CN101923181A - The manufacture method of the manufacture method of antiglare film, antiglare film and mould - Google Patents

Abstract

The invention provides manufacture method that is fit to the mould that uses in a kind of manufacture method, this manufacture method of antiglare film and the gray shade scale figure that is used for this manufacture method, the manufacture method of described antiglare film comprises the operation that forms convex-concave surface based on the gray shade scale figure on transparent base, this gray shade scale figure is more than the 15mm for the length on a minimum limit, and the power spectrum of gray shade scale figure is at spatial frequency 0.025～0.125 μ m ^-1Scope in present maximal value, this convex-concave surface is made of the repetitive structure of convex-concave surface unit, described convex-concave surface unit is made of gray shade scale corresponding concave part and the protuberance with the gray shade scale figure.

Description

The manufacture method of the manufacture method of antiglare film, antiglare film and mould

Technical field

The present invention relates to anti-dazzle (anti-dazzle: antiglare) manufacture method of film and the antiglare film of utilizing this manufacture method to obtain.In addition, the gray shade scale figure that the present invention relates to use in the manufacture method of this antiglare film, and the manufacture method of this antiglare film in be fit to the manufacture method of the mould that uses.

Background technology

(cathode-ray tube (CRT): CRT) image display device such as display, organic electroluminescent (EL) display when exterior light mirrors its display surface, causes identification significantly impaired for LCD, plasma display, Braun tube.At present, in order to prevent mirroring of this exterior light, in video camera and the Digital Video of paying attention to the TV of image quality, PC, the externally outdoor application of light intensity and utilize in the mobile phone that reflected light shows etc., be provided with on the surface of image display device and be used to the rete that prevents that exterior light from mirroring.This rete can generally be divided into: thus the rete that the film of being handled by the no reflection events of the interference of having implemented to utilize optical multilayer constitutes and by having implemented by forming the rete that film that micro concavo-convex makes the incident light scattering to mirror picture that dizzy non-glare treated of reflecting takes place constitutes from the teeth outwards.The former non reflecting film need form the multilayer film of blooming homogeneous, so the cost height.Relative therewith, the latter's antiglare film can be made more economically, therefore is widely used in purposes such as large-scale PC, monitor.

At present, this antiglare film waits by the following method and makes: for example, will disperse fine-grained resin solution to coat on the substrate sheets, and regulate thickness, and make this particulate expose the coated film surface, and form the method for concave-convex surface at random etc. thus on substrate sheets.But, the antiglare film of using the fine-grained resin solution of this dispersion to make, by about the disperse state of the particulate in the resin solution, coating state etc. the configuration of concave-convex surface, shape, therefore be difficult to the sort of concave-convex surface that obtains wanting, under the situation of hanging down the mist degree of setting antiglare film, existence can not obtain the problem of sufficient antiglare effect and so on.In addition, under the situation on the surface that this existing antiglare film is disposed at image display device, have following problem: display surface integral body is turned white because of scattered light, shows the color, so-called " whiting " that easily are muddy.In addition, high-definition along with nearest image display device, also have following problem: the concave-convex surface shape of the pixel of image display device and antiglare film interferes, and consequently, Luminance Distribution easily takes place to produce be difficult to see display surface, so-called " dazzling " phenomenon.Twinkling in order to eliminate, also try at binder resin and decompose between the particulate of this binder resin, to establish refringence and make light scattering, but when this antiglare film being disposed at image display device surperficial, also has the problem that contrast reduces and so on because of the scattering of light at the interface of particulate and binder resin.

On the other hand, following trial is also arranged: do not contain particulate and only be used in the micro concavo-convex that the surface of transparent resin layer forms and embody anti-dazzle property.For example, the spy opens the 2002-189106 communique and discloses a kind of antiglare film that is laminated with the solidfied material layer of ionizing radiation curable resin layer on transparent resin film, the solidfied material layer of described ionizing radiation curable resin layer have three-dimensional 10 mean roughness, and the three-dimensional roughness reference field on adjacent projection mean distance each other satisfy the fine concave-convex surface of setting respectively.This antiglare film is made by with state between embossing casting mold and the transparent resin film that the ionizing radiation curable resin is clipped in this ionizing radiation curable resin being solidified.But, open the disclosed antiglare film of 2002-189106 communique by the spy, also be difficult to realize inhibition, high-contrast, and the inhibition of dazzling of sufficient antiglare effect, whiting.

In addition, as making the method that is formed with the film of micro concavo-convex on the surface, the known method of concaveconvex shape transfer printing on film that will have the roller of convex-concave surface.As the method for making of the roller with this convex-concave surface, for example, the spy opens flat 6-34961 communique and discloses and a kind ofly use making cylinders such as metal and form concavo-convex method on its surface by methods such as electronic engraving, etching, sandblasts.In addition, the spy opens the 2004-29240 communique and discloses a kind of utilization spray bead (beads shot) legal system and make the method for knurling rolls, the spy open the 2004-90187 communique disclose a kind of process forms metallization layer on the surface of roller operation, to the surface of metallization layer carry out mirror ultrafinish operation, also have the method that operation that shot peening strengthening handles is made knurling rolls of carrying out as required.

But, under the state of so surface of knurling rolls having been implemented sandblast (blast) processing, the distribution of the concavo-convex diameter that generation is caused by the size distribution of sandblast particle, and be difficult to control the degree of depth of the pit that obtains by sandblast, have problem aspect the concaveconvex shape that obtains anti-dazzle function excellence with good repeatability.

In addition, above-mentioned spy opens the 2002-189106 communique and has recorded and narrated preferred use and carried out the cylinder of chromium plating on the surface of iron and utilized sand-blast, spray bead method to form the method for concavo-convex die face.In addition, following record is arranged also: the permanance when preferably the irregular die face of formation like this being implemented chromium plating etc. and uses to improve then re-uses, and can realize dura materization and anticorrosion thus.On the other hand, opening 2004-45471 communique, spy the spy opens to record and narrate among the embodiment separately of 2004-45472 communique following method is arranged: chromium plating is being carried out on the iron core surface, and after the liquid blasting of having carried out #250 is handled, carry out chromium plating once more and handle, form fine concaveconvex shape from the teeth outwards.

But, in the method for making of this knurling rolls, owing on the high chromium coating of hardness, carry out sandblast, shot-peening, therefore be difficult to form concavo-convex, and be difficult to critically control formed concavo-convex shape.

The spy opens the 2000-284106 communique and has recorded and narrated a kind of method of implementing the stacked operation of etching work procedure and/or film after base material having been implemented sandblast processing again.In addition, the spy open recorded and narrated in the 2006-53371 communique a kind of base material ground and implemented sandblast processing after implement the method for electroless plating nickel again.In addition, the spy opens the 2007-187952 communique and has recorded and narrated a kind of technology of making embossing plate: after base material has been implemented copper facing or nickel plating, grind, implemented after the sandblast processing, implement chromium plating again and make embossing plate.In addition, the spy opens the 2007-237541 communique and has recorded and narrated a kind of technology of making embossing plate: after having implemented copper facing or nickel plating, grind, implemented to implement etching work procedure or copper facing operation after the sandblast processing, implement chromium plating afterwards and make embossing plate.Use in the method for making of sandblast processing at these,, therefore cause being made into the concave-convex surface shape and have the 50 μ m bigger concaveconvex shape in above cycle owing to be difficult under the state that has carried out accurate control, form the concave-convex surface shape.Its result has following problem: the concaveconvex shape that these are bigger and the pixel of image display device are interfered, and Luminance Distribution takes place, thereby easily are difficult to see display surface " dazzling ".

Summary of the invention

The objective of the invention is to, a kind of be used to the make method of antiglare film and the antiglare film that is obtained by this manufacture method are provided, described antiglare film is a low haze, but when being applied to image display device, can present excellent anti-dazzle performance, and the identification that can prevent whitens causes descends, even and under the situation of the image display device that is applied to high-resolution, do not take place to dazzle yet and can embody high-contrast.In addition, other purposes of the present invention also are, the gray shade scale figure that uses in a kind of manufacture method of this antiglare film, the manufacture method that reaches the suitable mould that uses in the manufacture method of this antiglare film are provided.

The present invention relates to comprise the manufacture method of antiglare film that on transparent base, forms the operation of convex-concave surface based on the gray shade scale figure.The length on a limit of minimum of this gray shade scale figure is more than the 15mm, and the power spectrum of gray shade scale figure is at spatial frequency 0.025～0.125 μ m ^-1Scope in present maximal value.In the manufacture method of antiglare film of the present invention, the convex-concave surface that is formed on the transparent base is made of the repetitive structure (with the structure of a plurality of convex-concave surfaces unit repeated arrangement) of convex-concave surface unit, and described convex-concave surface unit is made of gray shade scale corresponding concave part and the protuberance with this gray shade scale figure.

In the manufacture method of antiglare film of the present invention,, can preferably use the view data that makes by computing machine as the gray shade scale figure.As the view data of gray shade scale figure, be preferably two-value and change into white and black view data.At the gray shade scale figure is that two-value changes under the situation of white and black view data, the convex-concave surface unit by with binaryzation after the gray shade scale corresponding concave part and the protuberance of view data constitute, particularly, the white region of the view data after the either party who constitutes the recess of convex-concave surface unit or protuberance and the binaryzation is corresponding.

