CN1721882A - Optical coating film - Google Patents

Abstract

The invention relates to an optically used film which uses a double-axis orientation polyester film with the thickness of more than 50 Mu m as the substrate. A gumminess modified resin layer is arranged on at least on surface of the substrate. The resin component of the gumminess modified resin layer is mainly composed of at least one of copolymerization polyester resin, polyurethane resin and acrylate-based resin. The invention is characterized in that the substrate of the film actually contains no particles. The particles are only contained in the gumminess modified resin layer. And total defects existing on the surface of the film of more than 1 Mu m in depth and more than 3mm in length are below 100/m<2>.

Description

Optical coated film

The present invention is denomination of invention the dividing an application for No. 01140238.5 application for a patent for invention of " optical coated film " of Dec 07 calendar year 2001 application.

Technical field

The present invention relates to the optical coated film that biaxially oriented thermoplastic resin film is a base material.

Background technology

The biaxially oriented thermoplastic resin film of polyester etc. is because have the good transparency, dimensional stability, resistance to chemical reagents, so be widely used for making the various optical films of light transmission or reflective condition application.Particularly in the purposes of the near-infrared absorption film used with the breakage-proof panel that shows with transparent and electrically conductive film, plasma with basement membrane, touch screen and electroluminescence on basement membrane, the cathode ray tube (CRT) with basement membrane, diffuser plate with basement membrane, antireflection (AR) of the basement membrane used of the prism lens board of LCD (LCD) usefulness, hard conating and electro-magnetic wave absorption film etc., owing to require good intensity, dimensional stability, use thicker film always.

These optical films are required to have the good transparency and add the cohesive of man-hour and these resin beds in the processing of rib lens, hard conating processing, antireflection good, and then wish existing optical defect minimizing as far as possible in the film.

Usually, the mar-resistance for the operability of improving film (easily sliding, coiling, anti-sticking property etc.) and film makes and contains particle in the film, forms concavo-convex on the surface of film.Because the difference of the refractive index of general particle and polyester hole bigger and that form around particle when stretched film makes the transparency of film reduce.

Therefore, in order to obtain high hyaline membrane, when the particle amount in the minimizing base material, though the transparency is improved, the defective of optics is more outstanding.

Biaxial oriented polyester film in the past particularly, general, with other material, for example acrylic resin is the prism lens jacket of main composition and the poor adhesion of hard conating.

In addition, the fault of membrane surface is one of optical defect reason that constitutes film.When there is small fault on the surface of base material, as when making lens board, because lens jacket enlarges the fault of substrate surface, the defective of optics appears sometimes on the display part of liquid crystal pictorial display.

Control the technology that these faults produce, in the open communique of No. 183201/1997 patent of invention of Japan, disclose, make the fault that length 20mm is above and depth capacity 0.5 μ m is above to be controlled at 10/m by surfactant being arranged on the film surface ²Following polyester is an optical film.It is difficult that the more small fault of this technology control produces, and it can not satisfy the nearest level that requires to optical film.

Summary of the invention

The present invention in view of the above-mentioned problems, the optical coated film that provides optical defect few is provided its main purpose.And then provide the transparency and all good optical coated film of cohesive.

Present inventors have carried out research with keen determination to achieve the above object, found that to make below the particular value at the fault number of the lip-deep specific modality of basement membrane, can reduce the method for optical defect effectively, thereby finish the present invention.

Promptly, optical coated film of the present invention, be as base material with the transparent biaxially oriented thermoplastic resin film more than the thickness 50 μ m, at least one mask of above-mentioned base material have cohesive modified resin layer by overlay film, it is characterized in that above-mentioned by more than the 1 μ m of the degree of depth on the surface of overlay film and the fault number more than the length 3mm at 100/m ²Below.

