WO2009107544A1 - 防眩フィルム、防眩性偏光板および画像表示装置 - Google Patents
防眩フィルム、防眩性偏光板および画像表示装置 Download PDFInfo
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- WO2009107544A1 WO2009107544A1 PCT/JP2009/052898 JP2009052898W WO2009107544A1 WO 2009107544 A1 WO2009107544 A1 WO 2009107544A1 JP 2009052898 W JP2009052898 W JP 2009052898W WO 2009107544 A1 WO2009107544 A1 WO 2009107544A1
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- resin layer
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- antiglare
- glare
- antiglare film
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- 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
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/30—Polarising elements
- G02B5/3025—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state
- G02B5/3033—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid
- G02B5/3041—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks
- G02B5/305—Polarisers, i.e. arrangements capable of producing a definite output polarisation state from an unpolarised input state in the form of a thin sheet or foil, e.g. Polaroid comprising multiple thin layers, e.g. multilayer stacks including organic materials, e.g. polymeric layers
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- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL 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
- G02F1/00—Devices 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
- G02F1/01—Devices 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
- G02F1/13—Devices 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
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
- G02F1/133502—Antiglare, refractive index matching layers
Definitions
- the present invention is an anti-glare film that exhibits excellent anti-glare performance, does not turn white, and exhibits high contrast and good visibility when it is applied to an image display device without causing glare. And an antiglare polarizing plate and an image display device using the antiglare film.
- Image display devices such as a liquid crystal display, a plasma display panel, a cathode ray tube (CRT) display, and an organic electroluminescence (EL) display, when external light is reflected on the display surface, remarkably deteriorates the visibility.
- display is performed using a television or a personal computer that emphasizes image quality, a video camera and a digital camera that are used outdoors with strong external light, and reflected light.
- a film layer that prevents reflection of external light has been provided on the surface of an image display device.
- the film used as such a film layer scatters incident light by forming a fine unevenness on the surface of the film (nonreflective film) that has been subjected to antireflective treatment using interference by the optical multilayer film. It is roughly divided into a film (antiglare film) that has been subjected to an antiglare treatment that blurs the reflected image.
- the former non-reflective film is costly because it is necessary to form a multilayer film having a uniform optical film thickness.
- the latter anti-glare film can be manufactured relatively inexpensively, it is widely used for applications such as large personal computers and monitors.
- an antiglare film is based on random surface irregularities, for example, by applying a resin solution in which a filler is dispersed on a substrate sheet while adjusting the film thickness and exposing the filler to the surface of the coating film. It is manufactured by a method of forming on a material sheet.
- the anti-glare film manufactured using the resin solution in which the filler is dispersed is affected by the arrangement and shape of the surface irregularities depending on the dispersion state and application state of the filler in the resin solution. It is difficult to obtain unevenness, and when the haze of the antiglare film is set low, there is a problem that sufficient antiglare performance cannot be obtained.
- Patent Document 1 discloses a three-dimensional 10-point average roughness and a three-dimensional roughness reference surface on a transparent resin film.
- An antiglare film is disclosed in which a cured product layer of an ionizing radiation curable resin layer having fine surface irregularities in which the average distance between adjacent convex portions on the top satisfies a predetermined value.
- This antiglare film is manufactured by curing the ionizing radiation curable resin in a state where the ionizing radiation curable resin is sandwiched between the embossing mold and the transparent resin film.
- This document describes that an uneven surface for embossing is formed by a sandblasting method or a bead shot method using a roller having a chromium plating on the surface of iron.
- chrome plating for the purpose of improving durability during use, thereby making it harder and preventing corrosion.
- Patent Document 3 discloses a method for producing an embossing roll by a bead shot method.
- Patent Document 4 includes a step of forming a metal plating layer on the surface of an embossing roll, a step of mirror polishing the surface of the metal plating layer, and using a ceramic bead on the mirror-polished metal plating layer surface.
- a method for producing an embossing roll through a step of performing a blasting process and a step of performing a peening process as necessary is disclosed.
- Patent Document 5 In Japanese Patent Laid-Open No. 2006-53371 (Patent Document 5, Claims 1 and 2), a metal mold is formed by bumping fine particles against a polished metal surface to form unevenness, and electroless nickel plating is applied to the uneven surface. And the method of manufacturing the anti-glare film which was excellent in the anti-glare performance although it was a low haze by transferring the uneven surface of the metal mold
- Patent Document 6 Claim 1 is a film having an antiglare hard coat layer on a transparent support, which is transmitted when light is incident from the transparent support side.
- An antiglare antireflection film is disclosed in which the amount of light scattered in a specific direction of light is within a specific range with respect to the amount of light traveling straight.
- Patent Document 7 discloses an antiglare film in which the scattering angle indicating the maximum value of scattered light intensity and the total light transmittance are within a specific range. .
- the present invention has been made in view of the present situation, and the object thereof is to provide a high-definition image display device in which deterioration in visibility due to whitish is prevented while exhibiting excellent anti-glare performance. Another object of the present invention is to provide an antiglare film that exhibits high contrast without causing glare. Another object of the present invention is to provide an antiglare polarizing plate and an image display device to which the antiglare film is applied.
- the inventors of the present invention have provided two types of resin layers having different refractive indexes on the transparent support on the side far from the transparent support in each resin layer.
- the haze inside the antiglare film made of such a laminate (typically haze due to the interface region between the two types of resin layers) is provided so that a fine uneven shape is formed on the surface. It has been found that an antiglare film exhibiting excellent antiglare performance can be obtained if the specific range is satisfied.
- the intensity of the scattered light is controlled including the control of the scattering at the interface region between these two resin layers. It was found that the reflection characteristics can be controlled as well as the control.
- the incident angle 30 from the surface opposite to the transparent support side in the antiglare film.
- the reflectance R (30) at a reflection angle of 30 °, the reflectance R (40) at a reflection angle of 40 °, and the reflectance R (50) at a reflection angle of 50 ° are in specific ranges, respectively.
- the relative scattered light intensity T (30) in the normal direction of the anti-glare film when light is incident can be set to a specific range, thereby preventing glare sufficiently and also providing an image display device. Contrast when applied to I found out that it almost never declined. The present invention has been completed based on such findings and further various studies.
- the antiglare film of the present invention includes a transparent support, a first resin layer laminated on the transparent support, and a second resin layer laminated on the first resin layer. It is related with an anti-glare film provided with.
- the first resin layer and the second resin layer have different refractive indexes.
- the first resin layer is made of an ionizing radiation curable resin having a fine uneven shape on the surface opposite to the transparent support side, and the second resin layer is also formed on the surface opposite to the transparent support side. It consists of an ionizing radiation curable resin having a fine uneven shape.
- the internal haze of the antiglare film of the present invention is 5% or more and 30% or less.
- the reflectance R (30) at a reflection angle of 30 ° is 0.05% or more and 2% or less.
- the reflectance R (40) at a reflection angle of 40 ° is 0.0001% or more and 0.005% or less
- the reflectance R (50) at a reflection angle of 50 ° is 0.00001% or more and 0.0005% or less. It is preferable.
- the relative scattered light intensity T (20) in the normal direction of the antiglare film is 0.0001% to 0.0005%
- the transparent support side When the light is incident at an incident angle of 30 °, the relative scattered light intensity T (30) in the normal direction of the antiglare film is preferably 0.00004% or more and 0.00025% or less.
- the ionizing radiation curable resin constituting the first resin layer and the ionizing radiation curable resin constituting the second resin layer are not mixed with each other. It is preferable that a clear interface is formed.
- the absolute value of the difference between the refractive index of the first resin layer and the refractive index of the second resin layer is preferably 0.08 or more.
- the first resin layer and / or the second resin layer may contain a conductivity imparting substance.
- the antiglare film of the present invention may further have a low reflection film including a low refractive index layer having a refractive index lower than that of the transparent support on the surface of the second resin layer.
- the fine concavo-convex shape of the first resin layer and / or the fine concavo-convex shape of the second resin layer is preferably a mold having irregularities on the surface, and the concavo-convex shape is ionized radiation curable resin. It is formed by transferring to.
- the present invention also provides an antiglare polarizing plate comprising any one of the above antiglare films and a polarizing film laminated on the antiglare film.
- the polarizing film is disposed on the transparent support side of the antiglare film.
- the antiglare film or the antiglare polarizing plate of the present invention can be combined with an image display element such as a liquid crystal display element or a plasma display panel to form an image display device. That is, according to the present invention, the antiglare film or the antiglare polarizing plate according to any one of the above and an image display element, wherein the antiglare film or the antiglare polarizing plate is the second resin.
- An image display device is provided that is disposed on the viewing side of the image display element with the layer side facing outward.
- the anti-glare film of the present invention exhibits excellent anti-glare performance, prevents deterioration of visibility due to whitening, and also generates glare when placed on the surface of a high-definition image display device. And high contrast can be exhibited.
- the anti-glare polarizing plate obtained by combining the anti-glare film of the present invention with a polarizing film also exhibits the same effect.
- positioned the anti-glare film or anti-glare polarizing plate of this invention has high anti-glare performance, and is excellent in visibility.
- FIG. 1 is a schematic cross-sectional view showing a preferred example of the antiglare film of the present invention.
- the antiglare film of the present invention comprises a transparent support 100, a first resin layer 101 laminated thereon, and a second laminate laminated on the first resin layer 101. And a resin layer 102.
- the first resin layer 101 is ionized having a fine uneven shape (first fine uneven surface 101a in FIG. 1) on the surface opposite to the transparent support 100 side (surface on the second resin layer 102 side). It is a resin layer made of a radiation curable resin.
- the second resin layer 102 is a resin made of an ionizing radiation curable resin having a fine uneven shape (second fine uneven surface 102a in FIG.
- the upper surface (surface opposite to the transparent support 100 side) of the antiglare film shown in FIG. 1 is constituted by the fine uneven surface 102a of the second resin layer 102.