The operation that forms convex-concave surface on above-mentioned transparent base preferably comprises following operation: according to above-mentioned gray shade scale figure, make the mould with male and fomale(M﹠F), the male and fomale(M﹠F) of this mould is transferred on the transparent base.

In addition, the invention provides the manufacture method of the mould that uses in a kind of manufacture method of the antiglare film that is adapted at the invention described above.The manufacture method of mould of the present invention comprises following operation: the first plating operation, and it implements copper facing or nickel plating to mould with the surface of base material; Grinding step, it grinds the surface of having been implemented plating by the first plating operation; Photosensitive resin film forms operation, and it forms photosensitive resin film on the face after the grinding; Exposure process, it exposes above-mentioned gray shade scale figure on photosensitive resin film; Developing procedure, the photoresist film development after it is exposed the gray shade scale figure; First etching work procedure, the photosensitive resin film after its use is developed carries out etch processes as mask, forms concavo-convex on the plating face after the grinding; The photosensitive resin film stripping process, it peels off photosensitive resin film; With the second plating operation, it implements chromium plating to formed male and fomale(M﹠F);

The manufacture method of mould of the present invention preferably comprises second etching work procedure between the photosensitive resin film stripping process and the second plating operation, this second etching work procedure makes the concaveconvex shape passivation of the male and fomale(M﹠F) that is formed by first etching work procedure by etch processes.

The enforcement that in the second plating operation, forms the male and fomale(M﹠F) of chromium plating, preferably be needed on the male and fomale(M﹠F) of the mould on the transparent base.That is, the operation of after the second plating operation, establishing lapped face not, the male and fomale(M﹠F) that preferably will implement chromium plating directly uses as the male and fomale(M﹠F) of the mould of transfer printing on transparent base.

The chromium coating that is formed by the chromium plating of the second plating operation preferably has the thickness of 1～10 μ m.

In addition, the present invention relates to antiglare film that the manufacture method by the antiglare film of the invention described above obtains, and in the manufacture method of the antiglare film of the invention described above length that use, a minimum limit as 15mm more than and power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present peaked gray shade scale figure.Gray shade scale figure of the present invention is preferably two-value and changes into white and black view data.

According to the present invention, can make antiglare film with good repeatability, this antiglare film is a low haze, but when being applied to image display device, can present excellent anti-dazzle performance, and the identification that can prevent whitens causes reduces, even and under the situation of the image display device that is applied to high-resolution, do not take place to dazzle yet and embody high-contrast.

Description of drawings

Fig. 1 is the figure that amplifies the part of an example of the preferred gray shade scale figure that uses in the manufacture method be illustrated in antiglare film of the present invention, and is the figure of the part of the gray shade scale figure that uses when amplifying the Mold Making that is illustrated in embodiment 1 and embodiment 3;

Fig. 2 is the figure of a preferred example of first half that schematically represents the manufacture method of mould of the present invention;

Fig. 3 is the figure of a preferred example of latter half that schematically represents the manufacture method of mould of the present invention;

Fig. 4 schematically is illustrated in the figure that carries out the state of sandblast in first etching work procedure;

Fig. 5 is the figure that schematically represents to make by second etching work procedure state of the male and fomale(M﹠F) passivation that is formed by first etching work procedure.

Fig. 6 is the figure of the part of the gray shade scale figure that uses when amplifying the Mold Making be illustrated in embodiment 2.

Fig. 7 is the figure of the part of the gray shade scale figure that uses when amplifying the Mold Making be illustrated in comparative example 1～3.

Fig. 8 is the figure of the part of the gray shade scale figure that uses when amplifying the Mold Making be illustrated in comparative example 4.

Fig. 9 is the figure of the part of the gray shade scale figure that uses when amplifying the Mold Making be illustrated in comparative example 5.

Figure 10 is the figure of the part of the gray shade scale figure that uses when amplifying the Mold Making be illustrated in comparative example 6.

Figure 11 is the figure of the part of the gray shade scale figure that uses when amplifying the Mold Making be illustrated in comparative example 7.

Figure 12 is the power spectrum G that expression calculates according to the gray shade scale figure that uses in embodiment 1 and embodiment 2 ²(f _x, f _y) f _xThe figure in=0 cross section.

Embodiment

The manufacture method of＜antiglare film 〉

Below, preferred forms of the present invention is elaborated.The manufacture method of antiglare film of the present invention is characterised in that, comprises the operation that forms fine convex-concave surface (micro concavo-convex surface) according to specific gray shade scale figure on transparent base.At this, " gray shade scale figure " typical meaning be meant uses for the micro concavo-convex surface that forms antiglare film, utilize that computing machine makes by 2 grades of gray shade scales or 3 grades of view data that the level more than the gray shade scale constitutes, but also can comprise can a meaning to the data (matrix data etc.) of this view data conversion.As can one meaning ground to the data of this view data conversion, can enumerate the coordinate of only preserving each pixel and the data of gray shade scale etc.By on transparent base, forming recess and protuberance, can on transparent base, form and a convex-concave surface unit that the gray shade scale figure is corresponding in mode corresponding to the gray shade scale of this gray shade scale figure.In the manufacture method of antiglare film of the present invention, the micro concavo-convex surface that on transparent base, forms can by with 2 above convex-concave surface unit closely the repetitive structure of the convex-concave surface unit that forms of repeated arrangement constitute.

(gray shade scale figure)

In the present invention, as above-mentioned gray shade scale figure, the length of using a minimum limit as more than the 15mm and power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present peaked figure.By on transparent base, forming the micro concavo-convex surface according to such gray shade scale figure, can provide a kind of following antiglare film: have low haze and when being applied to image display device, can present excellent anti-dazzle performance, and the identification that can prevent whitens causes reduces, even and under the situation of the image display device that is applied to high-resolution, can not take place to dazzle yet and can embody high-contrast.

That is, by using power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present peaked gray shade scale figure, can form the micro concavo-convex surface that presents specific spatial frequency distribution accurately, more specifically, can form the surface configuration that comprises cycle micro concavo-convex surface accurately as principal ingredient with 10～50 μ m, thus, can embody sufficient antiglare effect (the anti-effect etc. that mirrors), and can suppress twinkling fully.Comprise on the micro concavo-convex surface of antiglare film under the situation of the long period composition that surpasses 50 μ m, when the image display device that is disposed at high-resolution surperficial, exist and easily produce the tendency of dazzling, in addition, on the micro concavo-convex surface of the short period composition that only comprises less than 10 μ m, has the inadequate tendencies of antiglare effect such as preventing mirroring effect.

In addition, in by the antiglare film that will make corresponding to the repeated arrangement formation micro concavo-convex surface, convex-concave surface unit of certain figure, see the interference color that form with outside interference of light sometimes, when being disposed at image display device surperficial, interference stripes take place sometimes, but according to the present invention, by the length setting with the limit of minimum of gray shade scale figure is more than the 15mm, and it is excellent and can prevent the antiglare film of the generation of interference color and interference stripes efficiently to obtain the not only anti-ability that mirrors.Need to prove, even the curtailment 15mm on a limit of minimum of gray shade scale figure, sometimes do not interfere look and interference stripes yet, but under the situation of the curtailment 10mm on the limit of minimum of gray shade scale figure, the tendency that interferes look and interference stripes is strong, in order to prevent the generation of interference color and interference stripes reliably, preferably the length setting with the limit of minimum of gray shade scale figure is more than the 15mm.

And then, to form corresponding to the convex-concave surface unit repeated arrangement of certain figure under the situation on micro concavo-convex surface, when observing the antiglare film surface in the irradiation exterior light, may observe it and (for example repeat decorative pattern, formed the foursquare convex-concave surface unit cancellate line of micro concavo-convex boundary line when surface, that form each convex-concave surface unit that forms of repeated arrangement closely according to foursquare figure), but the length by using a limit of minimum as more than the 15mm and power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present peaked gray shade scale figure, can access the extremely excellent antiglare film of identification that does not observe this repetition decorative pattern.

At this, the length of a limit " minimum " of gray shade scale figure, the meaning is meant in the limit of the profile that constitutes the gray shade scale figure, the length on the shortest limit.About the outer shape of gray shade scale figure,, for example, can enumerate polygons such as triangle with the above limit of 15mm, quadrilateral, hexagon as long as the length on a minimum limit is more than the 15mm, just to be not particularly limited.The gray shade scale figure preferably has can not form the zone that do not dispose figure and the outer shape that can closely fill in abutting connection with repeated arrangement in the plane the time with a plurality of figures.Thus, when on transparent base, forming the micro concavo-convex surface based on the gray shade scale figure, can prevent not forming concavo-convex zone.From this point of view, the profile of gray shade scale figure is compared with being set at the profile that circle etc. has curve, is preferably set to polygon.Be set in the outer shape with the gray shade scale figure under the polygonal situations such as triangle, quadrilateral, hexagon, the length on each limit can be identical, also can be different.The length on a limit of minimum of gray shade scale figure is preferably more than the 16mm, more preferably more than the 20mm.In addition, the upper limit of the length on the limit of minimum of gray shade scale figure is not done special restriction, but when utilizing the computer manufacture view data, suppress calculated load and increase this viewpoint, be preferably below the 300mm.