Above-mentioned by the fault number on the surface of overlay film, be need be on the general optical applications at 100/m ²Below.For example by the fault number on the surface of overlay film at 100/m ²After following degree was meant that diffuser plate is scattered with the light of film, thinking on the observed purposes can not be as the degree of optical defect.In addition, liquid crystal diaphragm, general hard coating film, prevent the light that sees through of reflectance coating, near-infrared absorption film etc., above-mentioned by the surface-defect number of overlay film in the A of Direct observation level optical applications, preferably do not influence 30/m of visual degree ²Below.And then the touch screen that the lens coating of the extended projection of fault on film surface and surperficial hard conating, inner face are provided with nesa coating is with 10/m preferably in the special A level optical applications of transparent and electrically conductive film etc. ²Below.

If the number of such size fault is when surpassing above-mentioned scope, and optical defect increases, and the quality of using as blooming descends widely.In addition, said " by the overlay film surface " comprised above-mentioned modification aspect that is provided with and the face that modified layer is not set.

Above-mentioned fault, preferably the number in longitudinal direction fault and/or transverse direction fault is respectively 50/m ²Below.More preferably the fault in all directions is 30/m ²Below, 10/m most preferably ²Below.

Wherein, said vertical fault is meant its longest direction off-set optical lining vertically ± 45 spending with interior fault with film.Direction of travel when optical coated film is made is spent with interior fault with close wind direction skew ± 45 when just referring to make this film as vertically.Said horizontal fault is that it refers to the longest direction and the optics lining Width of film, and vertical coiling direction skew ± 45 degree are with interior fault when promptly referring to make this film.

Among the present invention, said fault is the fine recess and/or the protuberance on optical coated film surface, comprises the projection state.In addition, when the vertical direction viewing optics was used by overlay film, close 50 μ m concavo-convex thought a fault, will cover the rectangular length of outermost minimum area of these faults and width as the length of fault and wide.But, even with the naked eye judge when being one, and also leave sometimes during with microscopic examination, so the definition more than the length of fault and width done.In addition, the said fault degree of depth is meant the depth capacity from optical coated face along thickness direction, because of this fault when film surface produces protuberance, be meant from the top of protrusion to the depth capacity of bottom.

And then the preferred embodiment of optical coated film of the present invention is below 1.0% by the haze value of overlay film.More preferably below 0.8%, particularly preferably be below 0.6%.Haze value surpasses at 1.0% o'clock, and when using as component parts with optical coated film of the present invention, the vividness of image descends easily.

In addition, the preferred embodiment of optical coated film of the present invention is not contain particle in the base material in fact, and the mean grain size that contains 0.1～60 quality % in the cohesive modified resin layer is the particle of 0.005～1.0 μ m.More preferably the particle that contains in the cohesive modified resin layer is a monox.

In addition, the preferred embodiment of optical coated film of the present invention, its base material is by polyethylene terephthalate and/or poly-2,6-naphthoic acid glycol ester, in the above-mentioned polyester, contain 40～70ppm magnesium compound and 10～55ppm phosphorus compound, and the fusion of polyester is 0.10～0.45 * 10 than resistance ⁸Ω cm.

In addition, the preferred embodiment of optical coated film of the present invention, the cohesive modified resin layer of above-mentioned optical coated film is select from copolyester, polyurethane series resin, acrylic resin at least a.

Below explain the present invention.

(base material)

Base material used in the present invention on intensity, dimensional stability, so long as the above biaxially oriented thermoplastic resin film of thickness 50 μ m is just passable, does not have special restriction for the thermoplastic resin lipid species of this formation material.The higher limit of base material thickness has no particular limits, but sees it is 300 μ m from application with as the specification aspect of optics.

Above-mentioned thermoplastic resin, from the transparency, dimensional stability, resistance to chemical reagents polyester preferably, can enumerate polyethylene terephthalate, polybutylene terephthalate, poly-2,6-naphthoic acid glycol ester or be the multipolymer of main composition with the polymkeric substance composition that these resin constitutes, in these, specially suitable is polyethylene terephthalate (PET) and/or poly-2,6-naphthoic acid glycol ester (PEN).

