TWI748001B - Manufacturing method of film with coating layer - Google Patents

Manufacturing method of film with coating layer Download PDF

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TWI748001B
TWI748001B TW106140241A TW106140241A TWI748001B TW I748001 B TWI748001 B TW I748001B TW 106140241 A TW106140241 A TW 106140241A TW 106140241 A TW106140241 A TW 106140241A TW I748001 B TWI748001 B TW I748001B
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film
coating layer
protective sheet
manufacturing
thickness
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TW106140241A
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TW201833200A (en
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石原康隆
岸敦史
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日商日東電工股份有限公司
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/023—Optical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered 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
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/11—Anti-reflection coatings
    • G02B1/111—Anti-reflection coatings using layers comprising organic materials
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B1/00—Optical elements characterised by the material of which they are made; Optical coatings for optical elements
    • G02B1/10—Optical coatings produced by application to, or surface treatment of, optical elements
    • G02B1/14—Protective coatings, e.g. hard coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/20—Displays, e.g. liquid crystal displays, plasma displays

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Surface Treatment Of Optical Elements (AREA)

Abstract

本發明提供一種附有塗敷層之光學薄膜之製造方法，其係於薄型之薄膜形成塗敷層，並且能夠於不產生皺褶等之情況下製造附有塗敷層之薄膜。 本發明之附有塗敷層之薄膜之製造方法包括：於厚度為25 μm以下且剛挺性為40 mm以下之薄膜之一面積層保護片材，及於該薄膜之另一面形成塗敷層；該保護片材之算術平均表面Ra為0.1 μm以下，且該保護片材之剛挺性為40 mm以上。The present invention provides a method of manufacturing an optical film with a coating layer, which forms a coating layer on a thin film, and can manufacture the film with a coating layer without generating wrinkles or the like. The method for manufacturing a film with a coating layer of the present invention includes: forming a protective sheet on one area of a film with a thickness of 25 μm or less and a stiffness of 40 mm or less, and forming a coating layer on the other side of the film; The arithmetic average surface Ra of the protective sheet is 0.1 μm or less, and the stiffness of the protective sheet is 40 mm or more.

Description

附有塗敷層之薄膜之製造方法Manufacturing method of film with coating layer

本發明係關於一種附有塗敷層之薄膜之製造方法。The present invention relates to a method for manufacturing a film with a coating layer.

一般而言，於液晶顯示器(LCD)、陰極射線管顯示裝置(CRT)、電漿顯示器(PDP)、電致發光顯示器(ELD)等圖像顯示裝置之表面設置能夠發揮各種功能之塗敷層。例如設置用以防止因與外部接觸引起之損傷之硬塗層、用以提高防眩性之防眩層。先前，此種塗敷層係藉由在圖像顯示裝置之構件上積層由塗敷層與基材構成之表面薄膜(例如硬塗薄膜、防眩薄膜)而設置。 另一方面，近年來，圖像顯示裝置向薄型化方向發展，伴隨於此，業界正研究構成表面薄膜之基材之薄膜化，進而研究於薄型之光學薄膜上直接形成塗敷層。然而，於薄型之光學薄膜等上形成塗敷層之情形時存在如下問題：於塗敷層形成步驟中(例如硬塗層硬化處理時)易產生皺褶，易導致外觀不良、光學特性不良等。又，想到於形成塗敷層時利用保護片材支持光學薄膜之方法，但於採用該方法之情形時出現如下問題：於塗敷層形成步驟之加熱下，保護片材產生凹凸，該凹凸轉印至光學薄膜上。鑒於上述情況，業界要求確立即便使用厚度薄之薄膜亦能夠於不產生皺褶之情況下形成塗敷層的技術。 [先前技術文獻] [專利文獻] 專利文獻1：日本專利特開2016-68497號公報Generally speaking, a coating layer capable of performing various functions is provided on the surface of an image display device such as a liquid crystal display (LCD), a cathode ray tube display device (CRT), a plasma display (PDP), an electroluminescence display (ELD), etc. . For example, a hard coating to prevent damage caused by contact with the outside and an anti-glare layer to improve anti-glare properties are provided. Previously, such a coating layer was provided by laminating a surface film (for example, a hard coating film, an anti-glare film) composed of a coating layer and a substrate on a member of an image display device. On the other hand, in recent years, image display devices have been thinning. Accompanying this, the industry is studying the thinning of the substrate that forms the surface film, and further studies on directly forming a coating layer on a thin optical film. However, when forming a coating layer on a thin optical film, etc., there are problems as follows: during the coating layer formation step (for example, during hard coating hardening treatment), wrinkles are likely to occur, which can easily lead to poor appearance and poor optical properties, etc. . In addition, a method of using a protective sheet to support the optical film when forming the coating layer is thought of. However, when this method is used, the following problem arises: under the heating of the coating layer forming step, the protective sheet produces unevenness, and the unevenness is turned Printed on optical film. In view of the above situation, the industry requires the establishment of a technology that can form a coating layer without causing wrinkles even if a thin film is used. [Prior Art Document] [Patent Document] Patent Document 1: Japanese Patent Laid-Open No. 2016-68497

[發明所欲解決之問題] 本發明係為了解決上述先前之課題而成者，其目的在於提供一種附有塗敷層之薄膜之製造方法，其係於薄型之薄膜形成塗敷層，並且能夠於不產生皺褶等之情況下製造附有塗敷層之薄膜。 [解決問題之技術手段] 本發明之附有塗敷層之薄膜之製造方法包括：於厚度為25 μm以下且剛挺性為40 mm以下之薄膜之一面積層保護片材，及於該薄膜之另一面形成塗敷層；該保護片材之與上述薄膜相反側之面之算術平均表面粗糙度Ra為0.1 μm以下，且該保護片材之剛挺性為40 mm以上。 一實施形態中，上述保護片材具備基材、與形成於該基材上之黏著劑層，將該保護片材之黏著劑側貼合於上述薄膜。 一實施形態中，上述黏著劑層之厚度為10 μm以下。 一實施形態中，上述保護片材係可剝離地積層於上述薄膜。 一實施形態中，上述薄膜為光學薄膜。 一實施形態中，上述塗敷層係由硬化性樹脂構成。 一實施形態中，上述硬化性樹脂為光硬化性。 一實施形態中，上述硬化性樹脂為熱硬化性。 一實施形態中，上述塗敷層之厚度為4 μm以下。 [發明之效果] 根據本發明，藉由利用具有特定之表面粗糙度Ra及剛挺性之保護片材而支持薄膜，並於該薄膜形成塗敷層，可於防止皺褶產生之情況下製造附有塗敷層之薄膜。[Problems to be Solved by the Invention] The present invention was made to solve the above-mentioned previous problems, and its object is to provide a method of manufacturing a film with a coating layer, which forms a coating layer on a thin film and can Produce a film with a coating layer without wrinkles, etc. [Technical Means to Solve the Problem] The method for manufacturing a film with a coating layer of the present invention includes: an area layer protective sheet for a film with a thickness of 25 μm or less and a stiffness of 40 mm or less, and a protective sheet on the film A coating layer is formed on the other side; the arithmetic mean surface roughness Ra of the side opposite to the film of the protective sheet is 0.1 μm or less, and the stiffness of the protective sheet is 40 mm or more. In one embodiment, the protective sheet includes a substrate, and an adhesive layer formed on the substrate, and the adhesive side of the protective sheet is bonded to the film. In one embodiment, the thickness of the adhesive layer is 10 μm or less. In one embodiment, the protective sheet is releasably laminated on the film. In one embodiment, the above-mentioned film is an optical film. In one embodiment, the coating layer is made of curable resin. In one embodiment, the curable resin is photocurable. In one embodiment, the curable resin is thermosetting. In one embodiment, the thickness of the coating layer is 4 μm or less. [Effects of the Invention] According to the present invention, by using a protective sheet with a specific surface roughness Ra and stiffness to support the film, and forming a coating layer on the film, it can be manufactured while preventing wrinkles. Film with coating layer.