Then, the power spectrum to the gray shade scale figure describes.As mentioned above, gray shade scale figure used in the present invention is that power spectrum is at spatial frequency 0.025～0.125 μ m ^-1Scope in present peaked gray shade scale figure.By forming the micro concavo-convex surface according to the gray shade scale figure that presents this spatial frequency characteristic, can obtain anti-dazzle excellent performance and suppressed to dazzle, whiting, interference color, interference stripes and repeat the antiglare film of the identification excellence of decorative pattern.

At the gray shade scale figure is under the situation of view data, the power spectrum of gray shade scale figure is obtained by the following method: after this gray shade scale graph transformation is the progressive series of greys of 256 grades of gray shade scales, with two-dimensional function g (x, y) gray shade scale of expression gray shade scale graph data, with resulting two-dimensional function g (x, y) carry out Fourier transform, calculate two-dimensional function G (f _x, f _y), with resulting two-dimensional function G (f _x, f _y) carry out square calculating and obtain.At this, x and y represent the normal coordinates (for example, the x direction is the horizontal direction as the gray shade scale figure of view data, and the y direction is the longitudinal direction as the gray shade scale figure of view data) in the gray shade scale graph data face, f _xAnd f _yRepresent the spatial frequency of x direction, the spatial frequency of y direction respectively.

In fact, the gray shade scale of each pixel can be set at the set of discrete data point, thus the two-dimensional function g of the gray shade scale of presentation video data (x y) is discrete function.Thereby, by discrete Fourier transformation, calculate discrete function G (f by following formula (1) definition _x, f _y), by with resulting discrete function G (f _x, f _y) carry out a square calculating, obtain power spectrum G ²(f _x, f _y).At this, the π in the formula (1) is a circular constant, and i is an imaginary unit.In addition, M is the pixel count of x direction, and N is the pixel count of y direction, and I is-the following integer of the above M/2 of M/2 that m is-the following integer of the above N/2 of N/2.In addition, Δ f _xAnd Δ f _yBe respectively the spatial frequency interval of x direction and y direction, use the definition of following formula (2) and formula (3) respectively.Δ x in formula (2) and the formula (3) and Δ y are respectively x direction of principal axis, the axial horizontal resolution of y.Need to prove, be under the situation of view data at the gray shade scale figure, Δ x and Δ y respectively with axial length of the x of a pixel and the axial equal in length of y.That is, making under the situation of gray shade scale figure as the view data of 6400dpi, Δ x=Δ y=4 μ m is making under the situation of gray shade scale figure as the view data of 12800dpi, Δ x=Δ y=2 μ m.

$G(f_x,f_y)=G(\mathrm{l\Δ}{f}_x,\mathrm{m\Δ}{f}_y)=\frac{1}{\sqrt{\mathrm{MN}}}\underset{j=0}{\overset{M-1}{\mathrm{\Σ}}}\underset{k=0}{\overset{N-1}{\mathrm{\Σ}}}g(x,y)\exp [-2\mathrm{\πi}(\mathrm{jl\Δx\Δ}{f}_x+\mathrm{km\Δy\Δ}{f}_y)]---\left(1\right)$

$\mathrm{\Δ}{f}_x\≡\frac{1}{\mathrm{M\Δx}}---\left(2\right)$

$\mathrm{\Δ}{f}_y\≡\frac{1}{\mathrm{N\Δy}}---\left(3\right)$

As described later, under will being set at the figure that disposes a plurality of points randomly as the gray shade scale figure of view data or making situation based on this as the gray shade scale figure of view data, power spectrum G ²(f _x, f _y) with will be laterally, be set at f vertically, highly respectively _x, f _y, power spectrum G ²(f _x, f _y) three-dimensional curve when representing, become with f _x=0 and f _y=0 initial point is the point symmetry at center.Therefore, in the present invention, " the peaked spatial frequency of expression power spectrum " adopts according to expression power spectrum G ²(f _x, f _y) f _x(transverse axis is spatial frequency f to the figure in=0 cross section _y, the longitudinal axis is the two-dimensional curve of power spectrum) and the spatial frequency obtained.In this two-dimensional curve, about the spatial frequency f of transverse axis _y, because power spectrum is also about f _yTherefore=0 symmetry can be spatial frequency f _yAbsolute value.

Need to prove that in the present invention, " power spectrum is at spatial frequency 0.025～0.125 μ m ^-1Scope in present maximal value " comprise following situation: at expression power spectrum G ²(f _x, f _y) f _xAmong the figure in=0 cross section, power spectrum has a plurality of maximal values, these peaked spatial frequency 0.025～0.125 μ m that are located at more than 1 ^-1Scope in.

Fig. 1 is the figure that amplifies the part of an example (particularly, the gray shade scale figure that uses) of the preferred gray shade scale figure that uses in the manufacture method that is illustrated in antiglare film of the present invention when the Mold Making of embodiment 1 and embodiment 3.In the present invention, the concrete graphics shape that the gray shade scale figure is had, as long as the length on a minimum limit to be 15mm above and power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present maximal value, just do not do special restriction, but for example can be the sort of figure that a plurality of points (white portion of Fig. 1) form that disposes randomly shown in Figure 1 yet.Gray shade scale figure shown in Figure 1 is the two-value view data that changes into 2 a grades of white and black gray shade scales (image exploring degree: 12800dpi), and be the figure of a kind of point of 16 μ m for disposing a plurality of directly (diameters of point) randomly.In addition, this gray shade scale figure is a square that the limit is 20mm, and its power spectrum is at spatial frequency 0.046 μ m ^-1The place presents maximal value.

Like this, make under the situation of gray shade scale figure disposing a plurality of points randomly, both can random arrangement have a kind of a plurality of points of putting the footpath, also can random arrangement have multiple a plurality of points directly.Equalization point footpath (mean value in the some footpath of the whole points in the figure) to point is not particularly limited, but is preferably 6～30 μ m.In the situation of equalization point footpath less than 6 μ m or surpass under the situation of 30 μ m, power spectrum is at spatial frequency 0.025～0.125 μ m sometimes ^-1Scope in do not present maximal value.

At the gray shade scale figure is under the situation of view data, as the method for drawing a plurality of points randomly, for example can enumerate following method: for the image of width W X, height WY, by generating the pseudo-random number sequence R[b of value 0～1], for example generating, the x coordinate of dot center is WX * R[2 * a-1], the y coordinate is WY * R[2 * a] a plurality of points.At this, a, b are natural numbers.As the method that generates pseudo-random number sequence, so long as having, the special Saite rotation algorithm of linear congruent method, Xorshift or horse (Mersenne Twister) etc. can use pseudo random number method of formation arbitrarily corresponding to the long method of enough cycles of counting that is distributed.Perhaps, be not limited to pseudo random number, also can utilize hardware, make the graph data that random alignment is had a few by generation random numbers such as thermonoises.

In addition, the gray shade scale figure that uses among the present invention also can be implemented the graph data that specific operation obtains for the graph data that a plurality of points of above-mentioned random arrangement are formed.As this operation, can enumerate following operation etc., for example: (i) operation of use Hi-pass filter, this Hi-pass filter is removed the low spatial frequency composition that is made of the spatial frequency below the specific lower limit value B; (ii) use the operation of bandpass filter, this bandpass filter is removed the low spatial frequency composition that is made of the spatial frequency that is lower than specific lower limit value B ', and by the high spatial frequency composition that the spatial frequency that surpasses specific upper limit value T ' constitutes, is extracted the spatial frequency composition that is made of the spatial frequency from this lower limit B ' to the particular range this higher limit T '.

The gray shade scale figure that obtains according to the application Hi-pass filter of above-mentioned (i), because from the spatial frequency composition that can the figure that a plurality of points of random arrangement form, contain, remove the low spatial frequency composition, therefore more be difficult to the micro concavo-convex surface of formation cycle, can prevent from more efficiently to dazzle above 50 μ m.Above-mentioned lower limit B can be set at for example 0.02～0.05 μ m ^-1Scope in.

In addition, the gray shade scale figure that obtains according to above-mentioned application bandpass filter (ii), because from the spatial frequency composition that can the figure that a plurality of points of random arrangement form, contain, remove low spatial frequency composition and high spatial frequency composition, therefore more be difficult to the micro concavo-convex surface of formation cycle above 50 μ m, can prevent from more efficiently to dazzle, and can improve the machining reproducibility when on transparent base, forming convex-concave surface according to the gray shade scale figure.Lower limit B ' for example is 0.01 μ m ^-1More than, be preferably 0.02 μ m ^-1More than.Higher limit T ' is preferably 1/ (D * 2) μ m ^-1Below.At this, the resolution (spot diameter when for example, utilizing the laser scanning picture device to make the resist exposure form convex-concave surface, laser) of the processing unit (plant) that D (μ m) uses when forming convex-concave surface on transparent base.