Constituent material as base material uses vibrin, when using above-mentioned multipolymer as its composition, can enumerate aliphatic dicarboxylic acid, terephthalic acids, isophthalic acid, the phthalic acid and 2 of hexane diacid, decanedioic acid etc. as its dicarboxylic acid composition, the multi-functional carboxylic acid of the aromatic dicarboxylic acid of 6-two naphthoic acids etc., o-hydroxy propionic acid and Pyromellitic Acid etc., can enumerate ethylene glycol, diglycol, 1, the aliphatic diol of 4-butylene glycol, propylene glycol and neopentyl glycol etc. as the glycol composition; The aromatic diol of P-xylene glycol etc.; The aliphatic diol of 1,4 cyclohexane dimethanol etc.; The polyglycol of mean molecular weight 150～20000 etc.

Constituent material as base material uses vibrin, and when using above-mentioned multipolymer as its composition, the ratio of the multipolymer in the whole polyester resin is preferably below the 20 quality %.The ratio of multipolymer, when surpassing 20 quality %, then the intensity of base material, the transparency, thermotolerance descend easily.

When using vibrin as the constituent material of base material, the intrinsic viscosity of the resin particle that vibrin is used is 0.45～0.70dl/g preferably.When intrinsic viscosity was lower than 0.45dl/g, the resistance to tearing of base material film was insufficient, was easy to generate fracture when film is made.When intrinsic viscosity was greater than 0.70dl/g on the other hand, the filter during filtration under the molten condition pressed liter, is difficult to carry out high-precision filtration.

In addition, in polyester, contain 40～70ppm magnesium compound and 10～55ppm phosphorus compound, and the fusion of polyester is 0.10～0.45 * 10 than resistance ⁸Ω cm for keeping the static adaptation, prevents simultaneously because the separating out of impurity that magnesium atom and phosphorus atoms cause is desirable.When particularly impurity is separated out, form thick projection on the surface of film and become the reason that fault produces, this is unfavorable.

Thermoplastic resin as constituting sill as required, also can add various adjuvants in the scope that does not influence effect of the present invention.Can enumerate antistatic agent, UV absorbing agent, stabilizing agent etc. as adjuvant.

The base material that is used for optical coated film of the present invention for the amount that improves transparent preferably particle is few, does not more preferably contain particle in fact.Said " not containing particle in fact " is meant that the amount of the main composition that constitutes substrate particle is below the limit of fluorescent x-ray detection.When keeping the operability and scratch-resistant of base material, can improve the transparency again, can in base material, not contain particle in fact by for example, just the method that contains particle at cohesive modified resin layer reaches.

And then preferably inner to contain impurity few for employed base material among the present invention.In order not contain impurity, can enumerate when base material film is shaped the method for under molten condition, filtering.When there is impurity in base material inside, in the cooling procedure that base material film is made, around this impurity, be easy to generate crystallization, in resin stretched operation, cause the unevenness of stretching and produce small difference in thickness, then become lens state near it easily.When becoming lens state, light produces refraction or scattering in this part, when with the naked eye visual, can see also greatlyyer than the impurity of reality, becomes the figure image patch easily.

(cohesive modified resin)

The cohesive modified resin of optical coated film of the present invention, preferably from copolyester, polyurethane, acrylic resin, select at least a be main to constitute.

The employed copolyester of cohesive modified resin is a resin, has no particular limits, and can use known in the past.

Above-mentioned copolyester is the dicarboxylic acid composition of resin, can enumerate terephthalic acid (TPA), m-phthalic acid, 2,5-dimethyl terephthalic acid, 1,4-naphthalenedicarboxylic acid, 2,6-naphthalene dicarboxylic acids, 1,2-biphenylyloxy ethane-p, p '-dicarboxylic acid, hexane diacid, fumaric acid, decanedioic acid, dodecanedioic acid and form the derivant of these esters.