以下，對本發明之較佳實施形態進行說明，但本發明並不限定於該等實施形態。 圖1係說明本發明之一實施形態之本發明之製造方法的圖。本發明之附有塗敷層之薄膜之製造方法係於薄型之薄膜20形成塗敷層10之方法，其包括：於薄型之薄膜20之一面積層保護片材30(圖1(a))；及於該薄膜20之另一面(與積層有保護片材30之面相反一側之面)形成塗敷層10(圖1(b))。於一實施形態中，保護片材30可剝離地積層於薄膜20。於一實施形態中，形成塗敷層10而獲得附有塗敷層之薄膜後，將保護片材30剝離(圖1(c))。 上述薄膜之厚度為25 μm以下。於本發明中，即便使用厚度較薄而於先前容易產生皺褶之薄膜，亦可於防止皺褶產生之情況下形成塗敷層。薄膜之厚度可根據用途而適當設定。於一實施形態中，上述薄膜之厚度為20 μm以下。於另一實施形態中，上述薄膜之厚度為15 μm以下。薄膜之厚度之下限例如為1 μm。 上述薄膜之剛挺性為40 mm以下。根據本發明，即便使用剛挺性較小(即，無塑性)而以先前方法難免會產生皺褶之薄膜，亦可於防止皺褶產生之情況下形成塗敷層。於一實施形態中，可使用剛挺性為5 mm～35 mm之薄膜。於另一實施形態中，可使用剛挺性為5 mm～25 mm之薄膜。再者，於本說明書中，剛挺性係依據JIS L1096(45°、懸臂法)進行測定。測定方法詳見下文。 上述薄膜較佳為具有光透過性。於一實施形態中，上述薄膜之光透過率為40%以上，較佳為45%～50%。於另一實施形態中，上述薄膜之光透過率為70%以上，更佳為80%以上，進而較佳為90%以上。 於一實施形態中，使用光學薄膜作為上述薄膜。作為光學薄膜，例如可列舉：相位差薄膜、偏光薄膜(偏光元件、或由偏光元件與保護薄膜所構成之偏光板)、亮度提高薄膜、光擴散薄膜、集光薄膜等。 作為構成上述薄膜之材料，可採用任意適宜之材料。例如可列舉：聚碳酸酯樹脂、聚乙烯醇縮醛樹脂、環烯烴系樹脂、丙烯酸系樹脂、纖維素酯系樹脂、纖維素系樹脂、聚酯系樹脂、聚酯碳酸酯系樹脂、烯烴系樹脂、聚胺基甲酸酯系樹脂等。較佳列舉：聚碳酸酯樹脂、聚乙烯醇縮醛樹脂、纖維素酯系樹脂、聚酯系樹脂、聚酯碳酸酯系樹脂等能夠成為光學薄膜之材料之樹脂；聚乙烯醇系薄膜、部分縮甲醛化聚乙烯醇系薄膜、乙烯-乙酸乙烯酯共聚物系部分皂化薄膜等親水性高分子薄膜(成為偏光元件之材料之薄膜)等。薄膜亦可具有由複數層構成之積層構造。 ＜保護片材之積層＞ 上述保護片材之與上述薄膜相反側之面之算術表面粗糙度Ra為0.1 μm以下，較佳為0.08 μm以下，更佳為0.05 μm以下。保護片材之算術表面粗糙度Ra越小越佳，其下限例如為0.01 μm。再者，於本說明書中，算術表面粗糙度Ra係依據JIS B0601進行測定。 上述保護片材之剛挺性為40 mm以上，較佳為45 mm以上，更佳為50 mm以上，進而較佳為60 mm以上。 本發明中，如上所述，使用算術表面粗糙度Ra較小、且剛挺性較高之保護片材，利用該保護片材支持上述薄膜，藉此可抑制於塗敷層形成時產生皺褶。更具體而言，可防止因塗敷層形成時之加熱引起之薄膜之收縮，或可防止因塗敷層形成時之硬化收縮引起之附有塗敷層之薄膜。又，保護片材本身之平滑性優異、且具有剛挺性，因此防止由保護片材引起之不良情況(例如保護片材表面之微細凹凸轉印至上述薄膜、保護片材發生收縮而產生之凹凸轉印至上述薄膜等不良情況)。再者，保護片材之剛挺性之上限較佳為100 mm。若為此種範圍，則可無翹曲等不良情況地形成塗敷層。 上述保護片材較佳為以對上述薄膜之黏著力成為0.01 N/25 mm～1.00 N/25 mm之方式構成，更佳為以成為0.1 N/25 mm～0.5 N/25 mm之方式構成。若使用具有此種黏著力之保護片材，則可防止於塗敷層形成時產生皺褶，且可於塗敷層形成後容易地剝離保護片材。本說明書中，黏著力係藉由依據JIS Z 0237(2000)之方法(測定溫度：23℃、貼合條件：使2 kg輥往返1次、剝離速度：300 mm/min、剝離角度180°)進行測定。 於一實施形態中，上述保護片材具備基材、與形成於該基材上之黏著劑層。保護片材之積層步驟中，將保護片材之黏著劑層側貼合於上述薄膜。再者，於具備基材與黏著劑層之保護片材中，上述算術表面粗糙度Ra相當於基材之與黏著劑層相反側之面之算術表面粗糙度Ra。 作為構成上述基材之材料，只要能夠獲得本發明之效果，則可使用任意適宜之材料。作為構成基材之材料，例如可列舉：聚對苯二甲酸乙二酯、聚乙烯、聚丙烯、聚烯烴等。其中，較佳為聚對苯二甲酸乙二酯。若使用聚對苯二甲酸乙二酯，則可獲得厚度較薄且剛挺性較高之基材(最終獲得保護片材)。 上述基材之厚度較佳為10 μm～100 μm，更佳為15 μm～80 μm，進而較佳為20 μm～50 μm。 上述黏著劑層係由任意適宜之黏著劑構成。作為黏著劑之具體例，可列舉：丙烯酸系黏著劑、聚乙烯系黏著劑、聚丙烯系黏著劑、聚烯烴系黏著劑等。 上述黏著劑層之厚度較佳為10 μm以下，更佳為8 μm以下。藉由設為此種範圍，形成塗敷層時之皺褶產生變得更少。又，可抑制附有塗敷層之薄膜發生翹曲。黏著劑層之厚度之下限例如為1 μm。 ＜塗敷層之形成＞ 如上所述，於薄膜之一面積層保護片材後，於該薄膜之另一面形成塗敷層。該塗敷層形成步驟代表性而言包括塗敷層形成用組合物之塗佈、塗佈層之加熱等。於一實施形態中，塗敷層係由硬化性樹脂構成。該情形時，可於塗敷層形成步驟中進而進行塗佈層之硬化處理(例如紫外線照射或加熱)。本發明之製造方法對於需進行硬化處理之塗敷層之形成特別有用。先前，硬化處理引起之硬化性樹脂之硬化收縮大於藉由乾燥形成塗敷層時之收縮，此乃薄膜產生皺褶之較大原因，根據本發明，即便於硬化性樹脂產生硬化收縮之情形時，亦可於防止皺褶產生之情況下獲得附有塗敷層之薄膜。作為硬化性樹脂，可使用光硬化性樹脂(例如紫外線硬化性樹脂)或熱硬化性樹脂。其中，較佳為光硬化性樹脂。使光硬化性樹脂硬化時之硬化收縮較大，因此本案發明作為形成由光硬化性樹脂構成之塗敷層之方法而特別有用。再者，形成塗敷層後，亦可對該塗敷層實施電暈處理、電漿處理等表面處理。 作為上述塗敷層之具體例，可列舉：硬塗層、防眩層、抗黏連層、抗反射層、導電層等。其中，本案發明之製造方法於形成硬塗層或防眩層之情形時特別有用。 塗敷層形成用組合物包含任意適宜之樹脂材料(單體、低聚物、預聚物及/或聚合物)。