Make at a plurality of points of random arrangement the gray shade scale figure situation, and use Hi-pass filter or bandpass filter to make under the situation of gray shade scale figure to it, lower limit B by suitably footpath, reference mark, dot density, Hi-pass filter, the lower limit B ' of bandpass filter and higher limit T ' etc. can obtain power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present peaked gray shade scale figure.Dot density (draw a little zone with respect to the region-wide ratio of gray shade scale figure) is preferably 20～80%, and more preferably 40～70%.

When the operation that forms convex-concave surface on transparent base comprised the situation that the resist that used laser scanning picture device etc. handles etc., the gray shade scale figure that uses in the manufacture method of antiglare film of the present invention was preferably two-value and changes into white and black view data.This is because when comprising situation that the resist that used laser scanning picture device etc. handles etc., whether for example, normally utilizing, the two-value of irradiating laser forms concaveconvex shape.The view data that 3 grades of gray shade scales are above, the ratio by considering the exposure area in the resist processing etc. etc. are set suitable threshold, can easily be transformed to the view data after binaryzation.

(according to the formation of the convex-concave surface of gray shade scale figure)

In the manufacture method of antiglare film of the present invention,, on transparent base, form the micro concavo-convex surface according to above-mentioned gray shade scale figure.The micro concavo-convex surface that forms is made of gray shade scale corresponding concave part and protuberance with the gray shade scale figure.At the gray shade scale figure is that two-value changes under the situation of white and black view data, and the white region that constitutes the view data after the recess on micro concavo-convex surface or the either party in the protuberance and the binaryzation is corresponding.In addition, in the present invention, be formed at the micro concavo-convex surface on the transparent base, also can be the micro concavo-convex surface that constitutes by repetitive structure, this repetitive structure be make by the convex-concave surface cell abutment that constitutes with corresponding recess of the gray shade scale of a gray shade scale figure and protuberance and closely repeated arrangement form.The micro concavo-convex surface that constitutes by this repetitive structure, both can form, and also can form with the corresponding micro concavo-convex of a gray shade scale figure surface (convex-concave surface unit) and form by repeated arrangement successively by using view data to be about to the graph data that the gray shade scale figure repeated arrangement more than 2 makes.In addition, also can be by making and the corresponding mask of gray shade scale figure, and a plurality of these mask repeated arrangement are disposed, carry out blanket exposure and form across a plurality of masks of this alignment arrangements then.

As the concrete grammar that on transparent base, forms the micro concavo-convex surface according to above-mentioned gray shade scale figure, for example can enumerate print process, graph exposure method, embossing etc.In print process, the for example flexographic printing by using light-cured resin or heat-curing resin, screen printing, ink jet printing etc., above-mentioned gray shade scale figure is printed on the transparent base and after making, by dry or utilize active ray or heating to make its curing, can make antiglare film of the present invention thus.

For example, in flexographic printing, making is a flexographic plate based on the relief printing plate of above-mentioned figure, protuberance coating light-cured resin at flexographic plate, after the light-cured resin transfer printing that is coated with is on transparent supporting mass, utilize active ray to be cured, the micro concavo-convex based on above-mentioned figure can be formed on the transparent supporting mass thus.If screen printing, the orifice plate of then making based on above-mentioned figure is a web plate, utilizes this web plate and light-cured resin, after above-mentioned graphic printing is on transparent supporting mass, utilize active ray that light-cured resin is solidified, micro concavo-convex can be formed on the transparent supporting mass thus.If ink jet printing, then utilize light-cured resin directly with above-mentioned graphic printing on transparent supporting mass, thereafter, utilize active ray to make light-cured resin curing, micro concavo-convex can be formed on the transparent supporting mass thus.Steeper by the common inclination angle of micro concavo-convex that this print process forms, on transparent supporting mass, there is the position that does not form resin bed, therefore, preferably on the micro concavo-convex that utilizes print process to form, further be coated with light-cured resin, with the inclination angle smoothing, and on whole of transparent supporting mass, form resin bed.In the graph exposure method, after coating light-cured resin on the transparent supporting mass, by use above-mentioned gray shade scale figure based on laser instrument directly retouch exposure, and across the blanket exposure of mask with above-mentioned gray shade scale figure, carry out graph exposure, after developing as required, utilize active ray or heating to make its curing, can make antiglare film of the present invention thus.

Directly retouching in the exposure based on laser instrument, after coating light-cured resin on the transparent supporting mass, by laser light above-mentioned figure is directly retouched exposure, make the residual or dissolving in the position of exposing by development, and then to residual light-cured resin irradiation active ray, make its full solidification, the micro concavo-convex according to above-mentioned figure can be formed on the transparent supporting mass thus.This by based on laser instrument directly retouch the micro concavo-convex that forms of exposure, the inclination angle is steeper usually, therefore preferably by based on laser instrument directly retouch the further light-cured resin that is coated with on the micro concavo-convex that exposure forms, with the inclination angle smoothing.In the blanket exposure of mask, making has the mask of above-mentioned figure, after coating light-cured resin on the transparent supporting mass, across this mask light-cured resin is exposed, make the residual or dissolving in the position of exposing in the developing procedure, and then to residual light-cured resin irradiation active ray, make its full solidification, the micro concavo-convex according to above-mentioned figure can be formed on the transparent supporting mass thus.In the blanket exposure of mask, the inclination angle of micro concavo-convex also can be controlled by suitably controlling adjacent gap, also can control by the degree of control exposure, also controls by the degree that becomes the gray shade scale mask to control this exposure mask manufacture.In embossing,, make mould with micro concavo-convex surface according to above-mentioned gray shade scale figure, with the male and fomale(M﹠F) transfer printing of the mould of manufacturing on transparent base, next, there is the transparent base of male and fomale(M﹠F) to peel off transfer printing, can makes antiglare film of the present invention thus from mould.Wherein, good and repeatability forms the viewpoint on micro concavo-convex surface to antiglare film of the present invention well from precision, preferably makes by embossing.

As embossing, illustration is used the UV embossing of light-cured resin, the heat embossing method of use thermoplastic resin.Wherein, from the viewpoint of throughput rate, preferred UV embossing.

The UV embossing is following method: form the light-cured resin layer on the surface of transparent base, the limit presses on the male and fomale(M﹠F) of mould with its light-cured resin layer, and the limit is solidified it, and the male and fomale(M﹠F) with mould is needed on the light-cured resin layer thus.Particularly, on transparent base, be coated with ultraviolet curing resin, under the state of the male and fomale(M﹠F) driving fit of ultraviolet curing resin that is coated with making and mould, from transparent base side irradiation ultraviolet radiation, ultraviolet curing resin is solidified, thereafter, the transparent base that will be formed with the ultraviolet curing resin layer after the curing from the mould is peeled off, and the concaveconvex shape with mould is needed on ultraviolet curing resin thus.

Under the situation that adopts the UV embossing, transparent base comes down to optically transparent film, can enumerate tri acetyl cellulose membrane for example, polyethylene terephthalate film, polymethyl methacrylate film, polycarbonate membrane, be resin moldings such as the solvent cast films of thermoplastic resins such as noncrystalline cyclic polyolefin of monomer or squeeze film with the norborene compounds.

The kind of the ultraviolet curing resin during to employing UV embossing is not particularly limited, and can use the suitable ultraviolet curing resin of selling on the market.In addition, also can use the light trigger of will be suitably selecting to make up and promptly use the also curable resin of visible light of wavelength ratio ultraviolet line length with ultraviolet curing resin.As ultraviolet curing resin, for example can suitably use one or two or more kinds and Irgacure 907 (the vapour Bart plants chemical company system), Irgacure 184 (the vapour Bart plants chemical company system) of polyfunctional acrylic esters such as containing trimethylolpropane triacrylate, tetramethylol methane tetraacrylate, the resin combination of Lucirin TPO Photoepolymerizationinitiater initiaters such as (BASF AG's systems).

On the other hand, the heat embossing method be the transparent base that will constitute by thermoplastic resin under heated condition, press on mould and with the concave-convex surface shape transferred thereon of mould in the method for transparent base.Transparent base as the use of heat embossing method, so long as transparent in fact base material, any base material can, for example can use polymethylmethacrylate, polycarbonate, polyethylene terephthalate, triacetyl cellulose, be the solvent cast films of the thermoplastic resins such as noncrystalline cyclic polyolefin of monomer or squeeze film etc. with the norborene compounds.These transparent resin films also can also be suitable as the transparent base of the ultraviolet curing resin that is used for being coated with UV embossing described above.

The manufacture method of the mould that＜making antiglare film is used 〉

Below, the manufacture method of the mould that can be fit to use in the manufacture method of antiglare film of the present invention is described.Fig. 2 is the figure of a preferred example of first half that schematically represents the manufacture method of mould of the present invention.Fig. 2 schematically represents the section of the mould of each operation.The manufacture method of mould of the present invention comprises basically: (1) first plating operation; (2) grinding step; (3) photosensitive resin film forms operation; (4) exposure process; (5) developing procedure; (6) first etching work procedures; (7) photosensitive resin film stripping process; (8) second plating operations.Below, with reference to Fig. 2 each operation of the manufacture method of mould of the present invention is elaborated.