- the 2nd resin layer 102 is formed on the 1st resin layer 101 so that the recessed part of the fine uneven surface 101a which it has (it touches the fine uneven surface 101a).
- ionizing radiation curable resin means a cured product of a resin or a resin composition (hereinafter referred to as ionizing radiation curable resin) that can be cured by irradiation with ionizing radiation.
- ionizing radiation include ultraviolet rays, electron beams, and visible light.
- the antiglare film of the present invention having the above-described configuration is a part that determines the reflection characteristics of the antiglare film (second fine uneven surface 102a) and a part that determines the internal scattering characteristics of the antiglare film (first inside the antiglare film). Since the interface region between the resin layer 101 and the second resin layer 102, that is, the first fine uneven surface 101a region) is separately provided, the reflection characteristics and the internal scattering characteristics can be controlled independently. Is possible.
- the antiglare film having such a configuration it is possible to easily achieve desirable optical characteristics that the antiglare film should have, excellent antiglare performance, prevention of deterioration of visibility due to whitishness, high It is possible to simultaneously achieve glare prevention and high contrast when arranged on the surface of a fine image display device.
- corrugated shape of the 1st fine uneven surface and the uneven shape of the 2nd fine uneven surface are mutually independent.
- the antiglare film of the present invention is laminated on the transparent support and the transparent support, and has a fine uneven shape (first fine uneven surface) on the surface opposite to the transparent support.
- the first resin layer made of an ionizing radiation curable resin having a second resin layer made of an ionizing radiation curable resin having a fine uneven shape (second fine uneven surface) on the surface opposite to the transparent support side It is a laminated body.
- the “internal haze” of the antiglare film is 5% or more and 30% or less.
- the “internal haze” of the antiglare film is caused by fine irregularities on the surface of the antiglare film (unevenness on the surface of the second fine irregularities) among the hazes indicated by the entire antiglare film. Haze other than haze, that is, haze caused by the inside of the antiglare film.
- the haze caused by the second fine uneven surface of the second resin layer surface is defined as “surface haze”.
- the “internal haze” of the antiglare film is 30% or less. If the internal haze exceeds 30%, the screen becomes dark when applied to an image display device, and the visibility tends to be impaired. In order to ensure sufficient brightness, the internal haze is preferably 20% or less.
- the “surface haze” of the antiglare film is preferably 0.1% or more and 5% or less. By setting the surface haze to 5% or less, whitening can be effectively suppressed. When the surface haze is less than 0.1%, sufficient antiglare properties tend not to be exhibited.
- the “internal haze” and “surface haze” of the antiglare film are measured as follows. That is, first, the haze of the entire antiglare film including the transparent support and the first and second resin layers (hereinafter referred to as “total haze”) is measured according to JIS K 7136. Next, a triacetyl cellulose film (TAC film) having a haze of almost 0 is bonded to the second fine uneven surface of the anti-glare film using glycerin, and the haze is again applied according to JIS K 7136. taking measurement.
- TAC film triacetyl cellulose film
- This haze value can be regarded as the “internal haze” of the antiglare film because the haze (surface haze) caused by the second fine uneven surface is almost canceled. Therefore, the “surface haze” of the antiglare film is obtained from the following formula (1).
- Surface haze Overall haze-Internal haze (1)
- the “inner haze” of the antiglare film is substantially the same between the first resin layer and the second resin layer inside the antiglare film. It can be regarded as haze caused by the interface region (first fine uneven surface region). Since the internal haze of the first resin layer alone and the second resin layer alone does not contain a light diffusing agent such as fine particles, it is usually 1% or less.
- the “total haze” of the antiglare film is preferably 5% or more in order to effectively eliminate glare. However, if the overall haze exceeds 30%, the screen becomes dark when placed in an image display device, and the visibility tends to be impaired.
- the ionizing radiation curable resin constituting the first resin layer and the second resin layer are within a range in which the adhesion between the first resin layer and the second resin layer can be secured. It is preferable that the interface with the ionizing radiation curable resin constituting the is clearly formed. Thereby, the internal scattering effect by the said interface area
- the ionizing radiation curable resin constituting the first resin layer and the ionizing radiation curable resin constituting the second resin layer are partially mixed, and a mixed phase composed of these cured resins. In this case, it may be relatively difficult to control the optical characteristics of the antiglare film, particularly the internal scattering characteristics.
- Both the first resin layer and the second resin layer are made of ionizing radiation curable resin, but have different refractive indexes.
- the refractive index is the same, the scattered light does not scatter on the first fine uneven surface.
- the refractive index of the first resin layer is n 1 and the refractive index of the second resin layer is n 2 , the absolute value
- of the difference between these refractive indexes is 0.08 or more. It is preferable that it is 0.1 or more.
- the refractive index n 1 of the first resin layer is more preferably larger than the refractive index n 2 of the second resin layer.
- ionizing radiation curable resin used for the first resin layer and the second resin layer conventionally known ones can be used.
- acrylic resins examples include ether acrylate resins and ester acrylate resins.
- the ionizing radiation curable resins used for the first resin layer and the second resin layer are selected so that the refractive indexes of the cured resins obtained by curing them are different from each other, and preferably satisfy the above preferable refractive index difference. Is done.
- the refractive index of a cured product of generally available ionizing radiation curable resin is about 1.45 to 1.80.
- a photopolymerization initiator may be added to the ionizing radiation curable resin as necessary.
- the photopolymerization initiator may be a conventionally known one. Examples of commercially available photopolymerization initiators include “Irgacure 907”, “Irgacure 184” (above, manufactured by Ciba Specialty Chemicals), “Lucirin TPO” (produced by BASF), and the like.
- the transparent support is not particularly limited as long as it is made of a material that is substantially optically transparent.
- thermoplastics such as amorphous cyclic polyolefins having triacetyl cellulose, polyethylene terephthalate, polycarbonate, and norbornene compounds as monomers.
- a solvent cast film or an extruded film made of a resin can be used.
- the transparent support may be formed by forming the resin surface into a film sheet by an extrusion method or the like while embossing a resin surface such as an acrylate resin using a metal mold as described later.
- the thickness of the transparent support is not particularly limited and is, for example, 20 to 250 ⁇ m, preferably 40 to 150 ⁇ m.
- the refractive index of a cured product of generally available ionizing radiation curable resin is about 1.45 to 1.80.
- the arithmetic average height Pa in an arbitrary cross-sectional curve on the surface of the fine uneven surface is 0.1 ⁇ m or more and 1.0 ⁇ m or less, and the maximum cross-sectional height Pt is 0.5 ⁇ m or more and 3.5 ⁇ m or less.
- the length PSm is preferably 5 ⁇ m or more and 20 ⁇ m or less.
- the arithmetic average height Pa in an arbitrary cross section curve of the surface is 0.05 ⁇ m or more and 0.20 ⁇ m or less, and the maximum cross section height Pt is 0.2 ⁇ m or more and 1.5 ⁇ m or less.
- the average length PSm is preferably 15 ⁇ m or more and 100 ⁇ m or less.
- the arithmetic average height Pa is less than 0.05 ⁇ m, the second fine uneven surface (antiglare film surface) becomes almost flat and does not exhibit sufficient antiglare performance.
- the arithmetic average height Pa is larger than 0.20 ⁇ m, the surface shape becomes rough, whitishness occurs, and the texture when the appearance is visually observed tends to be rough.
- the antiglare film surface is also almost flat and does not exhibit sufficient antiglare performance. Further, when the maximum cross-sectional height Pt is larger than 1.5 ⁇ m, the surface shape becomes too rough, and problems such as whiteness and deterioration of texture may occur.
- the average length PSm is less than 15 ⁇ m, sufficient antiglare properties tend not to be obtained. This is presumably because when the average length PSm is too small, the uneven peak (the surface inclination angle is considered to be approximately 0 °) interval is close, so that an image is formed when visually observed. In addition, when the average length PSm is larger than 100 ⁇ m, the texture when the appearance is visually observed tends to be rough.
- the arithmetic average height Pa is the same as the value called centerline average roughness.
- the second fine uneven surface (antiglare film surface) has 50 or more and 100 or less convex portions in the region of 200 ⁇ m ⁇ 200 ⁇ m. If the number of convex portions on the uneven surface is small, glare due to interference with pixels occurs when applied to a high-definition image display device, and the image tends to be difficult to see and the texture tends to deteriorate. Further, when the number of convex portions is excessively large, the inclination angle of the surface irregularity shape becomes steep, and whitening is likely to occur.
- the surface shape is measured by an apparatus such as a confocal microscope, an interference microscope, an atomic force microscope (AFM), and the like.
- a convex portion is determined by the following algorithm, and the number of the convex portions is counted. That is, when an arbitrary point on the surface of the second fine concavo-convex surface is focused, there is no point higher than the focused point around the point, and the altitude on the concavo-convex surface of the point is uneven.
- the point is assumed to be the vertex of the convex part, and the number of convex parts obtained in this way is counted. And More specifically, as shown in FIG. 2, paying attention to an arbitrary point 201 on the second fine uneven surface 202, a radius of 2 ⁇ m to 5 ⁇ m parallel to the antiglare film reference surface 203 is centered on that point. When a circle is drawn, a point on the second fine uneven surface 202 included in the projection surface 204 of the circle on the anti-glare film reference surface 203 has a higher elevation than the point 201 of interest.
- the point 201 is determined to be the apex of the convex portion when the elevation on the concave-convex surface of the point is higher than the midpoint between the highest elevation and the lowest elevation of the concave-convex surface. Find a number.
- the radius of the projected circle 204 is required to be a size that does not count fine irregularities on the surface of the second fine irregularities and does not include a plurality of convex portions, and is preferably about 3 ⁇ m.
- a magnification of the objective lens of about 50 times and a reduced resolution. This is because if the measurement is performed at a high resolution, the fine irregularities on the surface of the second fine irregularities are measured, and the counting of the convex portions is hindered. Note that when the objective lens has a low magnification, the resolution in the height direction also decreases. Therefore, when measuring an anti-glare film with few unevenness
- the average area of the polygon formed when the surface of the second fine uneven surface (antiglare film surface) is Voronoi divided with the top of the convex portion as a generating point is 100 ⁇ m 2 or more and 1000 ⁇ m 2 or less. It is preferable.