於一實施形態中，塗敷層形成用組合物包含熱硬化型或光硬化型之硬化性化合物作為樹脂材料。若使用包含硬化性化合物之塗敷層形成用組合物，則例如可形成硬塗層或防眩層。硬化性化合物可為單體、低聚物及預聚物之任意者。作為硬化性化合物，可使用多官能單體或低聚物，例如可列舉：具有2個以上之(甲基)丙烯醯基之單體或低聚物、(甲基)丙烯酸胺基甲酸酯或(甲基)丙烯酸胺基甲酸酯之低聚物、環氧系單體或低聚物、聚矽氧系單體或低聚物等。 塗敷層形成用組合物可進而包含任意適宜之添加劑。作為添加劑，例如可列舉：聚合起始劑、調平劑、抗黏連劑、分散穩定劑、觸變劑、抗氧化劑、紫外線吸收劑、消泡劑、增黏劑、分散劑、界面活性劑、觸媒、填料、潤滑劑、抗靜電劑等。所含有之添加劑之種類、組合、含量等可根據目的或所需特性而適當設定。 於一實施形態中，塗敷層形成用組合物包含微粒子作為添加劑。若使用包含微粒子之塗敷層形成用組合物，則可形成防眩層。微粒子可為無機微粒子，亦可為有機微粒子。作為無機微粒子，例如可列舉：氧化矽微粒子、氧化鈦微粒子、氧化鋁微粒子、氧化鋅微粒子、氧化錫微粒子、碳酸鈣微粒子、硫酸鋇微粒子、滑石微粒子、高嶺土微粒子、硫酸鈣微粒子等。作為有機微粒子，例如可列舉：聚甲基丙烯酸甲酯樹脂粉末(PMMA微粒子)、聚矽氧樹脂粉末、聚苯乙烯樹脂粉末、聚碳酸酯樹脂粉末、丙烯酸苯乙烯樹脂粉末、苯并胍胺樹脂粉末、三聚氰胺樹脂粉末、聚烯烴樹脂粉末、聚酯樹脂粉末、聚醯胺樹脂粉末、聚醯亞胺樹脂粉末、聚氟乙烯樹脂粉末等。該等微粒子可單獨使用，亦可將複數種組合使用。 上述塗敷層形成用組合物可包含亦可不含溶劑。作為溶劑，例如可列舉：二丁醚、二甲氧基甲烷、二甲氧基乙烷、二乙氧基乙烷、環氧丙烷、1,4-二㗁烷、1,3-二氧雜環戊烷、1,3,5-三㗁烷、四氫呋喃、丙酮、甲基乙基酮(MEK)、二乙基酮、二丙基酮、二異丁基酮、環戊酮(CPN)、環己酮、甲基環己酮、甲酸乙酯、甲酸丙酯、甲酸正戊酯、乙酸甲酯、乙酸乙酯、丙酸甲酯、丙酸乙酯、乙酸正戊酯、乙醯丙酮、二丙酮醇、乙醯乙酸甲酯、乙醯乙酸乙酯、甲醇、乙醇、1-丙醇、2-丙醇、1-丁醇、2-丁醇、1-戊醇、2-甲基-2-丁醇、環己醇、異丙醇(IPA)、乙酸異丁酯、甲基異丁基酮(MIBK)、2-辛酮、2-戊酮、2-己酮、2-庚酮、3-庚酮、乙二醇單***乙酸酯、乙二醇單***、乙二醇單丁醚、乙二醇單甲醚、丙二醇單甲醚乙酸酯、丙二醇單甲醚等。該等可單獨使用，亦可將複數種組合使用。 作為塗敷層形成用組合物之塗佈方法，可採用任意適宜之方法。例如可列舉：棒式塗佈法、凹版輥式塗佈法、模嘴塗佈法、桿式塗佈法、孔縫式塗佈法、淋幕式塗佈法、噴注式塗佈法、刮刀式塗佈法。再者，於使用較薄且塑性較弱之薄膜之本發明中，若採用凹版輥式塗佈法，則可以更良好之厚度精度形成塗敷層。 塗敷層形成用組合物之塗佈層之加熱溫度可根據塗敷層形成用組合物之組成而設定為適宜溫度，較佳設定為上述薄膜所含之樹脂之玻璃轉移溫度以下。若於上述薄膜所含之樹脂之玻璃轉移溫度以下之溫度下加熱，則可獲得因加熱引起之變形得到抑制之附有塗敷層之薄膜。加熱溫度例如為60℃～140℃，較佳為60℃～100℃。藉由在此種範圍內進行加熱，可形成與薄膜之密接性優異之塗敷層。 作為上述硬化處理，可採用任意適宜之硬化處理。代表性而言，藉由紫外線照射而進行硬化處理。紫外線照射之累計光量較佳為200 mJ～400 mJ。 上述塗敷層之厚度較佳為10 μm以下，更佳為2 μm～6 μm。若為此種範圍，則可獲得作為塗敷層之功能能夠得到充分發揮且外觀優異之附有塗敷層之薄膜。 於一實施形態中，上述塗敷層之鉛筆硬度較佳為H以上，更佳為3H以上。若為此種範圍，則塗敷層能夠有效地發揮作為硬塗層之功能。鉛筆硬度可依據JIS K 5400之鉛筆硬度試驗而測定。 [實施例] 以下，藉由實施例而具體地說明本發明，但本發明並不限定於該等實施例。實施例中之評價方法如下所述。又，於實施例中，只要無特別記載，則「份」及「%」為重量基準。 (1)剛挺性 依據JIS L1096(45°、懸臂法)進行測定。具體而言，如圖2所示，於具有傾斜角45°之斜面之梯形且光滑之模B之上表面(水平面)，以試驗片A之一端a位於模水平面之斜面側端部b之方式載置試驗片A(尺寸：20 mm×150 mm)，使該試驗片A平緩地於斜面側滑動，測定當該試驗片之一端a接觸斜面下方時該試驗片之水平方向移動距離L。對於保護片材，以黏著劑層作為上側，藉由上述操作而測定移動距離L，將測定值作為該保護片材之剛挺性。對於附有塗敷層(硬塗層)之薄膜，將使塗敷層側朝上而測得之移動距離與使塗敷層朝下而測得之移動距離的平均值作為附有塗敷層之薄膜之剛挺性。 (2)算術表面粗糙度Ra 藉由下述方法測定構成保護片材之基材之算術表面粗糙度Ra。 於與測定面相反之面，利用黏著劑貼合MATSUNAMI公司製造之玻璃板(厚度1.3 μm)，使用三維光學輪廓分析儀NewView7300(ZYGO公司製造)測定表面形狀。根據所測得之資料，依據JIS B 0601-2001算出算術表面粗糙度Ra。 (3)外觀 藉由目視確認所獲得之附有塗敷層之薄膜之外觀。評價基準如下。 AA：無皺褶產生 A：有極少之可被視認到之程度之皺褶產生，於實用上能夠容許 B：有可視作凹凸之程度之皺褶產生，於實用上能夠容許 C：產生於實用上無法容許之程度之凹凸 ＜製造例1＞硬塗層形成用組合物之製備 將丙烯酸胺基甲酸酯樹脂(DIC公司製造，製品名「UNIDIC 17-806」)100份、調平劑(DIC公司製造，製品名「GRANDIC PC4100」)1份、及光聚合起始劑(Ciba Japan公司製造，商品名：Irgacure 907)3份進行混合，以固形物成分濃度成為40%之方式利用環戊酮加以稀釋，而製備硬塗層形成用組合物。 ＜實施例1＞ 於長條狀之聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)之一面積層保護片材A。作為保護片材A，使用於PET基材(表面粗糙度Ra：0.02 μm)之單面具備黏著劑層(厚度：5 μm)之保護片材A(SUN A.KAKEN公司製造，商品名「NSA32T」，厚度：25 μm)。保護片材A之剛挺性為45 mm。 