CN117624683A - Laminate, method for producing laminate, optical member, and image display device - Google Patents

Laminate, method for producing laminate, optical member, and image display device Download PDF

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Publication number
CN117624683A
CN117624683A CN202311102095.3A CN202311102095A CN117624683A CN 117624683 A CN117624683 A CN 117624683A CN 202311102095 A CN202311102095 A CN 202311102095A CN 117624683 A CN117624683 A CN 117624683A
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Prior art keywords
resin
laminate
solvent
layer
meth
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CN202311102095.3A
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Chinese (zh)
Inventor
河野文彦
桥本尚树
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Nitto Denko Corp
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Nitto Denko Corp
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Priority claimed from JP2023125127A external-priority patent/JP2024035100A/en
Application filed by Nitto Denko Corp filed Critical Nitto Denko Corp
Publication of CN117624683A publication Critical patent/CN117624683A/en
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Abstract

The laminate of the present invention is a laminate in which a resin layer is laminated on at least one surface of a resin base material, and is characterized in that the resin layer is formed from a cured product of a solvent-free curable resin composition containing at least one of (meth) acrylamide and a derivative thereof. The method for producing a laminate according to the present invention is a method for producing a laminate comprising a resin base material and a resin layer, the method comprising a resin layer forming step of forming the resin layer on at least one surface of the resin base material, the resin layer forming step comprising: a coating step of coating a solvent-free curable resin composition on the resin substrate to form a coating layer; and a curing step of curing the coating layer, wherein the solvent-free curable resin composition contains at least one of (meth) acrylamide and a derivative thereof.

Description

Laminate, method for producing laminate, optical member, and image display device
Technical Field
The invention relates to a laminate, a method for manufacturing the laminate, an optical member, and an image display device.
Background
In order to prevent scratches on a screen, a resin layer may be formed on a surface of a resin base material in a laminate used in an image display device or the like (patent document 1).
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2008-221746
Disclosure of Invention
Problems to be solved by the invention
Here, in order to form the resin layer, a diluting solvent is generally mixed with a coating liquid for forming the resin layer, and the viscosity is adjusted so as to have proper fluidity.
On the other hand, in the case of the organic solvent, for example, the diluting solvent penetrates into the surface of the resin base material, and therefore, the resin base material and the resin layer are weakened when the resin layer is formed. The weak portion (hereinafter, also simply referred to as "weak layer") formed in this way lacks weather resistance, and therefore becomes a cause of lowering the adhesion between the resin base material and the resin layer.
Accordingly, an object of the present invention is to provide a laminate excellent in adhesion between a resin base material and a resin layer, a method for producing the laminate, an optical member, and an image display device.
Means for solving the problems
In order to achieve the above object, the laminate of the present invention is a laminate in which a resin layer is laminated on at least one surface of a resin base material, wherein the resin layer is formed of a cured product of a solvent-free curable resin composition,
The solvent-free curable resin composition comprises at least one of (meth) acrylamide and its derivatives,
the solvent-free curable resin composition contains substantially no solvent.
The method for producing a laminate of the present invention is a method for producing a laminate comprising a resin base material and a resin layer, characterized in that,
comprises a resin layer forming step of forming the resin layer on at least one surface of the resin base material,
the resin layer forming step includes:
a coating step of coating a solvent-free curable resin composition on the resin substrate to form a coating layer; and
a curing step of curing the coating layer,
the solvent-free curable resin composition contains at least one of (meth) acrylamide and a derivative thereof.
The optical member of the present invention is characterized by comprising the laminate of the present invention.
The image display device of the present invention is characterized by comprising the laminate of the present invention or the optical member of the present invention.
Effects of the invention
According to the present invention, a method for producing a laminate, an optical member, and an image display device, each of which has excellent adhesion between a resin base material and a resin layer, can be provided.
Drawings
Fig. 1 (a) and (b) are cross-sectional views illustrating the constitution of the laminate of the present invention.
Fig. 2 (a) and (b) are cross-sectional views illustrating another example of the structure of the laminate of the present invention.
Fig. 3 (a) and (b) are cross-sectional views illustrating still another example of the structure of the laminate of the present invention.
Symbol description
10. 10a, 10b, 10c, 10d, 10e laminate
11. Resin base material
12. Resin layer
13. Surface treatment layer
14. Adhesive bonding layer
Detailed Description
The present invention will be described in more detail by way of examples. However, the present invention is not limited by the following description.
In the present invention, "mass%" and "weight%" may be replaced with each other, and "part by mass" and "part by weight" may be replaced with each other, as long as they are not particularly limited.
In the present invention, "on" or "on" … may be in direct contact with the surface or the surface, or may be in a state in which another layer or the like is interposed therebetween.
In the present invention, the "adhesive bonding layer" refers to a layer formed by at least one of an adhesive and a binder. In the present invention, the "adhesive bonding layer" may be an "adhesive layer" formed by an adhesive, or a layer containing both an adhesive and an adhesive, as long as the adhesive bonding layer is not particularly limited. In the present invention, the adhesive and the binder may be collectively referred to as "adhesive binder". In general, the adhesive force or the adhesion force is sometimes called "adhesive agent" when the adherend is in a weak state (e.g., the adherend can be peeled off again), and the adhesive force or the adhesion force is sometimes called "adhesive agent" when the adherend is in a strong state (e.g., the adherend is impossible or extremely difficult to be peeled off again), so that the distinction is made. In the present invention, the adhesive and the binder are not clearly distinguished. In the present invention, the "adhesive force" and the "adhesive force" are not clearly distinguished.
In the laminate of the present invention, for example, the adhesion ratio in the checkerboard adhesion test between the resin substrate and the resin layer is measured in weather resistance in the ultraviolet region (peak wavelength: 380nm, irradiation intensity: 500W/m) 2 The irradiation time may be 240 hours and the temperature may be 63 ℃ or higher at 70%.