[1] first plating operation

In the manufacture method of mould of the present invention, at first, copper facing or nickel plating are implemented in the surface of the base material that mould is used.Like this, by mould is implemented copper facing or nickel plating with the surface of base material, can improve adaptation, the glossiness of chromium plating of the second plating operation of back.That is, form in chrome-plated surface in the situation of the surface of iron etc. being implemented chromium plating or with sand-blast, spray bead method etc. and to implement once more under the situation of chromium plating after concavo-convex, it is coarse that the surface easily becomes, and generation hair check is difficult to control the concaveconvex shape of die surface.Relative therewith, at first, substrate surface is implemented copper facing or nickel plating, can eliminate this unfavorable condition thus.This be because, copper facing or nickel plating covering property are strong, the smoothing effect is also strong, so the landfill mould forms smooth and has the surface of gloss with the micro concavo-convex of base material, cavity (cavity) etc.Characteristic according to these copper facing or nickel plating, even in the second plating operation described later, implement chromium plating, also can eliminate the coarse of the micro concavo-convex of thinking to be present in base material, empty caused chrome-plated surface, in addition, because the covering property of copper facing or nickel plating is strong, therefore can reduce the generation of hair check.

As the copper or the nickel that use in the first plating operation, except can being the simple metal separately, also can use with copper as the alloy of main body or with the alloy of nickel as main body, therefore this instructions said " copper " is the meaning that comprises copper and aldary, in addition, " nickel " is the meaning that comprises nickel and nickel alloy.Copper facing and nickel plating are carried out with the electrolysis plating respectively, also can carry out with electroless plating, but adopt the electrolysis plating usually.

When implementing copper facing or nickel plating, when coating is too thin, can not thoroughly get rid of the influence of substrate surface, so its thickness is preferably more than the 50 μ m.The upper limit of thickness of coating is not the upper limit of criticality, but in view of cost etc., the upper limit of thickness of coating is preferably set to about maximum 500 μ m.

In the manufacture method of mould of the present invention,,, can enumerate aluminium, iron etc. from the viewpoint of cost as the metal material of mould suitable use with the formation of base material.From the convenience of operation, more preferably use the aluminium of light weight., also can use too except can be at this said aluminium and iron with aluminium or iron alloy as main body for simple metal separately.

In addition, mould gets final product with the suitable shape that adopts at present in this field that is shaped as of base material, for example, except that tabular, also can be coiled material cylindric or cylindraceous.If use the base material of web-like to make mould, has the advantage that to make antiglare film with continuous web-like.

[2] grinding step

In ensuing grinding step, the substrate surface of having implemented copper facing or nickel plating in above-mentioned the 1st plating operation is ground.Preferably substrate surface is ground to state near minute surface through this operation.This be because, in order to reach required precision, in most cases be that the sheet metal, the metallic coil that become base material are implemented machinings such as cutting, grinding, thus at substrate surface residual process eyelet, under the state of having implemented copper facing or nickel plating, sometimes also residual these processing eyelets, and under the intact state of plating, might not become level and smooth fully in the surface.Promptly, even have the surface of dark like this processing eyelet etc. to implement operation described later to residual, sometimes it is concavo-convex also dark that the concavo-convex ratio of processing eyelet etc. has been implemented to form after each operation, the influence of possible residual process eyelet etc., when using such mould to make antiglare film, sometimes optical characteristics is produced the not influence of expectability.Fig. 2 (a) represents schematically that flat mould has in the 1st plating operation with base material 7 its surface is implemented copper facing or nickel plating (layer of copper facing that forms in to this operation or nickel plating not have to illustrate) and then carried out the state on the surface 8 of mirror ultrafinish by grinding step.

For the substrate surface of having implemented copper facing or nickel plating is carried out abrasive method, there is no particular restriction, can use any method of mechanical milling method, electrolytic polishing method, chemical grinding method.As mechanical milling method, can illustration superfinishing method, polishing, fluid polishing, polishing (buff) polishing etc.Surfaceness after the grinding, preferably the center line average roughness Ra according to the regulation of JIS B 0601 is below the 0.1 μ m, more preferably below the 0.05 μ m.If the center line average roughness Ra after grinding might be to the influence of the surfaceness after the residual grinding of the concaveconvex shape of final die surface greater than 0.1 μ m.In addition, there is no particular restriction for the lower limit of center line average roughness Ra, from the viewpoint of process time, processing cost, has limit naturally, do not have specially appointed necessity.

[3] photosensitive resin film painting process

In ensuing photosensitive resin film painting process, with photoresist with the solution coat that is dissolved in solvent and obtains surface 8 through grinding to the base material 7 of having implemented mirror ultrafinish by above-mentioned grinding step, heat, drying, thereby form photosensitive resin film.Fig. 2 (b) schematically is illustrated in mould has formed photosensitive resin film 9 with the surface 8 through grinding of base material 7 state.

As photoresist, can use known in the past photoresist.Photoresist as minus with the partly solidified character of sensitization; for example can use monomer, the prepolymer of the acrylate that has acryloyl group or methacryl in the molecule; the potpourri of two-fold nitride (bisazide) and diene rubber, poly-vinyl cinnamate based compound etc.In addition, make sensitization part wash-out, the photoresist of the eurymeric of the character of residual not sensitization part only, for example can use phenolics system, novolac resin system etc. as having by development.In addition, can cooperate various adjuvants such as sensitizer, development accelerant, adaptation improver, coating improver in the photoresist as required.

When these photoresists are coated mould with the surface 8 through grinding of base material 7, in order to form good filming, preferably in appropriate solvent the dilution and be coated with, as solvent, can use cellosolve series solvent, propylene glycol series solvent, ester series solvent, pure series solvent, ketone series solvent, high polar solvent etc.

As the method for photosensitive resin coating solution, can use protruding liquid coating (meniscus coat), fountain type coating, dip-coating, rotary coating, print roll coating, the coating of coiling rod, airblade coating, scraper to be coated with, to reach known method such as curtain formula coating.The thickness of coated film preferably is the scope of 1～6 μ m after drying.

[4] exposure process

In ensuing exposure process, above-mentioned gray shade scale figure is being formed exposure on the photosensitive resin film 9 that operation forms by above-mentioned photosensitive resin film.The light source that exposure process uses can suitably be selected according to the wavelength photoreceptor of the photoresist of coating, light sensitivity etc., can use (the wavelength: 436nm), the h line of high-pressure mercury-vapor lamp (wavelength: 405nm), the i line of high-pressure mercury-vapor lamp (wavelength: 365nm), semiconductor laser (wavelength: 830nm, 532nm, 488nm, 405nm etc.), YAG laser (wavelength: 1064nm), KrF excimer laser (wavelength: 248nm), ArF excimer laser (wavelength: 193nm), F2 excimer laser (wavelength: 157nm) etc. of the g line of high-pressure mercury-vapor lamp for example.

In order to form the concave-convex surface shape accurately, preferably in exposure process, under the state of precision control, above-mentioned gray shade scale figure is exposed on photosensitive resin film in the manufacture method of mould of the present invention.In the manufacture method of mould of the present invention, in order accurately above-mentioned gray shade scale figure to be exposed on photosensitive resin film, be the gray shade scale figure preferably according to the view data that makes by computing machine, the laser light that utilization is sent from computer-controlled laser head is drawn figure on photosensitive resin film.Carrying out this laser when drawing, can use galley to make the laser scanning picture device of usefulness.As such laser scanning picture device, can enumerate for example Laser Stream FX ((strain) ThinkLaboratory system) etc.

Fig. 2 (c) schematically represents the state of graph exposure in photosensitive resin film 9.When forming photosensitive resin film with the photoresist of minus, exposed areas 10 is carried out the cross-linking reaction of resin, with respect to the decreased solubility of developer solution described later by exposure.Therefore, do not have exposed areas 11 to be developed liquid dissolving in the developing procedure, have only exposed areas 10 to remain on the substrate surface and become mask.On the other hand, when using the photoresist formation photosensitive resin film of eurymeric, exposed areas 10 is by exposure, with the combination cut-out of resin, with respect to the dissolubility increase of developer solution described later.Thus, exposed areas 10 is developed liquid dissolving in the developing procedure, has only unexposed regional 11 to remain on the substrate surface and become mask.

[5] developing procedure

In ensuing developing procedure, when the photoresist of minus is used for photosensitive resin film 9, unexposed regional 11 are developed liquid dissolving, have only that exposed areas 10 remains in mould with on the base material, play a role as mask in ensuing the 1st etching work procedure.On the other hand, when the photoresist of eurymeric is used for photosensitive resin film 9, have only that exposed areas 10 is developed the liquid dissolving, unexposed regional 11 remain in mould with on the base material, play a role as the mask in ensuing the 1st etching work procedure.

For the developer solution that uses in the developing procedure, can use known in the past developer solution.Can enumerate for example inorganic bases such as NaOH, potassium hydroxide, sodium carbonate, sodium silicate, sodium metasilicate, ammoniacal liquor, primary amine such as ethamine, n-propylamine class, secondary amine such as diethylamine, di-n-butylamine class, tertiary amines such as triethylamine, methyl diethylamide, alcamines such as dimethylethanolamine, triethanolamine, quaternary ammonium salts such as Tetramethylammonium hydroxide, tetraethyl ammonium hydroxide, trimethyl hydroxyethylammoniumhydroxide hydroxide, alkaline aqueous solutions such as cyclic amine such as pyrroles, piperidines, organic solvents such as dimethylbenzene, toluene etc.