繼而，一面搬送上述聚碳酸酯系薄膜，一面於該薄膜之另一面塗佈製造例1所製備之硬塗層形成用組合物，於75℃下加熱。利用高壓水銀燈，對加熱後之塗佈層照射累計光量300 mJ/cm2 之紫外線使塗佈層硬化，而形成硬塗層(厚度：2 μm)。再者，於該步驟中，未產生問題而順利地搬送了薄膜。 如此獲得附有塗敷層(硬塗層)之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。 ＜實施例2＞ 以硬塗層之厚度成為6 μm之方式調整硬塗層形成用組合物之塗佈量，除此以外，藉由與實施例1相同之方式獲得附有塗敷層之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。再者，於硬塗層形成步驟中，未產生問題而順利地搬送了薄膜。 ＜實施例3＞ 於聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)之一面積層保護片材B。作為保護片材B，使用於PET基材(表面粗糙度Ra：0.05 μm)之單面具備黏著劑層(厚度：5 μm)之保護片材B(日東電工公司製造，商品名「HP300」，厚度：38 μm)。保護片材B之剛挺性為60 mm。 於聚碳酸酯系薄膜之另一面藉由與實施例1相同之方式形成硬塗層。再者，於該步驟中，未產生問題而順利地搬送了薄膜。 將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。 ＜實施例4＞ 於聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)之一面積層保護片材C。作為保護片材C，使用於PET基材(表面粗糙度Ra：0.05 μm)之單面具備黏著劑層(厚度：23 μm)之保護片材C(日東電工公司製造，商品名「RP300」，厚度：38 μm)。保護片材C之剛挺性為60 mm。 於未延伸聚碳酸酯薄膜之另一面藉由與實施例1相同之方式形成硬塗層。再者，於該步驟中，未產生問題而順利地搬送了薄膜。 將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。 ＜實施例5＞ 使用聚碳酸酯系薄膜(厚度：15 μm，剛挺性：25 mm)代替聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)，除此以外，藉由與實施例1相同之方式獲得附有塗敷層之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。再者，於硬塗層形成步驟中，未產生問題而順利地搬送了薄膜。 ＜實施例6＞ 使用環烯烴系薄膜(厚度：25 μm，剛挺性：38 mm)代替聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)，除此以外，藉由與實施例1相同之方式獲得附有塗敷層之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。再者，於硬塗層形成步驟中，未產生問題而順利地搬送了薄膜。 ＜比較例1＞ 於聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)之一面積層保護片材D。作為保護片材D，使用於聚乙烯基材(表面粗糙度Ra：0.2 μm)之單面具備黏著劑層(厚度：3 μm)之保護片材D(Toray公司製造，商品名「TORETEC 7832C-30」，厚度：28 μm)。保護片材D之剛挺性為30 mm。 於未延伸聚碳酸酯薄膜之另一面藉由與實施例1相同之方式形成硬塗層。再者，於該步驟中，確認薄膜發生彎折(未斷裂)。 將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。 ＜比較例2＞ 使用環烯烴系薄膜(厚度：25 μm，剛挺性：38 mm)代替聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)，除此以外，藉由與比較例1相同之方式獲得附有塗敷層之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。再者，於硬塗層形成步驟中，確認薄膜發生彎折(未斷裂)。 ＜參考例1＞ 於聚碳酸酯系薄膜(厚度：40 μm，剛挺性：45 mm)之一面塗佈製造例1所製備之硬塗層形成用組合物，於75℃下加熱。利用高壓水銀燈，對加熱後之塗佈層照射累計光量300 mJ/cm2 之紫外線使塗佈層硬化，而形成硬塗層(厚度：2 μm)。再者，於該步驟中，未產生問題而順利地搬送了薄膜。 如此獲得附有塗敷層(硬塗層)之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。 ＜參考例2＞ 使用聚碳酸酯系薄膜(厚度：40 μm，剛挺性：45 mm)代替聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)，除此以外，藉由與實施例1相同之方式獲得附有塗敷層之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。再者，於硬塗層形成步驟中，未產生問題而順利地搬送了薄膜。 ＜參考例3＞ 使用聚碳酸酯系薄膜(厚度：40 μm，剛挺性：45 mm)代替聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)，並將硬塗層之厚度設為2 μm，除此以外，藉由與比較例1相同之方式獲得附有塗敷層之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。再者，於硬塗層形成步驟中，未產生問題而順利地搬送了薄膜。 ＜參考例4＞ 於聚碳酸酯系薄膜(厚度：20 μm，剛挺性：35 mm)之一面塗佈製造例1所製備之硬塗層形成用組合物，於75℃下加熱。利用高壓水銀燈，對加熱後之塗佈層照射累計光量300 mJ/cm2 之紫外線使塗佈層硬化，而形成硬塗層(厚度：2 μm)。再者，於該步驟中，確認薄膜發生斷裂。 如此獲得附有塗敷層(硬塗層)之薄膜。將所獲得之附有塗敷層之薄膜供於上述評價(3)。將結果示於表1。 [表1]