The laminate of the present invention may be, for example, a triacetyl cellulose substrate as the resin substrate.
The laminate of the present invention may have a scratch hardness (pencil method) of 2H or more at a load of 500g, and 4 or less scratches at a load of 400g in a steel wool abrasion test, for example, as described above.
The laminate of the present invention does not contain a compatible layer between the resin base material and the resin layer, for example, and the compatible layer is formed by mixing a component in which the resin base material is dissolved with a composition before curing of the resin layer.
In the laminate of the present invention, for example, the resin layer may be formed on one surface of the resin base material, and the adhesive layer may be formed on the other surface.
The method for producing a laminate of the present invention may include, for example, the solvent-free curable resin composition described above, and the monomer having a molecular weight of 60 to 800 g/mol.
In the method for producing a laminate of the present invention, the resin substrate may be a triacetyl cellulose substrate, for example.
The method for producing a laminate of the present invention may have a scratch hardness (pencil method) of 2H or more at a load of 500g and 4 or less at a load of 400g in a steel wool abrasion test, for example, on the resin layer.
The method for producing a laminate of the present invention is, for example, a weather resistance test (peak wavelength 380nm, irradiation intensity 500W/m) in the ultraviolet region of adhesion ratio in the checkerboard adhesion test between the resin substrate and the resin layer 2 The irradiation time may be 240 hours and the temperature may be 63 ℃ or higher at 70%.
The laminate produced by the method for producing a laminate of the present invention may be, for example, the laminate of the present invention.
The optical member of the present invention may be, for example, a hard coat film.
The optical member of the present invention may be, for example, a polarizing plate.
[1 ] laminate and method for producing laminate
Fig. 1 (a) is a cross-sectional view showing an example of the structure of a laminate of the present invention and a laminate produced by the production method of the present invention. As shown in the figure, the laminate 10 has a resin layer 12 directly laminated on one side of a resin base 11. Fig. 1 (b) is a cross-sectional view showing another example of the structure of the laminate of the present invention. As shown in the figure, the laminate 10a has resin layers 12 directly laminated on both surfaces of a resin base 11.
As shown in the laminate 10b of fig. 2 (a), a resin layer 12 is laminated on one surface of a resin base material 11 via a surface treatment layer 13. The laminate 10b is the same as the laminate 10 of fig. 1 (a), except that a surface treatment layer 13 is present between the resin base material 11 and the resin layer 12. The surface treatment layer 13 is a layer formed by corona treatment, adhesion-facilitating treatment, or the like. As shown in the laminate 10c of fig. 2 (b), resin layers 12 are laminated on both surfaces of a resin base material 11 via surface treatment layers 13. The laminate 10c is the same as the laminate 10a of fig. 1 (b), except that a surface treatment layer 13 is present between the resin base 11 and each resin layer 12. The surface treatment layer 13 is formed by corona treatment, adhesion-facilitating treatment, or the like, similarly to fig. 2 (a).
The laminate of the present invention and the laminate produced by the production method of the present invention may or may not contain other components than the resin base material, the resin layer, and the surface-treated layer. The other components are not particularly limited, and may be, for example, an adhesive layer. Fig. 3 shows an example of such a laminate of the present invention. The laminate 10d of fig. 3 (a) is the same as the laminate 10 of fig. 1 (a), except that the adhesive layer 14 is provided on the surface of the resin substrate 11 opposite to the resin layer 12 in direct contact therewith, as shown in the figure. As shown in the laminate 10e of fig. 3 (b), an adhesive layer 14 is provided on the surface of the resin layer 12 opposite to the resin base material 11 via a surface treatment layer 13. However, the present invention is not limited to this, and other components may be present between the adhesive layer 14 and the resin base 11 or the surface treatment layer 13, for example. The other components are not particularly limited, and may be, for example, an optical functional layer. The optical functional layer is not particularly limited, and may be an optical functional layer used in a general optical film, for example, a microlens film, a prism film, a diffusion film, a polarizing reflection film, a polarizing film, a retardation film, a high refractive index layer, or the like.
Examples of the resin base material in the present invention include polyester polymers such as polyethylene terephthalate and polyethylene naphthalate, cellulose polymers such as diacetyl cellulose and triacetyl cellulose, polycarbonate polymers, and acrylic polymers such as polymethyl methacrylate. Examples of the material for forming the resin base material include styrene polymers such as polystyrene and acrylonitrile-styrene copolymer, polyethylene, polypropylene, polyolefin having a cyclic or norbornene structure, olefin polymers such as ethylene-propylene copolymer, vinyl chloride polymers, amide polymers such as nylon and aromatic polyamide, and the like. Examples of the material for forming the resin base material include imide-based polymers, sulfone-based polymers, polyether ether ketone-based polymers, polyphenylene sulfide-based polymers, vinyl alcohol-based polymers, vinylidene chloride-based polymers, vinyl butyral-based polymers, aryl ester-based polymers, polyoxymethylene-based polymers, epoxy-based polymers, and blends of the above polymers. The resin base material may have light transmittance or may not have light transmittance.
Examples of the material for forming the resin base material in the present invention include polyethylene resin, polypropylene resin, cyclic polyolefin resin, polystyrene resin, acrylonitrile-styrene copolymer (AS resin), acrylonitrile-butadiene-styrene copolymer (ABS resin), polyvinyl chloride resin, fluorine resin, acrylic resin, polycarbonate resin, polyester resin, polyamide resin, polyimide resin, polyamideimide resin, polyarylene phthalate resin, silicone resin, polysulfone resin, polyphenylene sulfide resin, polyether sulfone resin, polyurethane, acetal resin, cellulose resin, and the like, and blends of the above-mentioned materials are also preferable from the viewpoint of high transmittance.