- the Voronoi division will be explained. When several points (called mother points) are arranged on a plane, the plane can be divided depending on which mother point is closest to any point in the plane. The figure is called Voronoi diagram, and the division is called Voronoi division.
- FIG. 3 shows an example in which the surface of the second fine uneven surface is Voronoi divided with the apex of the convex portion as a generating point. A plurality of points shown in FIG.
- Voronoi division generating points 301 are Voronoi division generating points 301, and a Voronoi polygon (also referred to as a Voronoi region) 302 including one generating point 301 is formed by Voronoi division.
- a Voronoi polygon also referred to as a Voronoi region
- the number of generating points coincides with the number of Voronoi polygons.
- the average area of the Voronoi polygon formed when Voronoi is divided with the vertex of the convex portion as the base point is less than 100 ⁇ m 2 , the inclination angle of the second fine uneven surface (antiglare film surface) is steep. As a result, whitening is likely to occur. Further, when the average area of the Voronoi polygon is larger than 1000 ⁇ m 2 , the uneven surface shape becomes rough, glare is likely to occur, and the texture tends to deteriorate.
- the surface shape is measured by the above-mentioned apparatus, and the three-dimensional coordinate value of each point on the second fine irregular surface is obtained, and then the Voronoi division is performed by the following algorithm to obtain the average area of the Voronoi polygon. That is, according to the algorithm described with reference to FIG. 2, first, the vertex of the convex portion on the second fine uneven surface is obtained, and then the vertex of the convex portion is projected onto the antiglare film reference plane.
- the average area of the Voronoi polygon is determined.
- the generating point in the Voronoi polygon 303 that is in contact with the boundary of the measurement visual field is included when obtaining the number of convex portions described above.
- the antiglare film of the present invention has a configuration capable of independently controlling the reflection characteristics and the internal scattering characteristics, and can exhibit excellent optical characteristics.
- the antiglare film of the present invention has a reflectance R (30) at a reflection angle of 30 ° of 0.05% or more and 2% or less when light is incident at an incident angle of 30 ° from the second fine uneven surface side.
- the reflectance R (40) at a reflection angle of 40 ° is 0.0001% or more and 0.005% or less
- the reflectance R (50) at a reflection angle of 50 ° is 0.00001% or more and 0.0005% or less.
- FIG. 4 is a perspective view schematically showing an incident direction and a reflection direction of light from the second resin layer side with respect to the antiglare film when the reflectance is obtained.
- the direction of the reflection angle of 30 ° with respect to the light 405 incident at an angle of 30 ° from the normal line 402 of the anti-glare film on the second fine uneven surface side of the anti-glare film 401 that is,
- the reflectance (that is, the regular reflectance) of the reflected light in the regular reflection direction 406 is R (30).
- the direction of the reflected light when measuring the reflectance is within the plane 409 including the direction of the incident light 405 and the normal 402. To do.
- the regular reflectance R (30) exceeds 2%, a sufficient antiglare function cannot be obtained, and the visibility tends to decrease. On the other hand, even if the regular reflectance R (30) is too small, it tends to cause whitening. Therefore, the regular reflectance R (30) is preferably 0.05% or more. The regular reflectance R (30) is more preferably 1.5% or less, particularly 0.7% or less. On the other hand, if R (40) exceeds 0.005% or R (50) exceeds 0.0005%, the antiglare film is whitened and the visibility tends to be lowered.
- R (40) and R (50) are not so large.
- R (40) is generally preferably 0.0001% or more
- R (50) is generally 0, since sufficient antiglare properties are not exhibited even if the reflectance at these angles is too small. It is preferably 0.0001% or more.
- R (50) is more preferably 0.0001% or less.
- FIG. 5 shows the reflection angle ⁇ and the reflectance of the light 407 reflected at the reflection angle ⁇ with respect to the light 405 incident at an angle of 30 ° from the normal 402 on the second fine uneven surface side of the antiglare film 401 in FIG.
- a reflectance is a logarithmic scale
- Such a graph representing the relationship between the reflection angle and the reflectance, or the reflectance for each reflection angle read therefrom may be referred to as a reflection profile.
- the regular reflectance R (30) is a reflectance peak with respect to the light 405 incident at 30 °, and the reflectance tends to decrease as the angle deviates from the regular reflection direction.
- the regular reflectance R (30) is about 0.17%
- R (40) is about 0.0004%
- R (50) is about 0.00005%. .
- the regular reflectance R (30) is 0. .05% or more and 2% or less
- reflectance R (40) at a reflection angle of 40 ° is 0.0001% or more and 0.005% or less
- reflectance R (50) at a reflection angle of 50 ° is 0.00001% or more.
- the anti-glare film of the present invention has a sufficient anti-glare performance, but is suppressed in whiteness and excellent in optical characteristics.
- a detector In measuring the reflectance of an antiglare film, it is necessary to accurately measure a reflectance of 0.001% or less. Therefore, it is effective to use a detector with a wide dynamic range.
- a detector for example, a commercially available optical power meter can be used, and an aperture is provided in front of the detector of this optical power meter so that the angle at which the antiglare film is viewed is 2 °. Measurements can be made using an angular photometer.
- incident light visible light of 380 to 780 nm can be used, and as a measurement light source, collimated light emitted from a light source such as a halogen lamp can be used, or in parallel with a monochromatic light source such as a laser. A high degree may be used.
- reflection from the back surface of the antiglare film may affect the measured value.
- the smooth surface of the antiglare film is adhered to a black acrylic resin plate with an adhesive or It is preferable that only the reflectance of the outermost surface of the antiglare film (second fine uneven surface) can be measured by optical adhesion using a liquid such as water or glycerin.
- the antiglare film of the present invention has a relative scattered light intensity observed in the normal direction of the second fine uneven surface (second resin layer) side when light is incident from the transparent support side at an incident angle of 20 °.
- T (20) shows a value of 0.0001% or more and 0.0005% or less, and the relative observation observed in the normal direction of the second fine unevenness surface side when light is incident at an incident angle of 30 ° from the transparent support side.
- the scattered light intensity T (30) preferably exhibits a value of 0.00004% or more and 0.00025% or less.
- FIG. 6 shows the incident direction of light and the measurement of transmitted scattered light intensity when light is incident from the transparent support side and the scattered light intensity is measured in the normal direction of the second fine uneven surface (second resin layer) side. It is the perspective view which showed the direction typically.
- the intensity of the transmitted scattered light 604 transmitted in the direction of the line 602 is measured, and a value obtained by dividing the transmitted scattered light intensity by the light intensity of the light source is defined as a relative scattered light intensity T ( ⁇ ).
- the transmitted scattered light is observed in the direction of the second fine uneven surface side normal line 602.
- the value obtained by dividing the intensity of 604 by the light intensity of the light source is T (20)
- a value obtained by dividing the intensity of the transmitted scattered light 604 observed in the direction of the irregular surface side normal 602 by the light intensity of the light source is T (30).
- the light 603 is incident such that the direction of the light 603 incident from the transparent support side and the normal line 602 of the antiglare film are on the same plane (plane 609 in FIG. 6).
- the relative scattered light intensity T (30) at 30 ° incidence is less than 0.00004%, the scattering effect is low, and glare occurs when applied to a high-definition image display device.
- the antiglare film is applied to a liquid crystal display that is not self-luminous, the effect of increasing the brightness due to scattering caused by light leakage during black display is large, and therefore the relative scattered light intensities T (20) and T (30) are high. If it exceeds the preferable range, the contrast is remarkably lowered and the visibility is impaired.
- FIG. 7 is an example of a graph in which the relative scattered light intensity (logarithmic scale) measured by changing the incident angle ⁇ of light incident from the transparent support side of the antiglare film 601 in FIG. 6 is plotted against the incident angle ⁇ . It is.
- a graph representing the relationship between the incident angle and the relative scattered light intensity, or the relative scattered light intensity for each incident angle read therefrom may be referred to as a transmission scattering profile.
- the relative scattered light intensity has a peak at an incident angle of 0 °, and the scattered light intensity tends to decrease as the angle from the normal direction of the incident light 603 increases.
- the transmission / scattering profile usually appears symmetrically about the incident angle of 0 °.
- the relative scattered light intensity T (0) at 0 ° incidence shows a peak at about 30%
- the relative scattered light intensity T (20) at 20 ° incidence is about
- the relative scattered light intensity T (30) at 0.0002% and 30 ° incidence is about 0.00004%.
- Patent Documents 6 and 7 as references referring to the transmitted scattered light intensity, but in any reference, unlike the scattering characteristics that can be exhibited by the antiglare film of the present invention, image display is possible. When applied to the apparatus, it has not always been sufficient to achieve high contrast and suppress glare.
- a detector In measuring the relative scattered light intensity of the antiglare film, it is necessary to accurately measure the relative scattered light intensity of 0.001% or less, as in the reflectance measurement. Therefore, it is effective to use a detector with a wide dynamic range.
- a detector for example, a commercially available optical power meter can be used, and an aperture is provided in front of the detector of this optical power meter so that the angle at which the antiglare film is viewed is 2 °. Measurements can be made using an angular photometer.
- Visible light of 380 to 780 nm can be used as incident light, and a collimated light emitted from a light source such as a halogen lamp can be used as a measurement light source, or a parallel light source using a monochromatic light source such as a laser. Higher ones may be used.
- a light source such as a halogen lamp
- a parallel light source using a monochromatic light source such as a laser. Higher ones may be used.
- an optically transparent adhesive is used to bond the antiglare film to the glass substrate so that the uneven surface (second fine uneven surface) is the surface. It is preferable to use for a measurement.
- the antiglare film of the present invention may be imparted with conductivity in order to prevent dust adhesion or to adversely affect the image display element used in combination.