Figure 106140241-A0304-0001
由表1可知，根據本發明之製造方法，可於薄型之薄膜上於不產生皺褶等之情況下形成塗敷層。更詳細而言，利用先前技術於薄型之薄膜上形成塗敷層時於搬送性方面存在問題(參考例4)，但藉由使用表面粗糙度Ra及剛挺性經適當調整之保護片材(實施例1～6)，能夠與於厚度較厚且剛直之薄膜上形成塗敷層之情形(參考例1)相同程度地抑制皺褶產生。 [產業上之可利用性] 藉由本發明之製造方法所獲得之附有塗敷層之薄膜可較佳地用於圖像顯示裝置。Hereinafter, preferred embodiments of the present invention will be described, but the present invention is not limited to these embodiments. Fig. 1 is a diagram illustrating the manufacturing method of the present invention in one embodiment of the present invention. The method for manufacturing a film with a coating layer of the present invention is a method for forming a coating layer 10 on a thin film 20, which includes: layering a protective sheet 30 on an area of the thin film 20 (Figure 1(a)); The coating layer 10 is formed on the other surface of the film 20 (the surface opposite to the surface on which the protective sheet 30 is laminated) (FIG. 1(b)). In one embodiment, the protective sheet 30 is releasably laminated on the film 20. In one embodiment, after the coating layer 10 is formed to obtain a film with the coating layer, the protective sheet 30 is peeled off (FIG. 1(c)). The thickness of the above film is 25 μm or less. In the present invention, even if a thin film is used that is prone to wrinkles in the past, the coating layer can be formed while preventing wrinkles. The thickness of the film can be appropriately set according to the application. In one embodiment, the thickness of the above-mentioned film is 20 μm or less. In another embodiment, the thickness of the above-mentioned film is 15 μm or less. The lower limit of the thickness of the film is, for example, 1 μm. The stiffness of the above film is below 40 mm. According to the present invention, even if a film with low stiffness (ie, no plasticity) is used and wrinkles are unavoidable in the previous method, the coating layer can be formed while preventing wrinkles. In one embodiment, a film with a stiffness of 5 mm to 35 mm can be used. In another embodiment, a film with a stiffness of 5 mm to 25 mm can be used. In addition, in this specification, the stiffness is measured in accordance with JIS L1096 (45°, cantilever method). The measurement method is detailed below. The above-mentioned film preferably has light transmittance. In one embodiment, the light transmittance of the above-mentioned film is more than 40%, preferably 45%-50%. In another embodiment, the light transmittance of the above-mentioned film is 70% or more, more preferably 80% or more, and still more preferably 90% or more. In one embodiment, an optical film is used as the above-mentioned film. Examples of the optical film include retardation films, polarizing films (polarizing elements, or polarizing plates composed of polarizing elements and protective films), brightness enhancing films, light diffusion films, and light-concentrating films. As the material constituting the above-mentioned film, any suitable material can be used. Examples include: polycarbonate resin, polyvinyl acetal resin, cycloolefin resin, acrylic resin, cellulose ester resin, cellulose resin, polyester resin, polyester carbonate resin, olefin resin Resins, polyurethane resins, etc. Preferable examples are: polycarbonate resins, polyvinyl acetal resins, cellulose ester resins, polyester resins, polyester carbonate resins and other resins that can be used as materials for optical films; polyvinyl alcohol-based films, parts Hydrophilic polymer films such as formalized polyvinyl alcohol films, ethylene-vinyl acetate copolymer partially saponified films (films used as materials for polarizing elements), etc. The film may have a laminated structure composed of a plurality of layers. <Layer of protective sheet> The arithmetic surface roughness Ra of the surface of the protective sheet opposite to the film is 0.1 μm or less, preferably 0.08 μm or less, and more preferably 0.05 μm or less. The arithmetic surface roughness Ra of the protective sheet is as small as possible, and its lower limit is, for example, 0.01 μm. In addition, in this specification, the arithmetic surface roughness Ra is measured based on JIS B0601. The stiffness of the protective sheet is 40 mm or more, preferably 45 mm or more, more preferably 50 mm or more, and still more preferably 60 mm or more. In the present invention, as described above, a protective sheet with a small arithmetic surface roughness Ra and high stiffness is used, and the protective sheet is used to support the film, thereby suppressing wrinkles during the formation of the coating layer . More specifically, it can prevent the shrinkage of the film caused by heating when the coating layer is formed, or it can prevent the film with the coating layer caused by the hardening shrinkage when the coating layer is formed. In addition, the protective sheet itself is excellent in smoothness and rigidity, so it prevents defects caused by the protective sheet (such as transfer of fine irregularities on the surface of the protective sheet to the above-mentioned film, and shrinkage of the protective sheet. Concave and convex transfer to the above-mentioned film and other defects). Furthermore, the upper limit of the stiffness of the protective sheet is preferably 100 mm. If it is in this range, the coating layer can be formed without problems such as warpage. The protective sheet is preferably constructed so that the adhesion to the film becomes 0.01 N/25 mm to 1.00 N/25 mm, and more preferably is constructed so as to be 0.1 N/25 mm to 0.5 N/25 mm. If a protective sheet having such an adhesive force is used, wrinkles can be prevented when the coating layer is formed, and the protective sheet can be easily peeled off after the coating layer is formed. In this manual, the adhesive force is based on the method based on JIS Z 0237 (2000) (measurement temperature: 23°C, bonding conditions: 2 kg roller reciprocating once, peeling speed: 300 mm/min, peeling angle 180°) Perform the measurement. In one embodiment, the protective sheet includes a substrate and an adhesive layer formed on the substrate. In the lamination step of the protective sheet, the adhesive layer side of the protective sheet is attached to the above-mentioned film. Furthermore, in a protective sheet having a substrate and an adhesive layer, the arithmetic surface roughness Ra is equivalent to the arithmetic surface roughness Ra of the surface of the substrate opposite to the adhesive layer. As the material constituting the above-mentioned base material, any suitable material can be used as long as the effect of the present invention can be obtained. Examples of the material constituting the base material include polyethylene terephthalate, polyethylene, polypropylene, and polyolefin. Among them, polyethylene terephthalate is preferred. If polyethylene terephthalate is used, a thinner and higher stiffness substrate can be obtained (the protective sheet is finally obtained). The thickness of the aforementioned substrate is preferably 10 μm to 100 μm, more preferably 15 μm to 80 μm, and still more preferably 20 μm to 50 μm. The above-mentioned adhesive layer is composed of any suitable adhesive. Specific examples of the adhesive include acrylic adhesives, polyethylene adhesives, polypropylene adhesives, polyolefin adhesives, and the like. The thickness of the adhesive layer is preferably 10 μm or less, more preferably 8 μm or less. By setting it as such a range, the generation of wrinkles when the coating layer is formed becomes less. In addition, the warpage of the film with the coating layer can be suppressed. The lower limit of the thickness of the adhesive layer is, for example, 1 μm. <Formation of Coating Layer> As described above, after the protective sheet is layered on one area of the film, a coating layer is formed on the other side of the film. The coating layer forming step typically includes coating of the coating layer forming composition, heating of the coating layer, and the like. In one embodiment, the coating layer is made of curable resin. In this case, the coating layer may be further cured (for example, ultraviolet irradiation or heating) in the coating layer formation step. The manufacturing method of the present invention is particularly useful for the formation of coating layers that require hardening treatment. Previously, the curing shrinkage of the curable resin caused by the curing treatment was greater than the shrinkage when the coating layer was formed by