Examples of the cellulose resin include cellulose esters such as cellulose diacetate, cellulose triacetate (triacetyl cellulose), cellulose propionate, cellulose acetate propionate, and cellulose acetate butyrate; cellulose ethers such as methyl cellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, and carboxymethyl cellulose; nitrocellulose, and the like.
Examples of the acrylic resin include an alkyl methacrylate or an alkyl acrylate monomer, and an alkyl methacrylate-alkyl acrylate copolymer. Examples of the alkyl methacrylate include methyl methacrylate, ethyl methacrylate, and propyl methacrylate, and examples of the alkyl acrylate include methyl acrylate, ethyl acrylate, and propyl acrylate.
Examples of the cyclic olefin resin include norbornene resins.
The resin base material of the present invention may be, for example, a laminate including a plurality of types of resin base materials, or may be a resin base material in which a plurality of types of resins are mixed.
The resin substrate may be subjected to a surface treatment such as corona treatment or adhesion-facilitating treatment on at least one surface of the resin substrate. The surface treatment may be performed by, for example, providing a surface treatment step before the resin layer forming step, and may be performed simultaneously with the resin layer forming step in the same step.
The thickness of the resin base material is not particularly limited, but is preferably in the range of 10 to 500 μm, more preferably in the range of 20 to 300 μm, and most preferably in the range of 30 to 200 μm in view of handling properties such as strength and handling properties, and thin layer properties. When the resin base material has light transmittance, the refractive index is not particularly limited, and is, for example, in the range of 1.30 to 1.80 or 1.40 to 1.70.
The solvent-free curable resin composition of the present invention contains at least one of (meth) acrylamide and its derivatives. In the present specification, "a" (meth) acryl group "means" at least one of acryl group and methacryl group ". "(meth) acrylamide" means "at least one of acrylamide and methacrylamide". "(meth) acrylic" means "at least one of acrylic acid and methacrylic acid". "(meth) acrylate" means "at least one of acrylate and methacrylate".
The (meth) acrylamide and its derivative can improve the adhesion between the resin substrate and the resin layer after weather resistance test, for example. The (meth) acrylamide and its derivatives may or may not contain a cyclic structure, for example. In the present invention, the "(meth) acrylamide derivative" may be, for example, a compound in which at least one of the hydrogen atoms of the amino group in (meth) acrylamide is substituted with a substituent. The substituent may form a ring together with the nitrogen atom of the amino group. When the substituent includes a linear alkyl group or a branched alkyl group, the number of carbon atoms of the alkyl group may be, for example, 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, or 6 or more, and may be, for example, 18 or less, 16 or less, 14 or less, 12 or less, 10 or less, or 8 or less. The alkyl group may be substituted with 1 or more substituents or may be unsubstituted. Examples of the substituent include a hydroxyl group, an amino group, an alkoxy group, and a mercapto group, and when a plurality of substituents are used, they may be the same or different. When the substituent forms a ring together with the nitrogen atom of the amino group, the number of the membered ring may be, for example, 5, 6, 7, 8 or 9.
Examples of the (meth) acrylamide derivative include N-alkyl-containing (meth) acrylamide derivatives such as N-methyl (meth) acrylamide, N-dimethyl (meth) acrylamide, N-diethyl (meth) acrylamide, N-isopropyl (meth) acrylamide, N-butyl (meth) acrylamide, and N-hexyl (meth) acrylamide; n-hydroxyalkyl group-containing (meth) acrylamide derivatives such as N-methylol (meth) acrylamide, N-hydroxyethyl (meth) acrylamide, and N-methylol-N-propane (meth) acrylamide; n-aminoalkyl-containing (meth) acrylamide derivatives such as aminomethyl (meth) acrylamide and aminoethyl (meth) acrylamide; n-alkoxy group-containing (meth) acrylamide derivatives such as N-methoxymethacrylamide and N-ethoxymethacrylamide; and N-mercaptoalkyl-containing (meth) acrylamide derivatives such as mercaptomethyl (meth) acrylamide and mercaptoethyl (meth) acrylamide. Examples of the heterocyclic ring-containing (meth) acrylamide derivative in which the nitrogen atom of the (meth) acrylamide group forms a ring include N-acryloylmorpholine, N-acryloylpiperidine, N-methacryloylpiperidine, and N-acryloylpyrrolidine. The (meth) acrylamide and its derivative may be used, for example, in an amount of 1, or in an amount of two or more.
The solvent-free curable resin composition may contain at least one of (meth) acrylic acid and a derivative thereof, for example. Examples of the (meth) acrylic acid derivative include (meth) acrylic acid esters and (meth) acrylic acid salts. The (meth) acrylic acid and its derivatives may be used, for example, in an amount of 1, or in an amount of a plurality of them may be used.
Examples of the (meth) acrylic acid ester include linear or branched alkyl esters of (meth) acrylic acid. In the linear or branched alkyl ester of (meth) acrylic acid, the number of carbon atoms of the alkyl group may be, for example, 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, or 6 or more, and may be, for example, 18 or less, 16 or less, 14 or less, 12 or less, 10 or less, or 8 or less. The alkyl group may be substituted with 1 or more substituents or may be unsubstituted. Examples of the substituent include a hydroxyl group, and when a plurality of substituents are used, they may be the same or different.
The (meth) acrylate may be 1-functional or polyfunctional, for example. In the case of polyfunctional, the (meth) acrylate is, for example, 2 to 10 functional groups or 3 to 10 functional groups.