There is no particular restriction for the developing method in the developing procedure, can use methods such as immersion development, spray developing, brushing development, ultrasound wave development.

Fig. 2 (d) represents that schematically the photoresist with minus is used for photosensitive resin film 9 and has carried out the state of development treatment.Unexposed regional 11 are developed liquid dissolving among Fig. 2 (c), have only exposed areas 10 to remain on the substrate surface and become mask 12.Fig. 2 (e) represents that schematically the photoresist with eurymeric is used for photosensitive resin film 9 and has carried out the state of development treatment.Exposed areas 10 is developed the liquid dissolving among Fig. 2 (c), has only unexposed regional 11 to remain on the substrate surface and become mask 12.

[6] the 1st etching work procedures

In ensuing the 1st etching work procedure, use behind the above-mentioned developing procedure that remaining photosensitive resin film is as mask on substrate surface at mould, main with the base material etching of the mould at maskless position, formation is concavo-convex on the plating face through grinding.Fig. 3 is the figure of a preferred example of the latter half of the manufacture method of schematically representing this mould.Fig. 3 (a) schematically represents by the 1st etching work procedure mainly the mould at maskless position 13 with base material 7 etched states.The mould of the bottom of mask 12 is not etched with substrate surface from mould with base material 7, but carries out along with etched, carries out from the etching at maskless position 13.Therefore, the boundary vicinity at mask 12 and maskless position 13, the mould of the bottom of mask 12 is also etched with base material 7.Boundary vicinity at such mask 12 and maskless position 13, the mould of the bottom of mask 12 is also etched with base material 7, below this is called lateral etch.The carrying out of lateral etch schematically is shown among Fig. 4.The dotted line 14 of Fig. 4 is represented with the surface of the etched mould that carries out and change with base material interimly.

Etch processes in the 1st etching work procedure is usually by using iron chloride (FeCl ₃) liquid, cupric chloride (CuCl ₂) liquid, alkali etching liquid (Cu (NH ₃) ₄Cl ₂) etc., corrosion is carried out, but also can use strong acid such as hydrochloric acid, sulfuric acid, also can use by applying the back-electrolysis etching of current potential opposite when plating with electrolysis.The concave shape that mould when having implemented etch processes forms on base material, because of the kind of the kind of base metal, photosensitive resin film and etching gimmick etc. different, therefore cannot treat different things as the same, etch quantity is 10 μ m when following, and is roughly isotropically etched from the metal surface that contacts with etching solution.Here said etch quantity is the thickness by the base material of etching reduction.

Etch quantity in the 1st etching work procedure is preferably 1～50 μ m.Etch quantity is during less than 1 μ m, and the metal surface almost can't form concaveconvex shape, becomes the mould of general planar, does not therefore show anti-dazzle property.In addition, when etch quantity surpassed 50 μ m, the difference of height of the concaveconvex shape that the metal surface forms increased, and in the image display device of using the antiglare film of using resulting mould and making, may produce whiting.Etch processes in the 1st etching work procedure can adopt 1 time etch processes to carry out, also can divide 2 times with on carry out etch processes.Divide when carrying out etch processes more than 2 times, the total of the etch quantity in the etch processes more than 2 times is preferably 1～50 μ m.

[7] photosensitive resin film stripping process

In ensuing photosensitive resin film stripping process, the remaining photosensitive resin film that uses as mask in the 1st etching work procedure dissolved fully remove.In the photosensitive resin film stripping process, use stripper that photosensitive resin film is dissolved.As stripper, can use the liquid same with above-mentioned developer solution, by changing pH, temperature, concentration and dip time etc., the photosensitive resin film of the photosensitive resin film of the exposure portion during with the photosensitive resin film that used minus, the non-exposure portion when having used the photosensitive resin film of eurymeric dissolves fully to be removed.For the stripping means in the photosensitive resin film stripping process, there is not special restriction yet, can use methods such as immersion development, spray developing, brushing development, ultrasound wave development.

Fig. 3 (b) schematically represents by the photosensitive resin film stripping process photosensitive resin film that uses as mask 12 in the 1st etching work procedure to be dissolved the state of removing fully.By having utilized the etching of the mask 12 that forms by photosensitive resin film, form the 1st concave-convex surface shape 15 with substrate surface at mould.

[8] the 2nd plating operations

Next, by formed male and fomale(M﹠F) (first surface concaveconvex shape 15) is implemented chromium plating, make the concaveconvex shape passivation on surface.Fig. 3 (c) expression is by forming the state that chromium coating 16 is formed with the concavo-convex surface (surface 17 of chromium plating) more blunt than first surface concaveconvex shape 15 on the first surface concaveconvex shape 15 that forms in the etch processes by first etching work procedure.

Among the present invention, adopt on the surface of flat board, coiled material etc. glossy, hardness is high, friction factor is little, the chromium plating that can give good release property.There is no particular restriction for the kind of chromium plating, and preferred the use is called so-called gloss chromium plating, decorates the chromium plating that manifests good gloss with chromium plating etc.Usually carry out chromium plating by electrolysis,, use and contain chromic anhybride (CrO as its plating bath ₃) and the aqueous solution of a small amount of sulfuric acid.Can control the thickness of chromium plating by regulating current density and electrolysis time.

Above-mentioned spy opens that 2002-189106 communique, spy are opened the 2004-45472 communique, the spy opens in 2004-90187 communique etc. and discloses employing chromium plating, but kind because of substrate before the plating of mould and chromium plating, usually coarse in the plating rear surface, or a large amount of small crackles that cause by chromium plating of generation, its result utilizes this mould and the optical characteristics of the antiglare film that obtains can develop to preferred direction.The mould of the state that plating surface is coarse is not suitable for making antiglare film.Reason is, and is generally rough in order to eliminate, after chromium plating, plating surface is ground, as described later, the grinding on the surface among the present invention behind the preferred plating.Among the present invention,, the such rough sledding that produces because of chromium plating is easily eliminated by base metal is implemented copper facing or nickel plating.

Need to prove, in the 2nd plating operation, preferably do not implement chromium plating plating in addition.Reason is that for the plating beyond the chromium, hardness, mar proof reduce, and therefore the permanance as mould reduces, concavo-convex wearing and tearing in the use, perhaps mould damage.By the antiglare film that such mould obtains, be difficult to obtain the possibility height of enough anti-dazzle functions, in addition, the possibility that produces defective on film also raises.

In addition, the above-mentioned spy surface grinding of opening behind the disclosed the sort of platings such as 2002-90187 communique is still not preferred in the present invention yet.That is, preferably after the second plating operation, the operation of not establishing lapped face uses the male and fomale(M﹠F) of having implemented chromium plating directly as the male and fomale(M﹠F) of the mould of transfer printing on transparent base.Its reason is, by grinding, can produce flat portions on the outer surface, therefore may cause the optical characteristics variation, and in addition, because the controlling factor of shape increases, so the good shape control of repeatability is than difficulty etc.

Like this, in the manufacture method of mould of the present invention,, can obtain the mould that concaveconvex shape passivation and its skin hardness increase by chromium plating is implemented on the surface that is formed with fine concave-convex surface shape.The concavo-convex passivation situation of this moment, the concavo-convex size that obtains because of the kind of base metal, by the 1st etching work procedure and the kind of the degree of depth and plating, thickness etc. are different, therefore cannot treat different things as the same, be still plating thickness in the factor of maximum aspect the control passivation situation.If the thin thickness of chromium plating makes the effect deficiency of the concavo-convex surface configuration passivation that obtains before the chromium plating processing, its concaveconvex shape is transferred to transparent base and the optical characteristics of the antiglare film that obtains can be not very good.On the other hand, if plating thickness is blocked up, then the throughput rate variation in addition, produces the plating defective of the overshooting shape that is called knot shape thing, and is therefore not preferred.Therefore, the thickness of chromium plating is preferably in the scope of 1～10 μ m, more preferably in the scope of 3～6 μ m.

The chromium coating that forms in the 2nd plating operation, preferably the mode that reaches more than 800 with Vickers hardness forms, and more preferably forms in the mode that reaches more than 1000.The Vickers hardness of chromium coating was less than 800 o'clock, permanance when mould uses reduces, and reduces because of chromium plating makes hardness, this be because, plating bath composition, electrolytic condition etc. produced unusual possibility height when plating was handled, and the situation occurred of defective is also caused not the preferably possibility height of influence.

In addition, in the manufacture method of mould of the present invention, comprise the 2nd etching work procedure that makes the male and fomale(M﹠F) passivation that forms by the 1st etching work procedure by etch processes between preferably above-mentioned [7] photosensitive resin film stripping process and [8] the 2nd plating operations.In the 2nd etching work procedure, make the 1st concave-convex surface shape 15 passivation that form by the 1st etching work procedure that photosensitive resin film is used as mask by etch processes.By the 2nd etch processes, the anxious steep part of the surface tilt in the 1st concave-convex surface shape 15 that is formed by the 1st etch processes disappears, and uses the optical characteristics of the antiglare film that the mould that obtains makes to change to preferred direction.Illustrated among Fig. 5 by the 2nd etch processes, the 1st concave-convex surface shape 15 passivation of base material 7 make the anxious steep part passivation of surface tilt, form the state of the 2nd concave-convex surface shape 18 of the surface tilt with mitigation.