drying. This is a greater cause of wrinkles in the film. According to the present invention, even when the curing shrinkage of the curable resin occurs , Can also obtain a film with a coating layer while preventing wrinkles. As the curable resin, a photocurable resin (for example, an ultraviolet curable resin) or a thermosetting resin can be used. Among them, photocurable resin is preferred. The curing shrinkage when the photocurable resin is cured is large, so the present invention is particularly useful as a method of forming a coating layer composed of a photocurable resin. Furthermore, after the coating layer is formed, surface treatments such as corona treatment and plasma treatment may be performed on the coating layer. As a specific example of the said coating layer, a hard-coat layer, an anti-glare layer, an anti-blocking layer, an anti-reflection layer, a conductive layer, etc. are mentioned. Among them, the manufacturing method of the present invention is particularly useful when forming a hard coat layer or an anti-glare layer. The composition for forming a coating layer contains any suitable resin material (monomer, oligomer, prepolymer, and/or polymer). In one embodiment, the composition for forming a coating layer contains a thermosetting or photocuring curable compound as a resin material. If a composition for forming a coating layer containing a curable compound is used, for example, a hard coat layer or an anti-glare layer can be formed. The curable compound may be any of monomers, oligomers, and prepolymers. As the curable compound, polyfunctional monomers or oligomers can be used. Examples include monomers or oligomers having two or more (meth)acrylic groups, and (meth)acrylate urethanes. Or (meth)acrylate urethane oligomers, epoxy monomers or oligomers, silicone monomers or oligomers, etc. The composition for forming a coating layer may further contain any suitable additives. Examples of additives include polymerization initiators, leveling agents, anti-blocking agents, dispersion stabilizers, thixotropic agents, antioxidants, ultraviolet absorbers, defoamers, thickeners, dispersants, and surfactants. , Catalysts, fillers, lubricants, antistatic agents, etc. The type, combination, content, etc. of the additives contained can be appropriately set according to the purpose or required characteristics. In one embodiment, the composition for forming a coating layer contains fine particles as an additive. If a composition for forming a coating layer containing fine particles is used, an anti-glare layer can be formed. The fine particles may be inorganic fine particles or organic fine particles. Examples of the inorganic fine particles include silica fine particles, titanium oxide fine particles, alumina fine particles, zinc oxide fine particles, tin oxide fine particles, calcium carbonate fine particles, barium sulfate fine particles, talc fine particles, kaolin fine particles, calcium sulfate fine particles, and the like. Examples of organic fine particles include: polymethyl methacrylate resin powder (PMMA fine 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, polyvinyl fluoride resin powder, etc. These fine particles can be used alone or in combination of plural kinds. The composition for forming the coating layer may or may not contain a solvent. Examples of solvents include dibutyl ether, dimethoxymethane, dimethoxyethane, diethoxyethane, propylene oxide, 1,4-dioxane, and 1,3-dioxane Cyclopentane, 1,3,5-trioxane, tetrahydrofuran, acetone, methyl ethyl ketone (MEK), diethyl ketone, dipropyl ketone, diisobutyl ketone, cyclopentanone (CPN), Cyclohexanone, methylcyclohexanone, ethyl formate, propyl formate, n-pentyl formate, methyl acetate, ethyl acetate, methyl propionate, ethyl propionate, n-pentyl acetate, acetone, Diacetone alcohol, methyl acetylacetate, ethyl acetylacetate, methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-pentanol, 2-methyl- 2-butanol, cyclohexanol, isopropanol (IPA), isobutyl acetate, methyl isobutyl ketone (MIBK), 2-octanone, 2-pentanone, 2-hexanone, 2-heptanone , 3-Heptanone, ethylene glycol monoethyl ether acetate, ethylene glycol monoethyl ether, ethylene glycol monobutyl ether, ethylene glycol monomethyl ether, propylene glycol monomethyl ether acetate, propylene glycol monomethyl ether, etc. These can be used alone or in combination of plural kinds. As the coating method of the composition for forming a coating layer, any appropriate method can be adopted. Examples include: bar coating method, gravure roll coating method, die nozzle coating method, rod coating method, slot coating method, curtain coating method, jet coating method, Doctor blade coating method. Furthermore, in the present invention using a thinner and weaker plastic film, if the gravure roll coating method is used, the coating layer can be formed with better thickness accuracy. The heating temperature of the coating layer of the coating layer forming composition can be set to an appropriate temperature according to the composition of the coating layer forming composition, and it is preferably set to a temperature equal to or lower than the glass transition temperature of the resin contained in the film. If it is heated at a temperature below the glass transition temperature of the resin contained in the above-mentioned film, a film with a coating layer in which deformation caused by heating is suppressed can be obtained. The heating temperature is, for example, 60°C to 140°C, preferably 60°C to 100°C. By heating in this range, a coating layer with excellent adhesion to the film can be formed. As the above-mentioned hardening treatment, any suitable hardening treatment can be adopted. Typically, curing treatment is performed by ultraviolet irradiation. The cumulative light intensity of ultraviolet irradiation is preferably 200 mJ to 400 mJ. The thickness of the coating layer is preferably 10 μm or less, more preferably 2 μm to 6 μm. If it is in this range, it is possible to obtain a film with a coating layer that can fully exhibit its function as a coating layer and has an excellent appearance. In one embodiment, the pencil hardness of the coating layer is preferably H or higher, more preferably 3H or higher. If it is in this range, the coating layer can effectively function as a hard coat layer. The pencil hardness can be measured according to the pencil hardness test of JIS K 5400. [Embodiments] Hereinafter, the present invention will be specifically explained with examples, but the present invention is not limited to these embodiments. The evaluation methods in the examples are as follows. In addition, in the examples, as long as there is no special description, "parts" and "%" are based on weight. (1) The stiffness is measured in accordance with JIS L1096 (45°, cantilever method). Specifically, as shown in Fig. 2, on the upper surface (horizontal plane) of the trapezoidal and smooth mold B with an inclined surface with an inclination angle of 45°, one end a of the test piece A is located at the inclined surface side end b of the horizontal plane of the mold. Place the test piece A (size: 20 mm×150 mm), make the test piece A slide gently on the slope side, and measure the horizontal movement distance L of the test piece when one end a of the test piece touches the bottom of the slope. For the protective sheet, the adhesive layer is used as the upper side, the movement distance L is measured by the above-mentioned operation, and the measured value is taken as the stiffness of the protective sheet. For a film with a coating layer (hard coating), the average value of the moving distance measured with the coating layer side up and the moving distance measured with the coating layer facing down is regarded as the coating layer attached The stiffness of the film. (2) Arithmetic surface roughness Ra The arithmetic surface roughness Ra of the base material constituting the protective sheet was measured by the following method. On the surface opposite to the measurement surface, a glass plate (thickness 1.3 μm) manufactured by MATSUNAMI was bonded with an adhesive, and the surface shape was measured using a three-dimensional optical profile analyzer NewView 7300 (manufactured by ZYGO). According to the measured data, the arithmetic surface roughness Ra is calculated according to JIS B 0601-2001. (3) Appearance The appearance of the obtained film with the coating layer was confirmed by visual inspection. The evaluation criteria are as follows. AA: No wrinkles are generated. A: There are very few wrinkles that can be seen and can be tolerated in practice. B: Wrinkles that can be seen as concavities and convexities are generated. C: Wrinkles are allowed in practice. <Production Example 1> Preparation of a composition for forming a hard coat layer. 