Examples of the (meth) acrylic acid ester include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, isooctyl (meth) acrylate, isodecyl (meth) acrylate, benzyl (meth) acrylate, phenyl (meth) acrylate, cyclohexyl (meth) acrylate, dicyclopentyl (meth) acrylate, dicyclopentadienyl (meth) acrylate, isobornyl (meth) acrylate, methoxycyclotriene (meth) acrylate, dicyclopentadienyloxy ethyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth) acrylate, 3-hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate, polyethylene glycol (meth) acrylate, alkylpolypropylene glycol (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, 2-hydroxy-3-phenoxypropyl (meth) acrylate, glycidyl (meth) acrylate, caprolactone (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, ethoxycarbonyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, 1-butanediol (meth) acrylate, and 1-butanediol (meth) acrylate Acrylonitrile butadiene methacrylate, dicyclopentadienyloxyethyl methacrylate, 1, 6-hexanediol di (meth) acrylate, 1, 9-nonanediol di (meth) acrylate, 1, 10-decanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, 2-hydroxy-3-methylpropenyl propyl (meth) acrylate, tripropylene glycol di (meth) acrylate, polydimethyl (meth) acrylate, tricyclodecanedimethanol di (meth) acrylate, ethoxylated bisphenol a di (meth) acrylate, trimethylol propane tri (meth) acrylate, ethoxylated trimethylol propane tri (meth) acrylate, glycerol tri (meth) acrylate, ethoxylated glycerol tri (meth) acrylate, bis- (2-acryloyloxyethyl) isocyanurate, tri (2-methacryloyloxyethyl) isocyanurate, pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, ditrimethylol propane tetra (meth) acrylate, dipentaerythritol di (meth) acrylate, ethoxylated di (meth) acrylate, pentaerythritol poly (meth) acrylate, and the like. For example, 1 kind of the (meth) acrylate may be used alone, or a plurality of kinds may be used in combination.
Examples of the (meth) acrylic acid salt include alkali metal salts, alkaline earth metal salts, and ammonium salts. Examples of the alkali metal salt include lithium salt, sodium salt, and potassium salt. Examples of the alkaline earth metal salt include magnesium salts, calcium salts, and barium salts. For example, 1 kind of the (meth) acrylic acid salt may be used alone, or a plurality of kinds may be used in combination.
The solvent-free curable resin composition may contain, for example, a monomer having a molecular weight of 60 to 800 g/mol. The monomer may be at least one selected from the group consisting of the (meth) acrylamide, the (meth) acrylic acid, and the (meth) acrylic acid ester, for example. The molecular weight may be, for example, 60g/mol or more, 70g/mol or more, 80g/mol or more, 90g/mol or more, 100g/mol or more, or 200g/mol or more, or 800g/mol or less, 700g/mol or less, 600g/mol or less, 500g/mol or less, 400g/mol or less, or 300g/mol or less. In order to reduce the viscosity of the solvent-free curable resin composition, the monomer is preferably the monomer of (meth) acrylamide.
The solvent-free curable resin composition in the present invention means a curable resin composition substantially free of solvent. That is, the curable resin composition substantially containing a solvent does not correspond to the solvent-free curable resin composition of the present invention. The solvent is not particularly limited, and is, for example, a diluting solvent such as an organic solvent, and specific examples thereof include solvents described below. The "curable resin composition substantially containing a solvent" is, for example, a resin composition in which an organic solvent or the like is added for dilution or the like, and the organic solvent or the like is dried by a heating step or the like, and then the resin is cured simultaneously with the drying. For example, the addition of a solvent to the solvent-free curable resin composition of the present invention corresponds to "a curable resin composition substantially containing a solvent". In the present invention, the term "substantially no solvent" means, for example, the solvent content in an amount determined as "OK" by the adhesion rate evaluation method described in examples below. In the present invention, the solvent-free curable resin composition is "substantially free of solvent", and preferably the solvent-free curable resin composition is completely free of solvent, but may contain a plurality of solvents. In the present invention, the solvent-free curable resin composition is "substantially free of solvent", and the content of the solvent contained in the solvent-free curable resin composition is 0% by weight relative to the weight of the entire solvent-free curable resin composition (that is, the solvent-free curable resin composition is completely free of solvent). The content of the solvent contained in the solvent-free curable resin composition exceeds 0 wt% based on the weight of the entire solvent-free curable resin composition, and the upper limit is less than 0.10 wt%, 0.08 wt% or less, or 0.07 wt% or less.
The solvent is, for example, water or an organic solvent, and does not contribute to the skeleton formation of the cured product. The curable resin composition of the present invention is, for example, a resin composition cured by polymerization by irradiation with light (ultraviolet rays or the like) or electron beams or the like. The organic solvent is not particularly limited, and examples thereof include general organic solvents used as a diluting solvent for the coating liquid, and examples thereof include alcohols such as methanol, ethanol, isopropyl alcohol (IPA), butanol, t-butanol (TBA), and 2-methoxyethanol; ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, cyclopentanone, and the like; esters such as methyl acetate, ethyl acetate, and butyl acetate; ethers such as diisopropyl ether and propylene glycol monomethyl ether; glycols such as ethylene glycol and propylene glycol; cellosolves such as ethyl cellosolve and butyl cellosolve; aliphatic hydrocarbons such as hexane, heptane, octane, etc.; aromatic hydrocarbons such as benzene, toluene and xylene. In addition, the above solvents may also include hydrocarbon solvents and ketone solvents, for example. The hydrocarbon solvent may be, for example, an aromatic hydrocarbon. The aromatic hydrocarbon may be at least one selected from toluene, o-xylene, m-xylene, p-xylene, ethylbenzene, and benzene, for example. The ketone solvent may be, for example, at least one selected from cyclopentanone, acetone, methyl ethyl ketone, methyl isobutyl ketone, diethyl ketone, cyclohexanone, isophorone, and diacetone. Thus, the method is applicable to a variety of applications. Since the resin composition of the present invention contains substantially no solvent (e.g., the diluent solvent), for example, when a resin substrate having a poor solvent resistance is used as the resin substrate, the resin composition can reduce the damage to the resin substrate or can inhibit the dissolution of the resin substrate. The solvent-resistant resin base material is not particularly limited, and examples thereof include cellulose polymers such as diacetyl cellulose and triacetyl cellulose, acrylic polymers such as polycarbonate polymers and polymethyl methacrylate.