Above-mentioned copolyester is the glycol composition of resin, can enumerate ethylene glycol, 1, ammediol, 1,4-butylene glycol, neopentyl glycol, diglycol, 1,4-cyclohexane diol, trimethylolpropane, tristane dihydroxymethyl etc.

In the film of the present invention, when forming cohesive modified resin, be to be dissolved in cohesive modified resin in the water or the state in the water of being dispersed in applies dry method when film is made, be said streamline coating method, this method is seen it is preferred for what obtain the wide width of cloth, thin thickness on the productivity of overlay film.So it is preferably water-soluble or water dispersible that above-mentioned copolyester is a resin.For example, obtain by containing carboxylic acid hydroxyl compound and/or the copolymerization of sulfonic acid hydroxyl compound.

As containing above-mentioned carboxylic acid hydroxyl compound, have no particular limits, can enumerate trimellitic acid, trimellitic anhydride, pyromellitic acid, the pyromellitic acid acid anhydride, 4-methylcyclohexene-1,2, the 3-tricarboxylic acids, trimesic acid, 1,2,3, the 4-BTCA, 1,2,3,4 ,-pentane tetrabasic carboxylic acid, 3,3 ', 4,4 '-benzophenone tetrabasic carboxylic acid, 5, (2,5-dioxo four furfuran methyl)-3-methyl-3-cyclohexene-1, the 2-dicarboxylic acid, 5-(2,5-dioxo four furfuran methyl-3-cyclohexene-1, the 2-dicarboxylic acid, the cyclopentane tetrabasic carboxylic acid, 2,3,6, the 7-naphthalene tetracarboxylic acid, 1,2,5, the 6-naphthalene tetracarboxylic acid, the acid of ethylene glycol bisthioglycolate polyester, 2,2 ', 3,3 '-xenyl tetrabasic carboxylic acid, thiophene-2,3,4, the 5-tetrabasic carboxylic acid, ethylidene tetrabasic carboxylic acid etc. or these alkali metal salt, alkali earth metal salt ammonium salt etc.

As containing above-mentioned sulfonic acid hydroxyl compound, have no particular limits, can enumerate sulfo group terephthalic acid (TPA), 5-sulfoisophthalic acid, 4-sulfoisophthalic acid, 4-sulfo group naphthalene-2,7-dicarboxylic acid, sulfo group-to xylylene glycol, 2-sulfo group-1, two (hydroxyl-oxethyl) benzene of 4-etc. or these alkali metal salt, alkali earth metal salt, ammonium salt etc.

Constitute the dicarboxylic acid composition and the glycol composition of above-mentioned copolymer polyester resin or be used for the compound of copolymerization, also can distinguish and with two or more.

In addition, as above-mentioned copolymer polyester resin for example can use with the compound with (methyl) acrylic acid, amino-formate bond, contain modification such as epoxy compounds the modified poly ester based copolymerized resin etc. of segmented copolymer, graft copolymer etc.

Particularly, in the hydrophobicity copolymer polyester resin, the polyester that grafting has the self-crosslinking of a kind of two key acid anhydride at least is a graft copolymer, the cohesive as the acryl resin of hard conating composition for prism lens jacket and hard coating film is very good, and, have excellent water-resistance, even under the environment of high humility, also can use.

The polyurethane series resin that is used for cohesive modified resin can be any of solvent solubility, water-soluble, water dispersible, can select aptly according to require rerum natura, the manufacture method of cohesive modified resin.In the operation of making base material film, can apply the coating liquid that contains cohesive modified resin, and dry, then stretch in the direction of an axle at least, when forming cohesive modified resin, preferably use the polyurethane series resin of water-soluble or water dispersible with the streamline coating.

Can enumerate with carboxylic acid hydroxyl, sulfonic acid hydroxyl, sulfate hemiester hydroxyl etc. as above-mentioned polyurethane series resin and to have improved polyurethane series resin the water affinity.