- Examples of the method for imparting conductivity include a method of incorporating a conductivity imparting substance into the first resin layer and / or the second resin layer.
- Examples of the conductivity-imparting substance include metal fine particles, metal oxide fine particles, conductive polymers, and surfactants.
- One kind or two or more kinds of conductivity imparting substances can be contained in the ionizing radiation curable resin constituting the first resin layer and / or the second resin layer.
- the antiglare film of the present invention exhibits a sufficient antiglare function even when there is no low reflection film on the outermost surface, that is, on the second fine uneven surface side, but the low antireflection film is provided on the second fine uneven surface. It can also be provided.
- the low reflection film can be formed by providing a layer made of a low refractive index material having a refractive index lower than that of the transparent support on the second resin layer. Specific examples of such a low refractive index material include lithium fluoride (LiF), magnesium fluoride (MgF 2 ), aluminum fluoride (AlF 3 ), cryolite (3NaF ⁇ AlF 3 or Na 3 AlF).
- Inorganic low reflection material containing inorganic material fine particles such as acrylic resin or epoxy resin; fluorine or silicone organic compound, thermoplastic resin, thermosetting resin, ultraviolet curable resin, etc.
- the organic low reflection material can be mentioned.
- the antiglare film of the present invention can be preferably produced by using an embossing method in which a metal mold having irregularities is used and the irregularities of the mold are transferred to an ionizing radiation curable resin. Specifically, when the first resin layer having the first fine uneven surface is formed by an embossing method using a metal mold, for example, ionization as described above is performed on the surface of the transparent support.
- a radiation curable resin is applied to form an ionizing radiation curable resin layer, and ionizing radiation (for example, ultraviolet rays) is irradiated from the transparent support side in a state where the curable resin layer is in close contact with the uneven surface of the metal mold.
- ionizing radiation for example, ultraviolet rays
- the curable resin layer is cured, and the uneven shape of the metal mold is transferred to the layer made of the ionizing radiation curable resin.
- the transparent support on which the first resin layer (ionizing radiation curable resin) is formed is peeled from the metal mold. The same applies when the second resin layer is formed on the first resin layer by an embossing method.
- At least one of the surface of the first resin layer (first fine uneven surface) or the surface of the second resin layer (second fine uneven surface) of the antiglare film uses a metal mold. It is preferably formed by an embossing method, and at least the first fine uneven surface is more preferably formed by an embossing method. Particularly preferably, both the first fine uneven surface and the second fine uneven surface are formed by an embossing method.
- the metal mold suitably used for producing the antiglare film of the present invention can be produced as follows.
- this mold manufacturing method in order to obtain a metal mold having surface irregularities, the surface of the metal substrate is subjected to copper plating or nickel plating, and after the plated surface is polished, fine particles are applied to the polished surface. After forming unevenness and processing to make the uneven shape dull, chromium plating is applied to the uneven surface to obtain a mold.
- the mold manufacturing method will be described in detail.
- copper plating or nickel plating is applied to the surface of the metal substrate.
- copper plating or nickel plating is applied to the surface of the metal substrate constituting the mold.
- chrome plating is applied to the surface of iron, etc., or if chrome plating is applied again after forming irregularities on the chrome plating surface by the sandblasting method or the bead shot method, the surface becomes rough as described above. It is easy to cause fine cracks and may adversely affect the uneven shape of the antiglare film. In contrast, it has been found that such inconvenience is eliminated by applying copper plating or nickel plating to the surface.
- copper plating and nickel plating have a high covering property and a strong smoothing action, so that a flat and glossy surface is formed by filling minute irregularities and nests of the metal substrate.
- Such characteristics of copper plating and nickel plating eliminate the roughness of the chrome plating surface, which is thought to be due to minute irregularities and nests existing in the metal substrate, and the high coverage of copper plating and nickel plating. Therefore, it is considered that the occurrence of fine cracks is reduced.
- Copper or nickel can be pure metal, respectively, or an alloy mainly composed of copper or an alloy mainly composed of nickel. Therefore, in this specification, copper is meant to include copper and copper alloys, and nickel is meant to include nickel and nickel alloys. Copper plating and nickel plating may be performed by electrolytic plating or electroless plating, respectively, but electrolytic plating is usually employed.
- aluminum, iron, and the like can be cited from the viewpoint of cost. From the viewpoint of handling convenience, lightweight aluminum is more preferable.
- Aluminum and iron can also be pure metals, respectively, or can be alloys mainly composed of aluminum or iron. After copper plating or nickel plating is applied to the surface of such a metal substrate, and the surface is further polished to obtain a smoother and more glossy surface, fine irregularities are formed by hitting the surface with fine particles. After performing the process of blunting the uneven shape, chrome plating is further applied thereto to form a mold.
- the thickness is preferably 10 ⁇ m or more.
- the upper limit of the plating layer thickness is not critical, but generally about 500 ⁇ m is sufficient in consideration of cost and the like.
- the metal substrate constituting the metal mold may be a flat metal plate or a columnar or cylindrical metal roll. If a metal mold
- FIG. 8 shows an example of a metal mold manufacturing method in the case where a flat metal substrate is used.
- FIG. 8 is a schematic cross-sectional view showing the state of the metal mold in each step.
- FIG. 8A shows a cross section of a metal substrate after copper plating or nickel plating and mirror polishing, and a plating layer 802 is formed on the surface of the metal substrate 801, and the surface is A polished surface 803 is formed. Concavities and convexities are formed by hitting fine particles against the surface of the plated layer 802 after such mirror polishing (see blast treatment, FIG. 8B). A fine concave surface 804 having a partial spherical shape is formed by hitting the fine particles.
- FIGS. 8C1 and 8C2 a process for dulling the uneven shape is applied to the surface on which the unevenness due to the fine particles is thus formed (see FIGS. 8C1 and 8C2).
- Examples of the method for dulling the uneven shape include a method by etching (FIG. 8 (c1)) and a method by copper plating (FIG. 8 (c2)).
- the etching method the partially spherical concave surface 804 shown in FIG. 8B and the acute protrusion formed thereby are cut away by etching, and the acute protrusion on the partial spherical surface is blunted.
- a surface 806a is formed.
- FIG. 8C1 a state before being blunted by etching (partial spherical concave surface 804 shown in FIG.
- the copper plating layer 805 is formed on the partial spherical concave surface 804 shown in FIG. 8 (b), whereby the surface 806b on which the acute protrusion on the partial spherical surface is blunted. Is formed.
- FIG. 8D1 is a schematic cross-sectional view showing a state in which a chromium plating layer 807 is formed on the surface 806a on which acute protrusions have been blunted by an etching process.
- FIG. 8D2 is a schematic cross-sectional view showing a state in which the chromium plating layer 807 is formed on the surface 806b on which the acute protrusions are blunted by copper plating.
- a chromium plating layer 807 is formed on the surface 806a on which acute protrusions are blunted by the etching shown in FIG. 8 (c1). .
- the unevenness of the surface 808 of the chrome plating layer is further dulled by chromium plating compared to the unevenness of the surface 806a, in other words, the uneven shape is relaxed.
- the copper plating layer 805 is formed on the fine concave surface formed in the plating layer 802 which consists of copper or nickel on the metal base material 801.
- a chromium plating layer 807 is formed thereon.
- the surface 808 of the chromium plating layer is duller than the unevenness of the surface 806b shown in FIG. 8C2 by the chromium plating, in other words, the uneven shape is relaxed.
- the surface 806a or 806b subjected to the process of dulling the irregularities is subjected to chromium plating, thereby substantially
- a metal mold having no flat portion can be obtained.
- such a mold is suitable for obtaining an antiglare film exhibiting preferable optical characteristics.
- the fine particles are applied to the plating layer made of copper or nickel on the metal substrate while the surface is polished.
- the plating layer made of copper or nickel is particularly preferably polished in a state close to a mirror surface. This is because the metal plate or metal roll as the base material is often subjected to machining such as cutting or grinding in order to obtain a desired shape with high accuracy, so that the processing surface remains on the surface of the base material. Because it is. Even when copper plating or nickel plating is applied, those processed marks may remain, and the surface may not be completely smooth in the plated state.
- the unevenness such as the processed eyes may be deeper than the unevenness formed by the fine particles, and the effects of the processed eyes remain. there is a possibility.
- the optical properties may be unexpectedly affected.
- the method for polishing the substrate surface on which plating has been performed there is no particular limitation on the method for polishing the substrate surface on which plating has been performed, and any of mechanical polishing, electrolytic polishing, and chemical polishing can be used.
- the mechanical polishing method include a superfinishing method, lapping, fluid polishing method, and buff polishing method.
- the surface roughness after polishing is expressed as an arithmetic average height Pa, and Pa is preferably 1 ⁇ m or less, and more preferably Pa is 0.5 ⁇ m or less. If Pa is too large, even if the metal surface is deformed by hitting fine particles, the influence of the surface roughness before deformation may remain, which is not preferable. Further, the lower limit of Pa is not particularly limited, and is set to an appropriate value in consideration of processing time, processing cost, and the like.
- an injection processing method is preferably used as a method for hitting the surface of the metal substrate plated with fine particles.
- the injection processing method include a sand blast method, a shot blast method, and a liquid honing method.
- the particles used in these processes are preferably in a shape close to a sphere rather than a shape having sharp corners, and particles of a hard material that are crushed during processing and do not produce sharp corners are preferable.
- spherical zirconia beads or spherical alumina beads are preferably used for ceramic particles.
- beads made of steel or stainless steel are preferred.
- particles in which ceramic or metal particles are supported on a resin binder may be used.
- fine particles having an average particle size of 10 to 150 ⁇ m, particularly spherical fine particles, as the fine particles that strike the plated surface of the metal substrate an anti-glare film exhibiting excellent anti-glare performance can be produced.
- the average particle size of the fine particles is smaller than 10 ⁇ m, it becomes difficult to form sufficient irregularities on the plated surface, and it becomes difficult to obtain sufficient antiglare performance.