The solvent-free curable resin composition of the present invention can reduce the amount of organic solvent used for adjusting the viscosity of the coating liquid. Therefore, CO can be reduced 2 Has effects in the aspect of (a). In addition, the use of the solvent-free curable resin composition has an effect of reducing the haze value of the laminate as compared with the case of using a solvent. Furthermore, even under the conditions after the weather resistance testThe invention can also ensure the adhesion.
In the laminate of the present invention, the adhesion ratio in the checkerboard adhesion test between the resin base material and the resin layer was as described above, and the weather resistance test in the ultraviolet region (peak wavelength: 380nm, irradiation intensity: 500W/m) 2 The irradiation time is 240 hours and the temperature is 63 ℃ and may be, for example, 70% or more, 75% or more, 80% or more, 85% or more, 90% or more, 95% or more, 96% or more, 97% or more, 98% or more, 99% or more, or 100%. The adhesion rate can be measured, for example, by the method described in examples described below.
In the present invention, the resin layer may have a scratch hardness (pencil method) of 2H or more under a load of 500g, and 4 or less scratches under a load of 400g in a steel wool abrasion test. The scratch hardness (pencil method) and the steel wool abrasion test can be performed, for example, by the method described in examples described below.
The thickness of the resin layer (hereinafter, sometimes simply referred to as "film thickness") of the present invention may be, for example, 0.5 μm or more, 1 μm or more, 1.5 μm or more, 2 μm or more, 2.5 μm or more, or 3 μm or more, and may be 30 μm or less, 20 μm or less, 15 μm or less, 10 μm or less, 8 μm or less, 7 μm or less, 6 μm or less, 5 μm or less, or 4 μm or less.
As described above, the laminate of the present invention may be formed without a compatible layer between the resin base material and the resin layer, for example, by mixing a component in which the resin base material is dissolved with a composition before curing of the resin layer. The compatible layer is formed, for example, by dissolving the resin base material with an organic solvent contained in a coating liquid before the formation of the resin layer, and mixing the dissolved component of the resin base material with the component of the coating liquid. Since the compatible layer is a fragile layer (fragile layer), for example, the weather resistance of a laminate having the compatible layer is deteriorated.
The total light transmittance of the laminate of the present invention may be, for example, 90% or more, 92% or more, or 95% or more, or 97% or less, 98% or less, or less than 100%, for example. The total light transmittance can be measured, for example, by the method described in examples below.
The haze value of the laminate of the present invention may be, for example, 0.35% or less, 0.3% or less, or 0.25% or less, or may be, for example, 0.1% or more, 0.15% or more, or 0.2% or more. The haze value can be measured, for example, by the method described in examples below.
As described above, the laminate of the present invention may be formed, for example, by forming the resin layer on one surface of the resin base material and forming the adhesive layer on the other surface. The pressure-sensitive adhesive or the adhesive for forming the pressure-sensitive adhesive layer is not particularly limited, and for example, a general pressure-sensitive adhesive or adhesive can be used. Examples of the adhesive or binder include polymer adhesives such as acrylic, vinyl alcohol, silicone, polyester, polyurethane, and polyether adhesives, and rubber adhesives. Further, an adhesive agent comprising a water-soluble crosslinking agent of a vinyl alcohol polymer such as glutaraldehyde, melamine, oxalic acid, and the like can be mentioned. Examples of the binder include the above binders. These binders and adhesives may be used in an amount of 1, or may be used in combination of plural types (for example, mixed, laminated, etc.). The thickness of the pressure-sensitive adhesive layer is not particularly limited, and is, for example, 0.1 to 100. Mu.m, 5 to 50. Mu.m, 10 to 30. Mu.m, or 12 to 25. Mu.m.
The method for producing a laminate of the present invention includes a resin layer forming step of forming a resin layer on at least one surface of the resin base material. The resin layer forming step may be, for example, to form the resin layer on only one surface of the resin base material.
The resin layer forming step of the method for producing a laminate of the present invention includes: a coating step of coating the solvent-free curable resin composition on the resin substrate to form a coating layer; and a curing step of curing the coating layer.
Examples of the coating step include coating methods such as a spray coating method, a die coating method, a spray coating method, a comma coating method, a gravure coating method, a roll coating method, and a bar coating method.
The curing step may be, for example, a curing step using light (ultraviolet ray)A wire, etc.), or an electron beam, etc. When the curing step is ultraviolet curing, the wavelength of ultraviolet light is, for example, 290 to 400nm, preferably 320 to 400nm, and more preferably 330 to 380nm. The irradiation time of the ultraviolet light is, for example, 1 to 10 minutes, preferably 1 to 5 minutes, and more preferably 1 to 3 minutes. The irradiation intensity of the ultraviolet light is, for example, 10 to 200mW/cm 2 Preferably 20 to 150mW/cm 2 Further preferably 30 to 160mW/cm 2 . The irradiation amount of the energy ray source is, for example, 50 to 500mJ/cm as the cumulative exposure amount at 365nm of ultraviolet wavelength 2 Preferably 100 to 450mJ/cm 2 Further preferably 150 to 400mJ/cm 2 . The irradiation amount is 50mJ/cm 2 In this case, the curing tends to be sufficiently performed, and the hardness of the formed resin layer tends to be high. In addition, if it is 500mJ/cm 2 The coloring of the resin layer to be formed can be prevented. In the case of electron beam curing, the amount of radiation is, for example, 5 to 50kGy, preferably 5 to 40kGy, since the resin base material is not deteriorated or colored. The acceleration voltage of the electron beam is 100 to 3000kV, preferably 150 to 300kV.