Above-mentioned polyurethane series resin synthesizes used poly hydroxyl compound, can enumerate for example polyglycol, polypropylene glycol, tygon, polypropylene glycol, poly-four propylene glycol, hexanediol, butylene glycol, 1,5-pentanediol, diglycol, triethylene glycol, polycaprolactone, polyhexamethylene adipate, polyhexamethylene sebacate, trimethylolpropane, trimethylolethane, pentaerythrite, glycerine etc.

Above-mentioned polyurethane series resin synthesizes used polyisocyanate compounds, can enumerate the addition product of hexamethylene diisocyanate, methyl diphenylene diisocyanate, inferior cresyl vulcabond, isophorone diisocyanate, methylene phenyl isocyanate and trimethylolethane etc.

Above-mentioned polyurethane series resin synthesizes the used polyol that contains carboxylic acid, can enumerate, for example dihydromethyl propionic acid, dimethylolpropionic acid, dihydroxymethyl valeric acid, trimellitic acid two (glycol ester) etc.

The carboxylic acid that contains amino that above-mentioned polyurethane series resin is synthetic used can be enumerated Beta-alanine, gamma-hydroxybutyric acid, P-(2-hydroxyethyl) benzoic acid, malic acid etc.

Synthetic used amino or hydroxyl and the sulfonic carboxylic acid compound of containing of above-mentioned polyurethane series resin, can enumerate propane sultone, butane sultone addition product of NSC 209983,2-amino-ethyl sulfonic acid, 2-amino-5-methylbenzene-2-sulfonic acid, beta-hydroxy ethyl sulfonic acid sodium, aliphatics di-primary amine compound etc., preferably the propane sultone addition product of aliphatics di-primary amine compound.

Above-mentioned polyurethane series resin synthesizes the used compound that contains amino or hydroxyl and sulfate hemiester, can enumerate ethylaminoethanol sulfuric acid, amino butanol sulfuric acid, hydroxyl ethanol sulfuric acid, Alpha-hydroxy butanols sulfuric acid etc.

Above-mentioned polyurethane series resin synthesizes used composition or compound, can be also with two or more.

And then, as above-mentioned polyurethane series resin, can enumerate Japan No. 24194/1967, No. 7720/1971, No. 10193/1971 and No. 37839/1974 patent of invention bulletin communique, Japan No. 123197/1975, No. 126058/1978 and No. 138098/1979 patent disclosure communique etc. are gone up the known polyurethane series resin with anion base or are the polyurethane series resin of benchmark with these.

The main composition composition of above-mentioned polyurethane series resin is polyisocyanate, polyvalent alcohol, chain elongation agent, crosslinking chemical etc.In addition, preferably by polyvalent alcohol, the polyisocyanate of molecular weight 300～20000, have hydrogen atoms the chain elongation agent, and and the base of isocyanate reaction, and have the resin that the compound of 1 anionic property base constitutes at least.Anionic property base in the polyurethane series resin preferably can be enumerated-SO ₃H ,-OSO ₂H ,-COOH, and these ammonium salt, lithium salts, sodium salt, sylvite or magnesium salts etc.

Be configured for the monomer composition of the acrylic resin of cohesive modified resin layer, have no particular limits, can use known.For example can enumerate alkyl acrylate, (as alkyl is methyl to alkylmethacrylate, ethyl, n-pro-pyl, the tert-butyl group, the 2-ethylhexyl, dodecyl, octadecyl, cyclohexyl, phenyl, benzyl, phenylethyl etc.), the 2-hydroxyethylmethacry,ate, 2-hydroxypropyl acrylate, the monomer that contains hydroxyl of 2-hydroxy propyl methacrylate etc., acrylamide, N methacrylamide, N hydroxymethyl acrylamide, the N-methylol methacrylamide, N, N-dihydroxymethyl acrylamide, N-methoxy acrylamide, the monomer that contains amide group of N phenyl acrylamide etc., N, N-diethylamino ethyl propylene acid esters, N, the monomer that contains amido of N-diethylamino ethyl-methyl acrylate etc., glycidyl acrylate, the monomer that contains epoxy radicals of glycidyl methacrylate etc., acrylic acid, methacrylic acid and these salt (lithium salts, sodium salt, sylvite etc.) etc. the monomer that contains carboxyl or its salt etc., these use one or more and use.And then, in the above-mentioned monomer also can and with other monomer.