- the average particle size of the fine particles is larger than 150 ⁇ m, the surface irregularities become rough, and glare is likely to occur or the texture is liable to deteriorate.
- a wet blast method in which the particles are processed by being dispersed in an appropriate dispersion medium so that the particles do not aggregate due to static electricity or the like.
- the pressure at the time of hitting the fine particles, the amount of the fine particles used, and the distance from the nozzle for injecting the fine particles to the metal surface are also the uneven shape of the metal mold after processing, and the first and / or the first of the antiglare film. 2 affects the shape of the surface of fine irregularities, but in general, the pressure is about 0.05 to 0.4 MPa in gauge pressure, and the amount of fine particles is about 2 to 12 g per cm 2 surface area of the metal to be treated. From the distance of about 200 mm to 600 mm from the nozzle to the metal surface, the type and particle diameter of the fine particles to be used, the type of metal, the shape of the nozzle for injecting the fine particles, the desired uneven shape, etc. may be appropriately selected.
- the uneven shape formed by hitting fine particles on the surface of the metal substrate plated is an arithmetic of an arbitrary cross-sectional curve.
- the average height Pa is 0.1 ⁇ m or more and 1.5 ⁇ m or less, and the ratio Pa / PSm between the arithmetic average height Pa and the average length PSm in the cross-sectional curve is preferably 0.02 or more and 0.1 or less.
- the arithmetic average height Pa is smaller than 0.1 ⁇ m or the ratio Pa / PSm is smaller than 0.02
- the uneven surface is almost flat when the uneven shape is blunted before chrome plating. It becomes difficult to obtain a mold having a desired surface shape.
- the processing for dulling the concavo-convex shape before chrome plating must be performed under strong conditions.
- the surface shape tends to be difficult to control.
- the substrate on which the unevenness is formed on the surface of the copper plating or the nickel plating is subjected to a process for dulling the uneven shape.
- etching treatment or copper plating is preferable.
- the sharp portions of the concavo-convex shape produced by hitting the fine particles are eliminated.
- die can be changed to a preferable direction.
- the copper plating has a strong smoothing action, the effect of dulling the uneven shape is stronger than that of the chromium plating. Thereby, the optical characteristic of the anti-glare film produced using the said metal mold
- the second resin layer is not laminated on the first resin layer, as will be described later, and the first fine uneven surface. Since it is preferable that the haze of the laminated film in a state where the surface is in contact with air is 50% or more, the chrome plating process is performed without the process of dulling the uneven shape, and the surface fine uneven shape It is also possible to use a mold having a rough roughness, that is, a large arithmetic average height.
- Etching is usually performed by corroding the surface using an aqueous ferric chloride (FeCl 3 ) solution, an aqueous cupric chloride (CuCl 2 ) solution, an alkaline etchant (Cu (NH 3 ) 4 Cl 2 ), or the like.
- a strong acid such as hydrochloric acid or sulfuric acid can be used, or reverse electrolytic etching by applying a potential opposite to that during electrolytic plating can be used.
- the degree of unevenness after etching is different depending on the type of base metal and the size and depth of the unevenness obtained by blasting techniques. The largest factor is the etching amount.
- the etching amount is the thickness of the base material (plating layer) to be cut by etching.
- the etching amount is preferably 1 ⁇ m or more and 20 ⁇ m or less, and more preferably 2 ⁇ m or more and 10 ⁇ m or less. preferable.
- the unevenness of the unevenness differs depending on the type of base metal, the size and depth of the unevenness obtained by blasting techniques, and the type and thickness of the plating.
- the biggest factor in controlling the degree of rounding is the plating thickness. If the thickness of the copper plating layer is thin, the effect of dulling the surface shape of the unevenness obtained by a technique such as blasting is insufficient, and the optical properties of the antiglare film obtained by transferring the uneven shape are not so good. . On the other hand, when the plating thickness is too thick, the productivity is deteriorated and the uneven shape is almost lost, so that the antiglare film does not exhibit sufficient antiglare property. Therefore, for the metal mold for forming the second fine uneven surface of the antiglare film, the thickness of the copper plating is preferably 1 ⁇ m to 20 ⁇ m, and more preferably 4 ⁇ m to 10 ⁇ m. Is more preferable.
- the surface of the surface of the unevenness is further blunted by further chrome plating, and the surface hardness is reduced.
- An enhanced metal mold is obtained.
- the degree of unevenness at this time also varies depending on the type of base metal, the size and depth of the unevenness obtained by techniques such as blasting, and the type and thickness of the plating. The greatest factor in controlling the thickness is the plating thickness. If the thickness of the chrome plating layer is thin, the effect of dulling the surface shape of the unevenness obtained before the chrome plating process is insufficient, and the optical properties of the antiglare film obtained by transferring the uneven shape are not so good. .
- the thickness of the chrome plating is preferably 1 ⁇ m or more and 10 ⁇ m or less, and more preferably 2 ⁇ m or more and 6 ⁇ m or less. Is more preferable.
- Chromium plating is preferable because it is glossy, has high hardness, has a low coefficient of friction, and can provide good releasability.
- the type of chrome plating is not particularly limited, but it is preferable to use a chrome plating that expresses a good luster, such as so-called bright chrome plating or decorative chrome plating.
- Chromium plating is usually performed by electrolysis, and an aqueous solution containing chromic anhydride (CrO 3 ) and a small amount of sulfuric acid is used as the plating bath. By adjusting the current density and electrolysis time, the thickness of the chromium plating can be controlled.
- the die surface to which chrome plating is applied preferably has a Vickers hardness of 800 or more, more preferably 1000 or more. If the Vickers hardness is low, the durability when using the mold is reduced, and the decrease in hardness due to chrome plating is likely to cause abnormalities in the plating bath composition and electrolytic conditions during the plating process. There is a high possibility that the occurrence of defects will also have an undesirable effect.
- Patent Documents 1 and 4 disclose chrome plating on the surface of a metal base material to be a mold.
- chrome plating is applied, depending on the base before plating of the mold or the type of chrome plating, the surface is often roughened after plating or many fine cracks are generated due to chrome plating.
- the optical properties of the antiglare film proceed in an undesirable direction.
- Those with a rough plating surface are not suitable for a mold for an antiglare film. This is because, in general, the plating surface is polished after chromium plating in order to eliminate roughness, but as described later, polishing of the surface after plating is not preferable.
- such an inconvenience easily caused by chromium plating is eliminated by applying copper plating or nickel plating to the base metal.
- the chrome plating must be thickened to sufficiently dull the concavo-convex shaped sharp parts produced by hitting the fine particles.
- the thickness of the chrome plating is too thick, nodules are likely to be generated, which is not preferable.
- the uneven shape produced by hitting the fine particles cannot be sufficiently dulled, and a mold having a desired surface shape cannot be obtained.
- Antiglare films also tend not to exhibit excellent antiglare performance.
- Patent Document 1 describes that a chrome-plated roller is formed on a surface of iron by forming a concavo-convex surface by a sandblasting method or a bead shot method, and Patent Documents 3 and 4 described above. Further, it is described that the roll surface is subjected to a bead shot method or a blast treatment. However, there is no mention of a method of further dulling the surface uneven shape by applying a chrome plating process after applying a process of actively dulling the surface shape after forming the uneven shape by hitting fine particles, and the present invention According to their study, an anti-glare film exhibiting excellent anti-glare performance could not be produced unless the surface shape was actively dulled as described above.
- plating other than chrome plating it is not preferable to apply plating other than chrome plating to the metal surface with irregularities. This is because plating other than chromium has low hardness and wear resistance, so that the durability as a mold is lowered, and unevenness is worn away during use or the mold is damaged. In the antiglare film obtained from such a mold, there is a high possibility that a sufficient antiglare function cannot be obtained, and there is a high possibility that defects will occur on the surface of the antiglare film.
- Patent Document 4 describes that the surface after plating is polished, but it is not preferable in the present invention to polish the chromium plating surface in this way. This is because the flat part on the outermost surface is generated by polishing, which may lead to deterioration of the optical characteristics of the antiglare film, and the control factor of the uneven shape of the mold increases, so the reproducibility. This is because good shape control becomes difficult.
- FIG. 9 shows a process in which the uneven shape obtained by hitting the fine particles is blunted, here, the surface subjected to the chromium plating shown in FIG. 8 (d1) after performing the etching process shown in FIG. 8 (c1).
- FIG. 9 shows an example in which the chrome-plated surface after etching shown in FIG. 8 (d1) is polished. However, even when chrome-plated after copper plating shown in FIG. If polished, a flat surface will be produced as well.
- both the first resin layer and the second resin layer may be formed by an embossing method using a metal mold having irregularities with a predetermined shape, which is produced by the method described above. preferable.
- the uneven shape of the metal mold is transferred to an ionizing radiation curable resin applied on a transparent support, and the cured resin (first resin layer) on which the uneven surface is transferred is laminated with the transparent support.
- an ionizing radiation curable resin is applied onto the first resin layer, and a metal mold having irregularities of a predetermined shape is used to form the irregular shape of the metal mold with an ionizing radiation curable resin.
- the antiglare film can be produced by peeling the laminate of the cured resin (second resin layer), the first resin layer, and the transparent support onto which the uneven surface is transferred, from the mold. .
- the second resin layer is not laminated on the first resin layer, and the laminated film (transparent support) in which the first fine uneven surface is the outermost surface in contact with air.
- the first resin layer preferably have a haze of 50% or more.
- the haze is less than 50%, when the difference in refractive index between the first resin layer and the second resin layer is relatively small, the internal scattering effect by the first fine uneven surface of the obtained antiglare film is small.
- the ionizing radiation curable resin is applied on the first resin layer without using a metal mold and is cured.
- the second resin layer can be formed.
- the uneven shape on the surface of the second resin layer greatly depends on the shape of the first fine uneven surface, although it depends on the thickness of the second resin layer.
- it is preferable that the reflection characteristic and the internal scattering characteristic are independently controlled.