The coating step is to form a coating layer by forming the solvent-free curable resin composition on the resin substrate as described above. Therefore, the method for producing a laminate of the present invention may not include a drying step between the coating step and the curing step, for example. In the present invention, the drying step is, for example, a step of applying heat to the undried coated surface after the coating liquid is applied to the substrate to evaporate the diluting solvent contained in the coating liquid. Since the drying step is not included, that is, since the time for drying the diluent solvent can be reduced, the processing speed can be increased, for example, in the case of roll-to-roll processing. In particular, the effect is more effective than the case where drying time is further taken and water or the like is used as a diluting solvent.
The method for producing a laminate of the present invention may further include an adhesive layer forming step of forming the resin layer on one surface of the resin base material and forming the adhesive layer on the other surface. Specifically, the adhesive layer may be formed by, for example, applying (coating) an adhesive or an adhesive to the resin substrate. The adhesive layer may be formed on the resin substrate by bonding the adhesive layer side of an adhesive tape or the like having the adhesive layer laminated on the substrate to the resin substrate. In this case, the base material such as the pressure-sensitive adhesive tape may be directly bonded to or peeled from the pressure-sensitive adhesive layer.
The laminate of the present invention and the laminate produced by the production method of the present invention can be used as a protective film for a polarizing plate, for example. In this case, the resin substrate is preferably a film formed of triacetylcellulose, polycarbonate, acrylic resin, acrylic polymer, polyolefin having a cyclic or norbornene structure, or the like. In the present invention, the resin substrate may be a polarizer itself. In such a configuration, since the protective layer made of TAC or the like is not required and the structure of the polarizing plate can be simplified, the number of manufacturing steps of the polarizing plate or the image display device can be reduced, and the production efficiency can be improved. In addition, with such a configuration, the polarizing plate can be further thinned. In addition, when the resin base material is a polarizer, the resin layer functions as a protective layer in the past. In addition, with such a configuration, the laminate also functions as a cover plate attached to the surface of the liquid crystal cell.
[2 ] optical Member and image display device ]
The optical member of the present invention may be, for example, a hard coat film, and may be a polarizing plate. The polarizing plate includes, for example, the laminate of the present invention, in which a polarizer is disposed on a surface of the resin substrate opposite to the resin layer.
The image display device of the present invention may be any image display device, and examples thereof include a liquid crystal display device and an organic EL display device.
The use of the laminate of the present invention is not particularly limited, and the laminate can be used in any application. Examples of the applications thereof include OA devices such as computer displays, notebook computers, and copiers, portable devices such as cellular phones, watches, digital cameras, portable information terminals (PDAs), portable game devices, home appliances such as video recorders, televisions, and microwave ovens, in-vehicle devices such as rear-view monitors, display screens for car navigation systems, and car audio, display devices such as information display screens for commercial stores, police devices such as monitor display screens, care display screens, and care-medical devices such as medical display screens.
Examples
Next, an embodiment of the present invention will be described. However, the present invention is not limited to the following examples.
In the following reference examples, examples and comparative examples, the parts (relative amounts) of the respective substances are parts by mass (parts by weight) unless otherwise specified.
In the examples and comparative examples below, the film thickness, total light transmittance, haze value, scratch hardness (pencil method), scratch resistance, and adhesion were evaluated by the following methods, respectively.
< film thickness >
The specular reflectance spectrum of the hard coat surface was measured by a reflectance spectrometer (FE-300 Otsuka electronics Co., ltd.). Using the actual measurement value of the specular reflectance and a theoretical formula, the film thickness is calculated by a least square method using the film thickness as a fitting parameter.
< total light transmittance, haze value >
Test pieces (5 cm. Times.5 cm) of a resin substrate provided with a resin layer were prepared, and the total light transmittance and haze were measured. The total light transmittance and haze were measured according to JIS K7361 and JIS K7136, respectively, using a haze meter (device name; HM-150, manufactured by color technology research Co., ltd.).
< scratch hardness (pencil method) >)
According to JIS K5600-5-4. The pencil of various hardness was brought into contact with the surface of the resin layer at an angle of 45 degrees, and a scratch test was performed by applying a load, and the hardness of the hardest pencil that did not cause a scratch was taken as the scratch hardness.
< scratch resistance >
Test pieces (5 cm. Times.5 cm) of a resin base material provided with a resin layer were prepared, and the surface on which the resin layer was not formed was placed on a glass plate with the surface facing downward. Steel wool #0000 was uniformly placed on a smooth cross section of a cylinder having a diameter of 25mm, and after going back and forth 10 times at a speed of about 100mm per second under a load of 400g, the number of flaws engraved into the surface of the sample was visually calculated, and the judgment was made using the following index.
Scratch resistance evaluation criterion
OK: the number of the flaws is below 4
NG: the number of the flaws is more than 5
< adhesion Rate >
The following checkerboard adhesion test was performed, and the adhesion before (initial) the weather resistance test was calculated. After the weather resistance test described below, the following checkerboard adhesion test was performed, and the adhesion after the weather resistance test was calculated. The determination was performed using the following index.
(checkerboard adhesion test)
Test pieces (5 cm. Times.5 cm) of a resin substrate provided with a resin layer were prepared, and a checkerboard adhesion test was performed. The tessellation adhesion test was carried out by preparing 100 tessellation pieces by the tessellation tape method of the old JIS K5400, adhering a transparent tape to the surface thereof, counting the number of residues of the peeled resin layer, and calculating the adhesion rate from the ratio of the residues of the tessellation pieces.
Adhesion evaluation criterion
OK: the adhesion after the initial weather resistance test was 100%
NG: the adhesion after the initial and weather resistance tests is less than 100%
(weather resistance test)
A test piece (5 cm. Times.5 cm) of a resin substrate provided with a resin layer was prepared, and for an ultraviolet fading meter (device name; U48, manufactured by Sugatest Co., ltd.) the temperature of the black panel was set to 63℃and ultraviolet rays having a peak of spectral illuminance at a wavelength of 380nm (irradiation intensity was set to 500W/m) 2 ) 240 hours.