100 parts of acrylic urethane resin (manufactured by DIC Corporation, product name "UNIDIC 17-806") and a leveling agent ( One part of DIC company, product name "GRANDIC PC4100"), and 3 parts of photopolymerization initiator (manufactured by Ciba Japan company, product name: Irgacure 907) were mixed, and cyclopentane was used so that the solid content concentration became 40% The ketone is diluted to prepare a composition for forming a hard coat layer. <Example 1> The protective sheet A is an area layer of a long polycarbonate film (thickness: 20 μm, stiffness: 35 mm). As the protective sheet A, a PET substrate (surface roughness Ra: 0.02 μm) provided with an adhesive layer (thickness: 5 μm) on one side of the protective sheet A (manufactured by SUN A. KAKEN, trade name "NSA32T) ", thickness: 25 μm). The stiffness of the protective sheet A is 45 mm. Then, while conveying the above-mentioned polycarbonate-based film, the composition for forming a hard coat layer prepared in Production Example 1 was applied on the other side of the film, and heated at 75°C. Using a high-pressure mercury lamp, the heated coating layer was irradiated with ultraviolet rays with a cumulative light intensity of 300 mJ/cm 2 to harden the coating layer to form a hard coat layer (thickness: 2 μm). Furthermore, in this step, no problem occurred and the film was smoothly conveyed. In this way, a film with a coating layer (hard coat layer) is obtained. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. <Example 2> Except for adjusting the coating amount of the hard-coat layer forming composition so that the thickness of the hard-coat layer became 6 μm, a film with a coating layer was obtained in the same manner as in Example 1 . The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. Furthermore, in the hard-coat layer forming step, the film was smoothly transported without causing any problems. <Example 3> The protective sheet B was layered on one area of a polycarbonate film (thickness: 20 μm, stiffness: 35 mm). As the protective sheet B, a protective sheet B (manufactured by Nitto Denko Co., Ltd., trade name "HP300", with an adhesive layer (thickness: 5 μm)) on one side of a PET substrate (surface roughness Ra: 0.05 μm) is used. Thickness: 38 μm). The stiffness of the protective sheet B is 60 mm. A hard coat layer was formed on the other side of the polycarbonate film in the same manner as in Example 1. Furthermore, in this step, no problem occurred and the film was smoothly conveyed. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. <Example 4> The protective sheet C was layered on one area of a polycarbonate-based film (thickness: 20 μm, stiffness: 35 mm). As the protective sheet C, a protective sheet C (manufactured by Nitto Denko Corporation, trade name "RP300" with an adhesive layer (thickness: 23 μm)) on one side of a PET substrate (surface roughness Ra: 0.05 μm) is used. Thickness: 38 μm). The stiffness of the protective sheet C is 60 mm. A hard coat layer was formed on the other side of the unstretched polycarbonate film in the same manner as in Example 1. Furthermore, in this step, no problem occurred and the film was smoothly conveyed. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. <Example 5> A polycarbonate-based film (thickness: 15 μm, stiffness: 25 mm) was used instead of a polycarbonate-based film (thickness: 20 μm, stiffness: 35 mm). In addition, by In the same manner as in Example 1, a film with a coating layer was obtained. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. Furthermore, in the hard-coat layer forming step, the film was smoothly transported without causing any problems. <Example 6> Cycloolefin-based film (thickness: 25 μm, stiffness: 38 mm) was used instead of polycarbonate-based film (thickness: 20 μm, stiffness: 35 mm). In the same manner as in Example 1, a film with a coating layer was obtained. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. Furthermore, in the hard-coat layer forming step, the film was smoothly transported without causing any problems. <Comparative Example 1> An area layer protective sheet D on a polycarbonate film (thickness: 20 μm, stiffness: 35 mm). As the protective sheet D, a protective sheet D (manufactured by Toray Corporation, trade name "TORETEC 7832C- 30", thickness: 28 μm). The stiffness of the protective sheet D is 30 mm. A hard coat layer was formed on the other side of the unstretched polycarbonate film in the same manner as in Example 1. Furthermore, in this step, it is confirmed that the film is bent (not broken). The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. <Comparative Example 2> Cycloolefin-based film (thickness: 25 μm, stiffness: 38 mm) was used instead of polycarbonate-based film (thickness: 20 μm, stiffness: 35 mm). In the same manner as in Comparative Example 1, a film with a coating layer was obtained. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. Furthermore, in the hard coat layer forming step, it was confirmed that the film was bent (not broken). <Reference Example 1> The composition for forming a hard coat layer prepared in Manufacturing Example 1 was applied to one side of a polycarbonate film (thickness: 40 μm, stiffness: 45 mm), and heated at 75°C. Using a high-pressure mercury lamp, the heated coating layer was irradiated with ultraviolet rays with a cumulative light intensity of 300 mJ/cm 2 to harden the coating layer to form a hard coat layer (thickness: 2 μm). Furthermore, in this step, no problem occurred and the film was smoothly conveyed. In this way, a film with a coating layer (hard coat layer) is obtained. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. <Reference Example 2> A polycarbonate-based film (thickness: 40 μm, stiffness: 45 mm) is used instead of a polycarbonate-based film (thickness: 20 μm, stiffness: 35 mm). In addition, by In the same manner as in Example 1, a film with a coating layer was obtained. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. Furthermore, in the hard-coat layer forming step, the film was smoothly transported without causing any problems. <Reference example 3> Use polycarbonate film (thickness: 40 μm, stiffness: 45 mm) instead of polycarbonate film (thickness: 20 μm, stiffness: 35 mm), and use a hard coat Except that the thickness was set to 2 μm, a film with a coating layer was obtained in the same manner as in Comparative Example 1. The obtained film with a coating layer was used for the above evaluation (3). The results are shown in Table 1. Furthermore, in the hard-coat layer forming step, the film was smoothly transported without causing any problems. <Reference Example 4> The composition for forming a hard coat layer prepared in Manufacturing Example 1 was applied to one side of a polycarbonate film (thickness: 20 μm, stiffness: 35 mm), and heated at 75°C. Using a high-pressure mercury lamp, the heated coating layer was irradiated with ultraviolet rays with a cumulative light intensity of 300 mJ/cm 2 to harden the coating layer to form a hard coat layer (thickness: 2 μm). Furthermore, in this step, it was confirmed that the film was broken. In this way, a film with a coating layer (hard coat layer) is obtained. The obtained film with a coating layer was used for the above-mentioned evaluation (3). The results are shown in Table 1. [Table 1]
Figure 106140241-A0304-0001
 It can be seen from Table 1 that according to the manufacturing method of the present invention, a coating layer can be formed on a thin film without wrinkles or the like. In more detail, when using the prior art to form a coating layer on a thin film, there is a problem in transportability (Reference Example 4), but by using a protective sheet with appropriately adjusted surface roughness Ra and stiffness ( In Examples 1 to 6), the generation of wrinkles can be suppressed to the same extent as in the case of forming a coating layer on a thick and rigid film (Reference Example 1). [Industrial Applicability] The film with a coating layer obtained by the manufacturing method of the present invention can be preferably used in an image display device.