- the shape of the first fine uneven surface and the second fine uneven surface Since the shape is preferably controlled independently, the anti-glare film of the present invention has an influence on the fine uneven shape of the surface of the second resin layer formed on the first fine uneven surface. It is preferable to be manufactured so as not to reach. Therefore, in the antiglare film of the present invention, it is preferable that both the first resin layer and the second resin layer are formed by an embossing method using a metal mold.
- the antiglare film of the present invention is excellent in the antiglare effect, effectively prevents whitening, and can effectively suppress the occurrence of glare and the decrease in contrast.
- An image display device provided with such an antiglare film of the present invention has excellent visibility.
- the polarizing plate generally has a form in which a protective film is bonded to at least one surface of a polarizing film made of a polyvinyl alcohol-based resin film in which iodine or a dichroic dye is adsorbed and oriented.
- an antiglare polarizing plate can be obtained by laminating the polarizing film and the antiglare film of the present invention on the transparent support side of the antiglare film.
- the other surface of the polarizing film may be in a state where nothing is laminated, another protective film or an optical film may be laminated, or an adhesive layer for bonding to a liquid crystal cell. May be formed.
- the antiglare film of the present invention may be bonded on the transparent support side of the polarizing film having a protective film bonded to at least one surface of the polarizing film to form an antiglare polarizing plate. it can.
- the above transparent support is used as the protective film, and the first and second resin layers are formed on the transparent support, thereby providing antiglare properties. It can also be a polarizing plate.
- the image display device of the present invention is a combination of the antiglare film or the antiglare polarizing plate of the present invention and an image display element.
- the image display element is typically a liquid crystal panel that includes a liquid crystal cell in which liquid crystal is sealed between upper and lower substrates and displays an image by changing the alignment state of the liquid crystal by applying a voltage.
- the antiglare film or the antiglare polarizing plate of the present invention can be applied to various known displays such as a display, a CRT display, and an organic EL display.
- the antiglare film is disposed on the viewing side with respect to the image display element.
- the antiglare film may be directly bonded to the surface of the image display element.
- the image display device provided with the antiglare film of the present invention can scatter incident light due to the unevenness of the surface of the antiglare film and blur the reflected image, and has excellent visibility in the image display device. give.
- the anti-glare film of the present invention does not cause glare as seen in conventional anti-glare films even when applied to a high-definition image display device. Prevention performance, glare suppression, and contrast reduction suppression performance.
- the antiglare film is bonded to a glass substrate using an optically transparent adhesive so that the second fine uneven surface is the surface.
- the overall haze (overall haze) was measured using a haze meter “HM-150” manufactured by Murakami Color Research Laboratory Co., Ltd. in accordance with JIS K 7136.
- HM-150 haze meter
- JIS K 7136 haze meter
- a triacetyl cellulose film having a haze of almost 0 was bonded to the second fine uneven surface of the antiglare film using glycerin, and the internal haze was measured again in accordance with JIS K 7136.
- the surface haze was calculated based on the above formula (1).
- Examples 1 to 3 and Comparative Examples 2 to 4 below a laminate in which only a first resin layer having a fine concavo-convex shape on the surface is laminated on a triacetyl cellulose film as a transparent support.
- the film was also measured for haze (referred to as “single-layer haze value” in Table 1). This haze measurement was performed in the same manner as the overall haze measurement, except that the target was a laminated film having no second resin layer.
- the reflection sharpness of the anti-glare film was measured using an image clarity measuring device “ICM-1DP” manufactured by Suga Test Instruments Co., Ltd. based on JIS K 7105.
- ICM-1DP image clarity measuring device manufactured by Suga Test Instruments Co., Ltd. based on JIS K 7105.
- measurement is performed after bonding to a glass substrate so that the uneven surface (second fine uneven surface) becomes the surface using an optically transparent adhesive.
- a 2 mm thick black acrylic resin plate is adhered and adhered to the glass surface of the glass substrate on which the antiglare film is pasted. Measurement was performed by entering light from the surface of the uneven surface.
- the measured value here is a total value of values measured using three types of optical combs in which the widths of the dark part and the bright part are 0.5 mm, 1.0 mm, and 2.0 mm, respectively (maximum value 300 %).
- a photomask having a unit cell pattern as shown in a plan view in FIG. 10 was prepared.
- the unit cell 1000 has a key-shaped chrome light-shielding pattern 1001 with a line width of 10 ⁇ m formed on a transparent substrate, and a portion where the chrome light-shielding pattern 1001 is not formed is an opening 1002.
- the unit cell 1000 has a size of 254 ⁇ m ⁇ 84 ⁇ m (vertical ⁇ horizontal in the drawing), and therefore the size of the opening 1002 is 244 ⁇ m ⁇ 74 ⁇ m (vertical ⁇ horizontal in the drawing).
- a large number of unit cells 1000 shown in the figure are arranged vertically and horizontally to form a photomask.
- the photomask 1003 is placed in a light box 1005 with the chrome light-shielding pattern 1001 facing up, and the antiglare film 1101 is attached to the glass plate 1007 with an adhesive.
- the sample bonded so that the surface of the fine irregularities of 2) becomes the surface is placed on the photomask 1003.
- a light source 1006 is arranged in the light box 1005. In this state, by visually observing from a position 1009 that is about 30 cm away from the sample, the degree of glare was sensory evaluated in seven stages. Level 1 corresponds to a state where no glare is recognized, level 7 corresponds to a state where severe glare is observed, and level 3 refers to a state where only slight glare is observed.
- Example 1 Production of first mold for resin layer A surface of an iron roll having a diameter of 200 mm (STKM13A by JIS) was prepared by applying copper ballad plating.
- the copper ballad plating was composed of a copper plating layer / a thin silver plating layer / a surface copper plating layer, and the thickness of the entire plating layer was about 200 ⁇ m.
- the surface of the copper-plated layer is mirror-polished, and the blasting device (Fuji Seisakusho Co., Ltd.) is used on the polished surface to make the zirconia beads “TZ-SX-17” (product of Tosoh Corporation) Name, average particle diameter 17 ⁇ m), bead usage 8 g / cm 2 (use per roll surface area 1 cm 2 , hereinafter referred to as “blasting amount”), blast pressure 0.2 MPa (gauge pressure, the same applies hereinafter), beads Was blasted at a distance of 300 mm (hereinafter referred to as “blasting distance”) from the nozzle for jetting the metal to the surface of the metal, and the surface was made uneven.
- the blasting device Fluji Seisakusho Co., Ltd.
- Chromium plating was performed on the obtained copper-plated iron roll having surface unevenness without subjecting the uneven shape to blunting, and a metal mold (A) was produced. At this time, the chromium plating thickness was set to 4 ⁇ m.
- the obtained metal mold (A) had a surface Vickers hardness of 1,000.
- Etching was performed on the obtained copper-plated iron roll having surface irregularities with an aqueous cupric chloride solution.
- the etching amount was set to 8 ⁇ m.
- chrome plating was performed to produce a metal mold (B).
- the chromium plating thickness was set to 4 ⁇ m.
- the obtained metal mold (B) had a surface Vickers hardness of 1,000.
- the resin composition (a) was applied on a triacetyl cellulose film (TAC film) having a thickness of 80 ⁇ m so that the coating thickness after drying was 10 ⁇ m, and dried in a dryer set at 60 ° C. for 3 minutes. I let you. Next, the dried film is placed so that the layer made of the resin composition (a) is on the uneven surface side of the metal mold (A) produced above, and the film is placed on the metal mold (A ) Was pressed against the uneven surface with a rubber roll and adhered.
- TAC film triacetyl cellulose film
- the layer made of the resin composition (a) was cured by irradiating light from a high-pressure mercury lamp having an intensity of 20 mW / cm 2 from the TAC film side so that the amount of light in terms of h-line was 200 mJ / cm 2 . . Thereafter, the TAC film was peeled from the metal mold (A) together with the cured resin layer to obtain a laminated film in which a first resin layer having irregularities was formed on the TAC film.
- the resin composition (b) is applied to the uneven surface (first fine uneven surface) of the laminated film so that the coating thickness after drying is 5 ⁇ m, and is 3 minutes in a dryer set at 55 ° C. Dried. Next, the dried film is arranged so that the layer made of the resin composition (b) is on the uneven surface side of the metal mold (B) produced above, and the film is placed on the metal mold (B ) Was pressed against the uneven surface with a rubber roll and adhered.
- Example 2 The first and second resins are the same as in Example 1 except that the resin composition (b) is used for the first resin layer and the resin composition (a) is used for the second resin layer.
- the anti-glare film which consists of a laminated body of a layer and a TAC film was produced.
- Example 1 uses the metal mold (A) for forming the uneven surface of the first resin layer and uses the metal mold (B) for forming the uneven surface of the second resin layer. It is.
- the second resin was formed in the same manner as in Example 2, except that the first resin layer was not formed and only the second resin layer was formed using the metal mold (B) and the resin composition (a).
- the anti-glare film which consists of a laminated body of a layer and a TAC film was produced.
- ⁇ Comparative Examples 2-3> It consists of a laminate of the first and second resin layers and the TAC film in the same manner as in Example 1 except that the first resin layer is formed using the metal mold (C) or (D). Antiglare films were prepared (Comparative Example 2 and Comparative Example 3).
- the resin composition (a) is used for the first resin layer, and the resin composition (b) is used for the second resin layer.
- Metal molds (C) and (D) were produced in the same manner as the metal mold (A) except that the blast pressure and the etching amount were set to the values shown in Table 1.
- FIG. 12 shows the angle dependency (reflection graph) of the reflected light obtained by the reflectance measurement for the antiglare films of Examples 1 and 2, and FIG. 12 shows the angle dependency of the scattered light intensity obtained by the scattered light intensity measurement.
- FIGS. 14 and 15 are a reflection profile graph and a transmission / scattering profile graph for the antiglare films of Comparative Examples 1 to 3, respectively.
- the antiglare films of Examples 1 and 2 that satisfy the requirements of the present invention exhibited excellent antiglare performance, but did not cause glare or whitishness.