The etch processes of the 2nd etching work procedure is also the same with the 1st etching work procedure, usually by using iron chloride (FeCl ₃) liquid, cupric chloride (CuCl ₂) liquid, alkali etching liquid (Cu (NH ₃) ₄Cl ₂) etc., surface corrosion is carried out, but also can be used strong acid such as hydrochloric acid, sulfuric acid, also can use by applying the back-electrolysis etching of current potential opposite when plating with electrolysis.Implemented the concavo-convex passivation situation after the etch processes, the concavo-convex size that obtains because of the kind of base metal, etching gimmick with by the 1st etching work procedure and the degree of depth etc. are different, therefore cannot treat different things as the same, and the factor of control passivation situation aspect maximum is an etch quantity.Here said etch quantity, also the same with the 1st etching work procedure is the thickness of the base material of etched reduction.If etch quantity is little, make the effect deficiency of the concavo-convex surface configuration passivation that obtains by the 1st etching work procedure, its concaveconvex shape is transferred on the transparent base and the optical characteristics of the antiglare film that obtains can be not very good.On the other hand,, can become concaveconvex shape hardly, become the mould of general planar, therefore can't show anti-dazzle property if etch quantity is excessive.Therefore, etch quantity is preferably in the scope of 1～50 μ m, more preferably in the scope of 4～20 μ m.For the etch processes in the 2nd etching work procedure, also the same with the 1st etching work procedure, can adopt 1 time etch processes to carry out, also can divide 2 times with on carry out etch processes.When branch carried out etch processes more than 2 times, the total of the etch quantity in the etch processes more than 2 times was preferably 1～50 μ m.

The mould that obtains by the manufacture method of using by mould of the present invention, therefore come precision to control and form the micro concavo-convex surface configuration well, also do not dazzle, present the antiglare film of high-contrast in the time of can obtaining embodying sufficient anti-dazzle property and not whiten, be disposed at image display device surperficial.In addition, can efficiently be suppressed the generation of interference color, interference stripes and repeat the antiglare film of the generation of decorative pattern.

Example

Below, the present invention will be described in more detail to enumerate embodiment, but the present invention is not limited to these embodiment.

(1) mensuration of the peaked spatial frequency that presents power spectrum of gray shade scale figure

With 12800dpi the gray shade scale graph data that makes is set at the view data of the progressive series of greys of 256 grades of gray shade scales, with discrete function g (x, y) the expression gray shade scale of two dimension.(x y) carries out discrete Fourier transformation, obtains two-dimensional function G (f with resulting two-dimensional discrete function g _x, f _y).With two-dimensional function G (f _x, f _y) carry out a square calculating, calculate the two-dimensional function G of power spectrum ²(f _x, f _y), by as f _xThe G of=0 cross section curve ²(0, f _y) [transverse axis is spatial frequency f _y, the longitudinal axis is the two-dimensional curve of power spectrum], obtain the peaked spatial frequency that presents power spectrum.At this, recording and narrating in " the peaked spatial frequency that presents power spectrum " shown in the following table 1 has the spatial frequency of being present in f _y=0 μ m ^-1The position beyond a plurality of maximal values in, present maximum peaked this spatial frequency with the spatial frequency of absolute value minimum.The horizontal resolution Δ x of the figure that uses in the calculating and Δ y are 2 μ m.In addition, computer capacity adopts 1000 μ m * 1000 μ m.

(2) mensuration of the mist degree of antiglare film

The mist degree of antiglare film is measured with the method for JIS K 7136 regulations.Particularly, use mist degree instrument HM-150 type (color technical institute system in the village), measure mist degree based on this specification.In order to prevent the warpage of antiglare film, use optically transparent bonding agent, the mode that becomes the surface with male and fomale(M﹠F) fits in after the glass substrate, in mensuration.Usually, when mist degree becomes big, when being applied to image display device, the image deepening, consequently, positive contrast easily reduces.Therefore, mist degree is preferably low.

(3) evaluation of the anti-dazzle performance of antiglare film

(visual valuation of repeat decorative pattern, interference color, mirroring, whiten)

In order to prevent reflection from the back side of antiglare film, become the mode on surface with male and fomale(M﹠F), antiglare film is fitted in the black acrylic resin board, be furnished with the bright indoor of fluorescent light, carry out visualization from the male and fomale(M﹠F) side, to having or not repetition decorative pattern, presence of interference look, having or not the whiting etc. of mirroring and have or not of fluorescent light to carry out visual valuation.Repeat decorative pattern, interference color, mirror and whiten and estimate by following standard with 1～3 Three Estate respectively.

Repeat decorative pattern 1, do not observe the repetition decorative pattern

2, observe a little and repeat decorative pattern

3, observe the repetition decorative pattern significantly

Interference color 1, do not observe interference color

2, observe a little interference color

3, observe interference color significantly

Mirror 1, do not observe and mirror

2, observing a little mirrors

3, observe significantly and mirror

Whiting 1, do not observe whiting

2, observe a little whiting

3, observe whiting significantly

(dazzle and reach the evaluation of interference stripes)

The LCD TV (LC-32GH3 (Sharp's (strain) system)) of selling from market is peeled off the Polarizer on table back of the body two sides.Replace these original Polarizers, rear side and display surface side all by tackifier applying polarization plates SUMIKARAN SRDB31E (Sumitomo Chemical (strain) system) so that absorption axes separately is consistent with the absorption axes of original polarization plates, and then the antiglare film shown in each example below fitting by tackifier on the display surface lateral deviation vibration plate is so that male and fomale(M﹠F) becomes the surface.Under this state, carry out visualization from the position of the about 30cm of distance sample, the degree that reaches interference stripes is estimated by following standard with Three Estate to dazzling.

Dazzle 1, do not observe twinkling

2, observing a little dazzles

3, observe significantly twinkling

Interference stripes 1, do not observe interference stripes

2, observe a little interference stripes

3, observe interference stripes significantly

＜embodiment 1 〉

The volume of copper Ba Lade plating (Copper バ ラ one De め つ I) has been implemented in preparation to the surface of the aluminium volume (based on the A5056 of JIS) of diameter 200mm.Copper Ba Lade coating is made up of copper coating/thin silvering/surperficial copper coating, and the thickness setting of coating integral body is about 200 μ m.Its copper coatings is carried out mirror ultrafinish,, carry out drying and form photosensitive resin film at copper coatings photosensitive resin coating through grinding.Then, graph data is exposed by laser light on photosensitive resin film, and develop, this graph data is with a plurality of gray shade scale graph datas shown in Figure 1 graph data of forming of repeated arrangement continuously.Adopt the exposure and the development of laser light, use Laser Stream FX ((strain) ThinkLaboratory system) to carry out.The photoresist of eurymeric is used for photosensitive resin film.Gray shade scale figure shown in Figure 1 is the figure of the point of 16 μ m for disposing a plurality of footpaths (diameter of point) randomly, and power spectrum is at spatial frequency 0.046 μ m ^-1The place presents maximal value.In addition, the gray shade scale graph data shown in Figure 1 square that to make a limit be 20mm.

Then, carry out the 1st etch processes with cupric chloride liquid.The etch quantity of this moment is set at 3 μ m.Coiled material after the 1st etch processes is removed photosensitive resin film, carries out the 2nd etch processes with cupric chloride liquid once more.The etch quantity of this moment is set at 10 μ m.Then, carry out chromium plating processing, make mould A.At this moment, the chromium plating thickness setting is 4 μ m.

With ethyl acetate dissolving Photocurable resin composition GRANDIC 806T (big Japanese ink chemical industry (strain) system); become the solution of 50 weight % concentration; and then add 5 weight portion Photoepolymerizationinitiater initiater Lucirin TPO (BASF AG's systems with respect to 100 weight portion curable resin compositions; chemical name: 2; 4; 6-trimethylbenzoyl diphenyl phosphine oxygen), modulation coating fluid.This coating fluid is applied on triacetyl cellulose (TAC) film of thickness 80 μ m, making dried coating thickness is 10 μ m, in being set at 60 ℃ dryer dry 3 minutes.With rubber rollers with dried mould to the male and fomale(M﹠F) of the mould A that had before obtained so that the Photocurable resin composition layer become die side and make their driving fits.Under this state from TAC film side exposure intensity 20mW/cm ²From the light of high-pressure mercury-vapor lamp so that reach 200mJ/cm with h line conversion quantometer ², the Photocurable resin composition layer is solidified.Then, peel off the TAC film with cured resin, make by the surface and have the transparent antiglare film A that the lamilated body of concavo-convex cured resin and TAC film constitutes from mould.

＜embodiment 2 〉

As the gray shade scale figure that utilizes laser light to expose, use gray shade scale figure shown in Figure 6, the etch quantity of recording and narrating with table 1 carries out first etch processes and second etch processes, in addition, similarly to Example 1, obtains mould B.Except utilizing resulting mould B, similarly to Example 1, make antiglare film B.Gray shade scale graph data shown in Figure 6 be random arrangement a plurality of footpath is arranged is the figure of the point of 12 μ m, power spectrum is at spatial frequency 0.056 μ m ^-1The place presents maximal value.In addition, the gray shade scale graph data shown in Figure 6 square that to make a limit be 100mm.