Example 1
A triacetyl cellulose base material (thickness: 40 μm, manufactured by Fuji FILM Co., ltd.) was prepared, and the above triacetyl cellulose was preparedThe coating solution was applied to one surface of the cellulose substrate, and ultraviolet irradiation was directly performed without putting the substrate into a hot oven (the cumulative light amount was 300 mJ/cm) 2 ) To 100 parts of a solvent-free curable resin composition comprising an ultraviolet curable resin monomer (manufactured by KJ Chemicals Co., ltd., "Viscoat # 300") containing N, N-dimethylacrylamide as a main component, and 3 parts of a photopolymerization initiator (Omnirad 127) mixed with an ultraviolet curable resin monomer (manufactured by Osaka organic chemical Co., ltd.) as a main component, a coating solution of example 1 having a resin layer on a triacetyl cellulose substrate surface was prepared by curing the coating film.
Example 2
The procedure of example 1 was repeated except that N, N-dimethylacrylamide was changed to N-acryloylmorpholine (KJ Chemicals Co., ltd.) as the coating liquid.
Comparative example 1
The procedure of example 1 was repeated except that N, N-dimethylacrylamide was changed to 1, 6-hexanediol diacrylate (Viscoat #230 manufactured by Osaka organic chemical Co., ltd.) as a coating liquid.
Comparative example 2
As a coating solution, 5 parts of a photopolymerization initiator (Omnirad 127) and 0.01 part of a leveling agent (DIC Co., ltd., product name "GRANDIC PC 4100") were added to 100 parts of a solid content of an ultraviolet curable resin composition (trade name "LUXYDIR 17-806", 80% solid content concentration) containing urethane acrylate as a main component. Then, cyclopentanone (hereinafter, "CPN") and propylene glycol monomethyl ether (hereinafter, "PGME") were added to the solution so that the solid content concentration in the solution became 36%, and the coating solution was adjusted. The composition was applied to one surface of the above triacetyl cellulose substrate, and dried at 80℃for 2 minutes, and subjected to ultraviolet irradiation (cumulative light amount: 300 mJ/cm) 2 ) The coating film was cured to form a resin layer of 7 μm, thereby producing a laminate of comparative example 2 having a triacetyl cellulose base material and a hard coat layer.
For each laminate of examples and comparative examples thus obtained, various characteristics were measured or evaluated. The results are shown in table 1 below. In all of examples and comparative examples, the curability of the resin composition was not a problem.
As shown in table 1, the adhesive ratios after the initial and weather resistance tests of examples 1 and 2 using the solvent-free curable resin composition containing at least one of (meth) acrylamide and its derivative were all 100%, and were good. Further, the total light transmittance and haze were maintained as the same as those in the case where the acrylic acid ester used in general was contained as the reactive diluent (comparative example 1) or the case where the solvent-type curable resin was used (comparative example 2).
When the film thickness was large, the adhesion rate generally tended to be low, and as shown in example 1, even when the film thickness was made 7 μm, the adhesion was good while maintaining high scratch hardness and scratch resistance. In addition, when the film thickness is thin, scratch hardness and scratch resistance generally tend to be low, but as shown in example 2, even if the film thickness is made 3 μm, high scratch hardness and scratch resistance are maintained while maintaining adhesion.
The laminate of comparative example 1, which did not use the solvent-free curable resin composition containing at least one of (meth) acrylamide and its derivative, had poor initial adhesion. In addition, the laminate of comparative example 2 was poor in adhesion after weather resistance test.
< remarks >
Some or all of the above embodiments and examples may be described as noted below, but are not limited to the following.
(remark 1)
A laminate comprising a resin layer laminated on at least one surface of a resin base material,
it is characterized in that the method comprises the steps of,
the resin layer is formed from a cured product of a solvent-free curable resin composition,
the solvent-free curable resin composition comprises at least one of (meth) acrylamide and its derivatives,
the solvent-free curable resin composition contains substantially no solvent.
(remark 2)
The laminate of note 1, wherein the adhesion ratio of the checkerboard adhesion test between the resin substrate and the resin layer was measured in the weather resistance test in the ultraviolet region (peak wavelength: 380nm, irradiation intensity: 500W/m 2 The irradiation time was 240 hours and the temperature was 63 ℃ at 70% or more.
(remark 3)
The laminate of remarks 1 or 2, wherein the resin substrate is a triacetyl cellulose substrate.
(remark 4)
The laminate according to any one of remarks 1 to 3, wherein the resin layer has a scratch hardness (pencil method) of 2H or more under a load of 500g and 4 or less scratches under a load of 400g in a steel wool abrasion test.
(remark 5)
The laminate according to any one of remarks 1 to 4, wherein a compatible layer is not contained between the resin base material and the resin layer, and the compatible layer is formed by mixing a component in which the resin base material is dissolved with a composition before curing of the resin layer.
(remark 6)
The laminate according to any one of notes 1 to 5, wherein the resin layer is formed on one surface of the resin base material, and an adhesive layer is formed on the other surface.
(remark 7)
The laminate according to any one of remarks 1 to 6, wherein the solvent content of the solvent-free curable resin composition is 0 wt% or more and less than 0.10 wt% based on the weight of the entire solvent-free curable resin composition.
(remark 8)
A method for producing a laminate comprising a resin substrate and a resin layer, characterized by comprising a resin layer forming step of forming the resin layer on at least one surface of the resin substrate,
the resin layer forming step includes:
a coating step of coating a solvent-free curable resin composition on the resin substrate to form a coating layer; and
a curing step of curing the coating layer,
The solvent-free curable resin composition contains at least one of (meth) acrylamide and a derivative thereof.