- the antiglare films of Comparative Examples 1 to 3 have substantially no internal haze due to the absence of the first resin layer (Comparative Example 1), or different metals for forming the first fine uneven surface. Since the internal haze was small due to the use of the mold (Comparative Examples 2 and 3), the glare was relatively remarkable as compared with Example 1.
- the antiglare films of Examples 1 and 2 and the antiglare films of Comparative Examples 1 to 3 have almost the same surface shape with respect to the second fine uneven surface, and therefore both have excellent antiglare performance ( Have white).
- Example 3 An antiglare film comprising a laminate of the first and second resin layers and the TAC film is formed in the same manner as in Example 1 except that the second resin layer is formed using the metal mold (E). Produced.
- the resin composition (a) is used for the first resin layer, and the resin composition (b) is used for the second resin layer.
- the metal mold (E) was produced in the same manner as the metal mold (A) except that the blast pressure and the etching amount were the values shown in Table 2.
- the refractive index after curing of this composition is 1.66.
- Example 1 uses the metal mold (A) for forming the uneven surface of the first resin layer and uses the metal mold (B) for forming the uneven surface of the second resin layer. It is.
- the anti-glare film of Example 3 has a lower relative scattering intensity T (30) than that of Examples 1 and 2, the anti-glare performance (whiteness and glare) is low. Although somewhat inferior to Examples 1 and 2, almost good results are given.
- the antiglare film of Comparative Example 4 is cured to constitute these resin layers in the interface region between the first resin layer and the second resin layer by changing the constituent material of the second resin layer. Resin mixing occurs and the internal haze is reduced. Therefore, the glare is larger than the antiglare films of Examples 1 to 3.
- the antiglare film of the present invention By arranging the antiglare film of the present invention on the viewer side from the image display element to constitute an image display device, whitening and in various displays such as a liquid crystal display, a plasma display, a CRT display, an organic EL display, etc.
- a liquid crystal display a plasma display
- a CRT display a CRT display
- an organic EL display etc.
- the occurrence of glare can be prevented, the reflected image can be blurred, and excellent visibility can be obtained.
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Abstract
Description
図1は、本発明の防眩フィルムの好ましい一例を示す断面模式図である。図1に示されるように、本発明の防眩フィルムは、透明支持体100と、その上に積層された第1の樹脂層101と、第1の樹脂層101上に積層された第2の樹脂層102とを備える。第1の樹脂層101は、その透明支持体100側とは反対側の表面(第2の樹脂層102側表面)に微細な凹凸形状(図1における第1の微細凹凸表面101a)を有する電離放射線硬化樹脂からなる樹脂層である。また、第2の樹脂層102は、その第1の樹脂層101側とは反対側の表面に微細な凹凸形状(図1における第2の微細凹凸表面102a)を有する電離放射線硬化樹脂からなる樹脂層である。すなわち、図1に示される防眩フィルムの上側表面(透明支持体100側とは反対側の表面)は、第2の樹脂層102が有する微細凹凸表面102aによって構成されている。第2の樹脂層102は、第1の樹脂層101上に、それが有する微細凹凸表面101aの凹部を埋めるように(微細凹凸表面101aに接するように)形成されている。
表面ヘイズ=全体ヘイズ-内部ヘイズ (1)
防眩フィルムの「内部ヘイズ」は、第1の樹脂層を平坦な透明支持体上に積層する場合、実質的には、防眩フィルム内部の第1の樹脂層と第2の樹脂層との界面領域(第1の微細凹凸表面領域)に起因するヘイズとみなすことができる。第1の樹脂層単独および第2の樹脂層単独での内部ヘイズは、微粒子などの光拡散剤を含有しないことから、通常、それぞれ1%以下である。
次に、本発明の防眩フィルムを好適に製造し得る方法について説明する。本発明の防眩フィルムは、凹凸が形成された金属金型を用い、その金型の凹凸形状を電離放射線硬化樹脂に転写するエンボス法を用いて好適に製造することができる。具体的には、第1の微細凹凸表面を有する第1の樹脂層を、金属金型を用いたエンボス法により形成する場合には、たとえば、透明支持体の表面上に、上記したような電離放射線硬化性樹脂を塗布して電離放射線硬化性樹脂層を形成し、その硬化性樹脂層を金属金型の凹凸表面に密着させた状態で透明支持体側から電離放射線(たとえば紫外線など)を照射することにより硬化性樹脂層を硬化させ、金属金型の凹凸形状を電離放射線硬化樹脂からなる層に転写させる。ついで、金属金型から、第1の樹脂層(電離放射線硬化樹脂)が形成された透明支持体を剥離する。第2の樹脂層をエンボス法により第1の樹脂層上に形成する場合も同様である。
本発明の防眩フィルムは、防眩効果に優れ、白ちゃけも有効に防止され、ギラツキの発生およびコントラストの低下を効果的に抑制できる。このような本発明の防眩フィルムを備える画像表示装置は、視認性に優れたものとなる。画像表示装置が液晶ディスプレイである場合には、この防眩フィルムを偏光板に適用することができる。すなわち、偏光板は一般に、ヨウ素または二色性染料が吸着配向されたポリビニルアルコール系樹脂フィルムからなる偏光フィルムの少なくとも片面に保護フィルムが貼合された形態のものが多いが、その一方の保護フィルムを本発明の防眩フィルムとすることにより、防眩性偏光板とすることができる。より具体的には、偏光フィルムと、本発明の防眩フィルムとを、その防眩フィルムの透明支持体側で貼り合わせることにより、防眩性偏光板とすることができる。この場合、偏光フィルムの他方の面は、何も積層されていない状態でもよいし、別の保護フィルムまたは光学フィルムが積層されていてもよいし、または液晶セルに貼合するための粘着剤層が形成されていてもよい。また、偏光フィルムの少なくとも片面に保護フィルムが貼合された偏光板の当該保護フィルム上に、本発明の防眩フィルムをその透明支持体側で貼合して、防眩性偏光板とすることもできる。さらに、少なくとも片面に保護フィルムが貼合された偏光板において、当該保護フィルムとして上記透明支持体を用い、この透明支持体上に第1および第2の樹脂層を形成することにより、防眩性偏光板とすることもできる。
本発明の画像表示装置は、本発明の防眩フィルムまたは防眩性偏光板を画像表示素子と組み合わせたものである。ここで、画像表示素子は、上下基板間に液晶が封入された液晶セルを備え、電圧印加により液晶の配向状態を変化させて画像の表示を行なう液晶パネルが代表的であるが、その他、プラズマディスプレイ、CRTディスプレイ、有機ELディスプレイなど、公知の各種ディスプレイに対しても、本発明の防眩フィルムまたは防眩性偏光板を適用することができる。本発明の画像表示装置においては、防眩フィルムは、画像表示素子よりも視認側に配置される。この際、防眩フィルムの凹凸面、すなわち第2の樹脂層側が外側(視認側)となるように配置される。防眩フィルムは、画像表示素子の表面に直接貼合してもよいし、液晶パネルを画像表示素子とする場合は、たとえば先述のように、偏光フィルムを介して液晶パネルの表面に貼合することもできる。このように、本発明の防眩フィルムを備えた画像表示装置は、防眩フィルムの有する表面の凹凸により入射光を散乱して映り込み像をぼかすことができ、画像表示装置に優れた視認性を与える。
Krautkramer社製の超音波硬度計「MIC10」を用いて、JIS Z 2244に準拠した方法でビッカース硬度を測定した。測定は、金型自体の表面にて行なった。
(2-1)反射プロファイル
防眩フィルムの凹凸面(第2の微細凹凸表面)に、防眩フィルム法線に対して30゜傾斜した方向から、He-Neレーザーからの平行光を照射し、防眩フィルム法線と照射方向を含む平面内における反射率の角度変化の測定を行なった。反射率の測定には、いずれも横河電機(株)製の「3292 03 オプティカルパワーセンサー」および「3292 オプティカルパワーメーター」を用いた。