10‧‧‧塗敷層20‧‧‧薄膜30‧‧‧保護片材a‧‧‧試驗片之一端A‧‧‧試驗片b‧‧‧模水平面之斜面側端部B‧‧‧模L‧‧‧試驗片之水平方向移動距離10‧‧‧Coating layer 20‧‧‧Film 30‧‧‧Protection sheet a. ‧‧‧The moving distance of the test piece in the horizontal direction

圖1(a)～(c)係說明本發明之一實施形態之本發明之製造方法的圖。 圖2係說明剛挺性之測定方法的圖。Fig. 1 (a) to (c) are diagrams illustrating the manufacturing method of the present invention in one embodiment of the present invention. Figure 2 is a diagram illustrating the method of measuring stiffness.

10‧‧‧塗敷層 10‧‧‧Coating

20‧‧‧薄膜 20‧‧‧Film

30‧‧‧保護片材 30‧‧‧Protection sheet

Claims (10)

一種附有塗敷層之薄膜之製造方法，其包括：於厚度為25μm以下且剛挺性為40mm以下之薄膜之一面積層保護片材；及於該薄膜之另一面形成塗敷層；並且該保護片材之與該薄膜相反側之面之算術平均表面粗糙度Ra為0.1μm以下，且該保護片材之剛挺性為40mm以上。 A method for manufacturing a film with a coating layer, comprising: a protective sheet for an area layer of a film with a thickness of 25 μm or less and a stiffness of 40 mm or less; and forming a coating layer on the other side of the film; and the The arithmetic mean surface roughness Ra of the surface of the protective sheet opposite to the film is 0.1 μm or less, and the stiffness of the protective sheet is 40 mm or more. 如請求項1之附有塗敷層之薄膜之製造方法，其中上述保護片材具備基材、與形成於該基材上之黏著劑層，將該保護片材之黏著劑側貼合於上述薄膜。 The method for producing a film with a coating layer of claim 1, wherein the protective sheet includes a substrate, and an adhesive layer formed on the substrate, and the adhesive side of the protective sheet is attached to the above film. 如請求項2之附有塗敷層之薄膜之製造方法，其中上述黏著劑層之厚度為10μm以下。 The method for manufacturing a film with a coating layer of claim 2, wherein the thickness of the adhesive layer is 10 μm or less. 如請求項2之附有塗敷層之薄膜之製造方法，其中上述保護片材係可剝離地積層於上述薄膜。 The method for manufacturing a film with a coating layer of claim 2, wherein the protective sheet is releasably laminated on the film. 如請求項3之附有塗敷層之薄膜之製造方法，其中上述保護片材係可剝離地積層於上述薄膜。 The method for manufacturing a film with a coating layer according to claim 3, wherein the protective sheet is releasably laminated on the film. 如請求項1至5中任一項之附有塗敷層之薄膜之製造方法，其中上述薄膜為光學薄膜。 The method for manufacturing a film with a coating layer according to any one of claims 1 to 5, wherein the film is an optical film. 如請求項1至5中任一項之附有塗敷層之薄膜之製造方法，其中上述塗敷層係由硬化性樹脂構成。 The method for manufacturing a film with a coating layer according to any one of claims 1 to 5, wherein the coating layer is composed of a curable resin. 如請求項7之附有塗敷層之薄膜之製造方法，其中上述硬化性樹脂為光硬化性。 The method for manufacturing a film with a coating layer according to claim 7, wherein the curable resin is photocurable. 如請求項7之附有塗敷層之薄膜之製造方法，其中上述硬化性樹脂為熱硬化性。 The method for manufacturing a film with a coating layer according to claim 7, wherein the curable resin is thermosetting. 如請求項1至5中任一項之附有塗敷層之薄膜之製造方法，其中上述塗敷層之厚度為4μm以下。 The method for manufacturing a film with a coating layer according to any one of claims 1 to 5, wherein the thickness of the coating layer is 4 μm or less.
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