＜embodiment 3 〉

As the gray shade scale figure that utilizes laser light to expose, the length that graph data is made a limit is the square of 16mm, in addition, use with embodiment 1 in the identical gray shade scale figure of use, except the etch quantity of recording and narrating with table 1 carries out first etch processes and second etch processes, similarly to Example 1, obtain mould C.Except utilizing resulting mould C, similarly to Example 1, make antiglare film C.

＜comparative example 1 and comparative example 2 〉

As the gray shade scale figure that utilizes laser light to expose, use the gray shade scale graph data shown in Figure 7 that makes as the square of 20mm as the length on a limit, the etch quantity of recording and narrating with table 1 carries out first etch processes and second etch processes, in addition, similarly to Example 1, obtain mould D and mould E.Except utilizing resulting mould D and mould E, similarly to Example 1, make antiglare film D and antiglare film E.Gray shade scale graph data shown in Figure 7 be random arrangement a plurality of footpath is arranged is the figure of the point of 36 μ m, power spectrum is at spatial frequency 0.017 μ m ^-1The place presents maximal value.The power spectrum of gray shade scale graph data shown in Figure 7 is at spatial frequency 0.025～0.125 μ m ^-1Scope in do not have maximal value.

＜comparative example 3 〉

As the gray shade scale figure that utilizes laser light to expose, use the gray shade scale graph data shown in Figure 7 that makes as the square of 10mm as the length on a limit, in addition same with comparative example 1, obtain mould F.Except utilizing resulting mould F, same with comparative example 1, make antiglare film F.

＜comparative example 4～7 〉

As the gray shade scale figure that utilizes laser light to expose, use the gray shade scale figure shown in Fig. 8～11 respectively, the etch quantity of recording and narrating with table 1 carries out first etch processes and second etch processes, in addition, similarly to Example 1, obtains mould G～J.Except utilizing resulting mould G～J, similarly to Example 1, make antiglare film G～J.Gray shade scale figure shown in Figure 8 be random arrangement a plurality of footpath is arranged is the figure of the point of 16 μ m, power spectrum is at spatial frequency 0.056 μ m ^-1The place presents maximal value.In addition, the gray shade scale graph data shown in Figure 8 square that to make a limit be 10mm.Gray shade scale graph data shown in Figure 9 be random arrangement a plurality of footpath is arranged is the figure of three kinds of points of 14 μ m, 18 μ m and 22 μ m, power spectrum is at spatial frequency 0.042 μ m ^-1The place presents maximal value.In addition, the gray shade scale graph data shown in Figure 9 square that to make a limit be 2mm.Gray shade scale graph data shown in Figure 10 be random arrangement a plurality of footpath is arranged is the figure of the point of 20 μ m, power spectrum is at spatial frequency 0.033 μ m ^-1The place presents maximal value.In addition, the gray shade scale graph data shown in Figure 10 square that to make a limit be 1mm.Gray shade scale graph data shown in Figure 11 be random arrangement a plurality of footpath is arranged is the figure of the point of 22 μ m, power spectrum is at spatial frequency 0.033 μ m ^-1The place presents maximal value.In addition, the gray shade scale graph data shown in Figure 11 square that to make a limit be 1mm.

First etch processes when making mould A～J and the etch quantity of second etch processes and make in the gray shade scale figure that uses the some footpath, (as mentioned above, the spatial frequency recorded and narrated of this hurdle is at power spectrum G to present the peaked spatial frequency of power spectrum ²(f _x, f _y) f _x=0 cross section curve is G ²(0, f _y) on be present in spatial frequency f _y=0 μ m ^-1The position beyond a plurality of maximal values in, present maximum peaked this spatial frequency with the spatial frequency of absolute value minimum.), the length on the shape of gray shade scale figure and a minimum limit is summarised in the table 1.In addition, Figure 12 is the power spectrum G that expression is calculated according to the gray shade scale figure that uses among embodiment 1 and the embodiment 2 ²(f _x, f _y) f _xThe figure in=0 cross section.The numeric representation spatial frequency f of the transverse axis of Figure 12 _yAbsolute value.

Table 1

In addition, table 2 expression is the measurement result of mist degree of resulting antiglare film and the evaluation result of anti-dazzle performance.

Table 2

By the evaluation result of table 2 as can be known, antiglare film A～C of the embodiment 1～3 that is obtained by manufacture method of the present invention is following antiglare film: the length of utilizing a minimum limit for more than the 15mm and power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present peaked gray shade scale figure, make mould, the male and fomale(M﹠F) transfer printing of resulting mould is formed the micro concavo-convex surface, therefore anti-ly mirror the ability excellence, and do not observe twinkling, whiting, repeat decorative pattern, interference color and interference stripes and the identification excellence.In addition, antiglare film A～C is a low haze, also brings into play good anti-dazzle performance, and therefore a kind of image display device that excellent anti-dazzle property also embodies high-contrast simultaneously that has can be provided.

On the other hand, in the antiglare film D and E of comparative example 1 and 2, the length on a limit of minimum of the gray shade scale figure that uses is 20mm, therefore do not interfere look and interference stripes, but power spectrum is at spatial frequency 0.025～0.125 μ m ^-1Scope in do not present maximal value, therefore dazzle and the inhibition effect of whiting insufficient.In addition, in above-mentioned scope, do not present peaked gray shade scale figure by using power spectrum, and observe repetition decorative pattern (constituting the cancellate line of the profile of the convex-concave surface unit corresponding) with the gray shade scale figure of repeated arrangement.

In addition, in the antiglare film F～J of comparative example 3～7, the length on a limit of minimum of the gray shade scale figure of use is 1～10mm, therefore, even in power spectrum at spatial frequency 0.025～0.125 μ m ^-1Scope in present under the peaked situation, also can observe the repetition decorative pattern.In addition, in the antiglare film H～J of the comparative example 5～7 of the curtailment 10mm on the limit of minimum of the gray shade scale figure that uses, also can observe interference color and interference stripes.And then in the antiglare film F of comparative example 3, the power spectrum of the gray shade scale figure of use is at spatial frequency 0.025～0.125 μ m- ¹Scope in do not present maximal value, therefore can observe twinkling.

Claims (10)

1. the manufacture method of an antiglare film, it comprises the operation that forms convex-concave surface according to the gray shade scale figure on transparent base,

The length on a limit of minimum of described gray shade scale figure is more than the 15mm, and the power spectrum of described gray shade scale figure is at spatial frequency 0.025～0.125 μ m ^-1Scope in present maximal value,

Described convex-concave surface is made of the repetitive structure of convex-concave surface unit, and described convex-concave surface unit is made of gray shade scale corresponding concave part and the protuberance with described gray shade scale figure.

2. the method for claim 1, wherein described gray shade scale figure is that two-value changes into white and black view data,

The white region of the view data after the either party who constitutes the recess of described convex-concave surface unit or protuberance and the described binaryzation is corresponding.

3. the operation that the method for claim 1, wherein forms convex-concave surface on described transparent base comprises following operation: according to described gray shade scale figure, make mould with male and fomale(M﹠F), with the male and fomale(M﹠F) transfer printing of described mould on described transparent base.

4. the manufacture method of a mould, it makes the described mould of claim 3, comprises following operation:

The first plating operation, it implements copper facing or nickel plating to mould with the surface of base material;

Grinding step, it grinds the surface of having been implemented plating by the first plating operation;

Photosensitive resin film forms operation, and it forms photosensitive resin film on the face after the grinding;

Exposure process, it exposes described gray shade scale figure on photosensitive resin film;

Developing procedure, the photosensitive resin film after it is exposed described gray shade scale figure develops;

First etching work procedure, the photosensitive resin film after its use is developed carries out etch processes as mask, forms concavo-convex on the plating face after the grinding;

The photosensitive resin film stripping process, it peels off photosensitive resin film; With

The second plating operation, it implements chromium plating to formed male and fomale(M﹠F).

5. method as claimed in claim 4 wherein, contains second etching work procedure between described photosensitive resin film stripping process and the described second plating operation, this second etching work procedure makes the concaveconvex shape passivation of formed male and fomale(M﹠F) by etch processes.

6. method as claimed in claim 4, wherein, the enforcement that in the described second plating operation, forms the male and fomale(M﹠F) of chromium plating be the male and fomale(M﹠F) that is needed on the mould on the described transparent base.

7. method as claimed in claim 4, wherein, the chromium coating that is formed by the chromium plating in the described second plating operation has the thickness of 1～10 μ m.

8. an antiglare film utilizes the described manufacture method of claim 1 to make.

9. gray shade scale figure, it is used for the manufacture method of the described antiglare film of claim 1,

The length on a limit of minimum of described gray shade scale figure is more than the 15mm, and power spectrum is at spatial frequency 0.025～0.125 μ m ^-1Scope in present maximal value.

10. gray shade scale figure as claimed in claim 9, the view data that it is white and black for two-value changes into.

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