display device according to claim 17.
19. The image display device according to claim 18, comprising the display panel for an image display device and the backlight for an image display device according to claim 17.
CN202080023415.4A 2019-04-03 2020-04-02 Light diffusion film, method for producing light diffusion film, optical member, display panel for image display device, and image display device Pending CN113614584A (en)

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