防眩フィルムを、その凹凸面(第2の微細凹凸表面)が表面となるようガラス基板に貼合し、そのガラス面側より、防眩フィルム法線に対して所定の角度傾斜した方向から、He-Neレーザーからの平行光を照射し、防眩フィルム凹凸面(第2の微細凹凸表面)側での防眩フィルム法線方向の透過散乱光強度を測定した。透過散乱光強度の測定には、いずれも横河電機(株)製の「3292 03 オプティカルパワーセンサー」および「3292 オプティカルパワーメーター」を用いた。
防眩フィルムの反りを防止するため、防眩フィルムを光学的に透明な粘着剤を用いて、その第2の微細凹凸表面が表面となるようにガラス基板に貼合し、JIS K 7136に準拠した(株)村上色彩技術研究所製のヘイズメーター「HM-150」型を用いて全体のヘイズ(全体ヘイズ)を測定した。次に、防眩フィルムの第2の微細凹凸表面に、ヘイズがほぼ0であるトリアセチルセルロースフィルムをグリセリンを用いて貼合し、再度JIS K 7136に準拠して、内部ヘイズを測定した。表面ヘイズは、上記式(1)に基づいて算出した。
JIS K 7105に準拠したスガ試験機(株)製の写像性測定器「ICM-1DP」を用いて、防眩フィルムの反射鮮明度を測定した。この場合も、防眩フィルムの反りを防止するため、光学的に透明な粘着剤を用いて凹凸面(第2の微細凹凸表面)が表面となるようにガラス基板に貼合してから測定に供した。また、裏面のガラス面からの反射を防止するために、防眩フィルムを貼ったガラス基板のガラス面に2mm厚みの黒色アクリル樹脂板を水で密着させて貼り付け、この状態で第2の微細凹凸表面側から光を入射し、測定を行なった。ここでの測定値は、暗部と明部との幅がそれぞれ0.5mm、1.0mmおよび2.0mmである3種類の光学くしを用いて測定された値の合計値である(最大値300%)。
Sensofar社製の共焦点顕微鏡「PLμ2300」を用いて、防眩フィルムの表面形状(第2の微細凹凸表面の形状)を測定した。この場合も、防眩フィルムの反りを防止するため、光学的に透明な粘着剤を用いて凹凸面(第2の微細凹凸表面)が表面となるようにガラス基板に貼合してから測定に供した。測定の際、対物レンズの倍率は50倍とし、解像度を落として測定を行なった。高解像度で測定すると、防眩フィルム表面の細かい凹凸を測定してしまい、凸部のカウントに支障をきたすためである。
上記測定データをもとに、JIS B 0601に準拠した計算により、断面曲線における算術平均高さPa、最大断面高さPt、および平均長さPSmを求めた。
上記測定で得られた防眩フィルム表面各点の三次元的な座標値をもとに、先に図2を参照して説明したアルゴリズムに従って、200μm×200μmの領域内に存在する凸部の数を求めた。
上記測定で得られた防眩フィルム表面各点の三次元的な座標値をもとに、先に図2および図3を参照して説明したアルゴリズムに基づいて計算し、ボロノイ多角形の平均面積を求めた。
(4-1)白ちゃけの評価
防眩フィルムの裏面からの反射を防止するために、凹凸面(第2の微細凹凸表面)が表面となるように黒色アクリル樹脂板に防眩フィルムを貼合し、蛍光灯のついた明るい室内で凹凸面側から目視で観察し、白ちゃけの程度を次の3段階で評価した。
ギラツキは以下の方法で評価した。まず、図10に平面図で示すようなユニットセルのパターンを有するフォトマスクを用意した。この図において、ユニットセル1000は、透明な基板上に、線幅10μmでカギ形のクロム遮光パターン1001が形成され、そのクロム遮光パターン1001の形成されていない部分が開口部1002となっている。ユニットセル1000の寸法は、254μm×84μm(図の縦×横)であり、したがって開口部1002の寸法は、244μm×74μm(図の縦×横)である。図示するユニットセル1000が縦横に多数並んで、フォトマスクを形成する。
(A)第1の樹脂層用金型の作製
直径200mmの鉄ロール(JISによるSTKM13A)の表面に銅バラードめっきが施されたものを用意した。銅バラードめっきは、銅めっき層/薄い銀めっき層/表面銅めっき層からなるものであり、めっき層全体の厚さは約200μmであった。その表面銅めっき層の表面を鏡面研磨し、さらにその研磨面に、ブラスト装置((株)不二製作所製)を用いて、東ソー(株)製のジルコニアビーズ「TZ-SX-17」(商品名、平均粒径17μm)を、ビーズ使用量8g/cm2(ロールの表面積1cm2あたりの使用量、以下「ブラスト量」とする)、ブラスト圧力0.2MPa(ゲージ圧、以下同じ)、ビーズを噴射するノズルから金属表面までの距離300mm(以下「ブラスト距離」とする)でブラストし、表面に凹凸をつけた。得られた表面凹凸を有する銅めっき鉄ロールに対し、凹凸形状を鈍らせる加工を施さずに、クロムめっき加工を行ない、金属金型(A)を作製した。このとき、クロムめっき厚みが4μmとなるように設定した。得られた金属金型(A)は、表面のビッカース硬度が1,000であった。
上記と同様に、直径200mmの鉄ロール(JISによるSTKM13A)の表面に銅バラードめっきが施されたものを用意した。その表面銅めっき層の表面を鏡面研磨し、さらにその研磨面に、ブラスト装置((株)不二製作所製)を用いて、東ソー(株)製のジルコニアビーズ「TZ-B53」(商品名、平均粒径53μm)を、ブラスト量8g/cm2、ブラスト圧力0.15MPa、ブラスト距離450mmでブラストし、表面に凹凸をつけた。得られた表面凹凸を有する銅めっき鉄ロールに対し、塩化第二銅水溶液でエッチングを行なった。エッチング量は8μmとなるように設定した。その後、クロムめっき加工を行ない、金属金型(B)を作製した。このとき、クロムめっき厚みが4μmとなるように設定した。得られた金属金型(B)は、表面のビッカース硬度が1,000であった。
(C-1)第1の樹脂層の形成
ペンタエリスリトールトリアクリレートと多官能ウレタン化アクリレート(ヘキサメチレンジイソシアネートとペンタエリスリトールトリアクリレートの反応生成物)とが重量比60/40、固形分濃度60重量%で酢酸エチルに溶解し、レベリング剤が配合されている紫外線硬化性樹脂組成物(樹脂組成物(a))を入手した。この組成物の硬化後の屈折率は1.53である。
S,S’-(チオジエチレン)-ビス(チオメタクリレート)が酢酸エチルに固形分濃度60重量%で溶解している紫外線硬化性樹脂組成物(樹脂組成物(b))を入手した。この組成物の硬化後の屈折率は1.63である。
第1の樹脂層に上記樹脂組成物(b)を用い、第2の樹脂層に上記樹脂組成物(a)を用いたこと以外は実施例1と同様にして、第1および第2の樹脂層とTACフィルムとの積層体からなる防眩フィルムを作製した。第1の樹脂層の凹凸表面形成のために金属金型(A)を用い、第2の樹脂層の凹凸表面形成のために金属金型(B)を用いたことは、実施例1と同じである。
第1の樹脂層を形成せず、金属金型(B)および樹脂組成物(a)を用いて第2の樹脂層のみ形成したこと以外は、実施例2と同様にして、第2の樹脂層とTACフィルムとの積層体からなる防眩フィルムを作製した。
金属金型(C)または(D)を用いて第1の樹脂層を形成したこと以外は、実施例1と同様にして、第1および第2の樹脂層とTACフィルムとの積層体からなる防眩フィルムを作製した(それぞれ比較例2、比較例3)。第1の樹脂層には樹脂組成物(a)を、第2の樹脂層には樹脂組成物(b)を用いている。金属金型(C)および(D)は、ブラスト圧力およびエッチング量を表1に示される値としたこと以外は、金属金型(A)と同様にして作製した。
0.5mm光学くし : 10.6%
1.0mm光学くし : 11.1%
2.0mm光学くし : 21.0%
合計 42.7%
金属金型(E)を用いて第2の樹脂層を形成したこと以外は、実施例1と同様にして、第1および第2の樹脂層とTACフィルムとの積層体からなる防眩フィルムを作製した。第1の樹脂層には樹脂組成物(a)を、第2の樹脂層には樹脂組成物(b)を用いている。金属金型(E)は、ブラスト圧力およびエッチング量を表2に示される値としたこと以外は、金属金型(A)と同様にして作製した。
5価のアンチモン化合物を含有する酸化スズ(IV)が16重量部、アクリレートモノマーが80重量部、光重合開始剤が3重量部、および変性シリコーンが1重量部の割合で配合され、メチルエチルケトンとジアセトンアルコールとの混合溶媒に固形分濃度60重量%で溶解している紫外線硬化性樹脂組成物(樹脂組成物(c))を入手した。この組成物の硬化後の屈折率は1.66である。
Claims (9)
- 透明支持体(100)と、
前記透明支持体(100)の上に積層された第1の樹脂層(101)と、
前記第1の樹脂層(101)の上に積層された第2の樹脂層(102)と、
を備え、
前記第1の樹脂層(101)および前記第2の樹脂層(102)は、互いに異なる屈折率を有し、
前記第1の樹脂層(101)は、前記透明支持体(100)側とは反対側の表面に微細な凹凸形状を有する電離放射線硬化樹脂からなり、
前記第2の樹脂層(102)は、前記透明支持体(100)側とは反対側の表面に微細な凹凸形状を有する電離放射線硬化樹脂からなり、かつ、
内部ヘイズが5%以上30%以下である防眩フィルム。 - 前記第2の樹脂層(102)側から入射角30゜で光を入射したときに、
反射角30゜の反射率R(30)が0.05%以上2%以下であり、
反射角40゜の反射率R(40)が0.0001%以上0.005%以下であり、
反射角50゜の反射率R(50)が0.00001%以上0.0005%以下であり、
前記透明支持体(100)側から入射角20゜で光を入射したときに、防眩フィルム法線方向の相対散乱光強度T(20)が0.0001%以上0.0005%以下であり、
前記透明支持体(100)側から入射角30°で光を入射したときに、防眩フィルム法線方向の相対散乱光強度T(30)が0.00004%以上0.00025%以下である請求の範囲第1項に記載の防眩フィルム。 - 前記第1の樹脂層(101)と前記第2の樹脂層(102)とは、明確な界面を有する請求の範囲第1項に記載の防眩フィルム。
- 前記第1の樹脂層(101)の屈折率と前記第2の樹脂層(102)の屈折率との差の絶対値は、0.08以上である請求の範囲第1項に記載の防眩フィルム。
- 前記第1の樹脂層(101)および/または前記第2の樹脂層(102)は、導電性付与物質を含有する請求の範囲第1項に記載の防眩フィルム。
- 前記第2の樹脂層(102)表面上に、前記透明支持体(100)よりも低い屈折率を有する低屈折率層を含む低反射膜をさらに有する請求の範囲第1項に記載の防眩フィルム。
- 前記第1の樹脂層(101)が有する微細凹凸形状および/または前記第2の樹脂層(102)が有する微細凹凸形状は、表面に凹凸を有する金型を用い、該凹凸形状を電離放射線硬化樹脂に転写することにより形成される請求の範囲第1項に記載の防眩フィルム。
- 請求の範囲第1項に記載の防眩フィルムと、前記防眩フィルム上に積層された偏光フィルムとを備える防眩性偏光板であって、
前記偏光フィルムは、前記防眩フィルムの前記透明支持体(100)側に配置される防眩性偏光板。 - 請求の範囲第1項に記載の防眩フィルムまたは請求の範囲第8項に記載の防眩性偏光板と、画像表示素子とを備え、
前記防眩フィルムまたは防眩性偏光板は、その第2の樹脂層(102)側を外側にして画像表示素子の視認側に配置される画像表示装置。
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