(remark 9)
The method for producing a laminate according to item 8, wherein the solvent-free curable resin composition comprises a monomer having a molecular weight of 60 to 800 g/mol.
(remark 10)
The method for producing a laminate of remarks 8 or 9, wherein the resin substrate is a triacetyl cellulose substrate.
(remark 11)
The method for producing a laminate according to any one of remarks 8 to 10, wherein the resin layer has a scratch hardness (pencil method) of 2H or more under a load of 500g and 4 or less scratches under a load of 400g in a steel wool abrasion test.
(remark 12)
The method for producing a laminate according to any one of notes 8 to 11, wherein the adhesion ratio of the checkered adhesion test between the resin base material and the resin layer is measured in the ultraviolet region by the weather resistance test (peak wavelength: 380nm, irradiation intensity: 500W/m) 2 The irradiation time was 240 hours and the temperature was 63 ℃ at 70% or more.
(remark 13)
The method for producing a laminate according to any one of notes 8 to 12, wherein the laminate produced is the laminate according to any one of notes 1 to 7.
(remark 14)
An optical member comprising the laminate of any one of notes 1 to 7.
(remark 15)
The optical member of note 14, which is a hard coat film.
(remark 16)
The optical member of note 14, which is a polarizing plate.
(remark 17)
An image display device comprising the laminate of any one of remarks 1 to 7, or the optical member of any one of remarks 14 to 16.
The present invention has been described above with reference to the embodiments, but the present invention is not limited to the above embodiments. The constitution or details of the present invention may be variously changed within the scope of the present invention as will be understood by those skilled in the art. Further, each embodiment may be combined with other embodiments as appropriate.
Industrial applicability
As described above, the present invention can provide a method for producing a laminate, an optical member, and an image display device, which are excellent in adhesion between a resin base material and a resin layer even under conditions after a weather resistance test, for example. The application of the present invention is not particularly limited. Further, the use of the laminate of the present invention is not limited to the optical member and the image display device of the present invention, and can be used in a wide variety of applications.
The present application claims priority based on japanese patent application publication nos. 2022-137599, 31 at 2022, 8 and 2023-125127, 31 at 2023, 7, and the disclosure is incorporated herein in its entirety.

Claims (17)

1. A laminate comprising a resin layer laminated on at least one surface of a resin base material, characterized in that,
the resin layer is formed from a cured product of a solvent-free curable resin composition,
the solvent-free curable resin composition comprises at least one of (meth) acrylamide and its derivatives,
the solvent-free curable resin composition is substantially free of solvent.
2. The laminate according to claim 1, wherein the resin substrate has a bonding ratio in the ultraviolet region in a weather resistance test (peak wavelength of 380nm, irradiation intensity of 500W/m 2 The irradiation time was 240 hours and the temperature was 63 ℃ at 70% or more.
3. The laminate according to claim 1 or 2, wherein the resin substrate is a triacetyl cellulose substrate.
4. The laminate according to claim 1 or 2, wherein the resin layer has a scratch hardness (pencil method) of 2H or more under a load of 500g and 4 or less under a load of 400g in a steel wool abrasion test.
5. The laminate according to claim 1 or 2, wherein a compatible layer formed by mixing a component in which the resin base material is dissolved with a composition before curing of the resin layer is not contained between the resin base material and the resin layer.
6. The laminate according to claim 1 or 2, wherein the resin layer is formed on one surface of the resin base material, and an adhesive layer is formed on the other surface.
7. The laminate according to claim 1 or 2, wherein the solvent-free curable resin composition contains a solvent in an amount of 0 wt% or more and less than 0.10 wt% based on the weight of the entire solvent-free curable resin composition.
8. A method for producing a laminate comprising a resin substrate and a resin layer, characterized by comprising a resin layer forming step of forming the resin layer on at least one surface of the resin substrate,
the resin layer forming step includes:
a coating step of coating the resin substrate with a solvent-free curable resin composition to form a coating layer; and
a curing step of curing the coating layer,
The solvent-free curable resin composition includes at least one of (meth) acrylamide and a derivative thereof.
9. The method for producing a laminate according to claim 8, wherein the solvent-free curable resin composition comprises a monomer having a molecular weight of 60 to 800 g/mol.
10. The method for producing a laminate according to claim 8 or 9, wherein the resin substrate is a triacetyl cellulose substrate.
11. The method for producing a laminate according to claim 8 or 9, wherein the resin layer has a scratch hardness (pencil method) of 2H or more under a load of 500g and 4 or less scratches under a load of 400g in a steel wool abrasion test.
12. The method for producing a laminate according to claim 8 or 9, wherein the resin substrate and the resin layer have a bonding ratio in the checkerboard adhesion test in the ultraviolet region (peak wavelength of 380nm, irradiation intensity of 500W/m 2 The irradiation time was 240 hours and the temperature was 63 ℃ at 70% or more.
13. The method for producing a laminate according to claim 8 or 9, wherein the produced laminate is the laminate according to claim 1 or 2.
14. An optical member comprising the laminate of claim 1.
15. The optical member according to claim 14, which is a hard coat film.
16. The optical member of claim 14 which is a polarizing plate.
17. An image display device comprising the laminate according to claim 1 or 2, or the optical member according to any one of claims 14 to 16.
CN202311102095.3A 2022-08-31 2023-08-30 Laminate, method for producing laminate, optical member, and image display device Pending CN117624683A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2022-137599 2022-08-31
JP2023-125127 2023-07-31
JP2023125127A JP2024035100A (en) 2022-08-31 2023-07-31 Laminate, method for manufacturing the laminate, optical member, and image display device

Publications (1)

Publication Number Publication Date
CN117624683A true CN117624683A (en) 2024-03-01

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Country Link
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