As other above-mentioned monomer, can enumerate the monomer that contains epoxy radicals of allyl glycidyl ether etc., styrene sulfonic acid, vinyl sulfonic acid and salt (lithium salts thereof, sodium salt, sylvite, ammonium salt etc.) etc. the monomer that contains sulfonic group or its salt, crotonic acid, itaconicacid, maleic acid, fumaric acid and salt (lithium salts thereof, sodium salt, sylvite, ammonium salt etc.) etc. the monomer that contains carboxyl or its salt, maleic anhydride, itaconicacid acid anhydride etc. contain anhydride monomers, vinyl isocyanate, the allyl isocyanates, styrene, vinyl methyl ether, EVE, vinyl tri-alkoxy monosilane, alkyl maleic acid monoesters, the alkyl fumaric monoalkylester, vinyl cyanide, methacrylonitrile, alkyl itaconicacid monoesters, vinylidene chloride, vinyl acetate-chloroethylene etc.

In addition,, can use as above-mentioned acryl resin, with have modifications such as urethane bond compound, epoxy compounds the modified acroleic acid of block polymer, graft copolymer etc. be resin.

The number-average molecular weight of aforesaid propylene acid resin is preferably more than 100,000, more preferably more than 300,000, can guarantee with the formed lens jacket of the secondary processing of base material film and/or optical coated film of the present invention, hard conating like this, prevent the adherence of the laminate of reflection horizon, antiglare layer etc.

Above-mentioned polyester based resin, polyurethane series resin and acrylic resin can be individually or two or more and use.Particularly polyester based resin and polyurethane series resin and time spent can obtain good cohesive, solvent resistance, so be the array mode of recommending.

Among the present invention, the formation of cohesive modified resin layer is that the coating liquid that will contain above-mentioned composition applies on base material and carries out, and still, when the above-mentioned coating liquid of preparation, above-mentioned composition dissolving can be dispersed in the solvent.

And then, in above-mentioned coating liquid,, also can add catalyzer in order to promote cross-linking reaction.As catalyzer, can enumerate all cpds such as dead matter, salt, organic substance, alkaline matter, acidic materials and containing metal organic compound.

When above-mentioned coating liquid is made aqueous solution,, also can add alkaline matter and/or acidic materials in order to regulate the pH value.

When base material applies, in order to improve wetting state, will apply liquid and apply equably substrate surface, can in above-mentioned coating liquid, add the surfactant of necessary amount.As surfactant, can use known anionic surfactant, non-ionic surfactant.

Be used in the solvent of above-mentioned coating liquid, preferably water beyond still also can dewatering, cooperates alcohols such as ethanol, isopropyl alcohol and benzyl alcohol.Using pure time-like, alcohols applies ratio shared in the liquid preferably less than 50 quality % at full coat.And then, also can mixed alcohols organic solvent in addition in soluble scope.During organic solvent beyond using alcohols, other organic solvent applies ratio shared in the liquid preferably less than 10 quality % at full coat.In addition, the total of alcohols and other organic solvent needs only concerning full coat applies liquid and just can less than 50 quality %.

The cooperation ratio that the organic solvent that contains alcohols applies liquid for full coat is during less than 50 quality %, can improve the drying property of coating liquid when dry, simultaneously, improves the effect of the aesthetic appearance of cohesive modified resin layer more in addition as ratio of solvent with a water.During greater than 50 quality %, the velocity of evaporation of solvent is accelerated, and causes the concentration change of coating liquid in coating, and viscosity rises, and screening characteristics descends, so cause the bad effect of aesthetic appearance of cohesive modified resin layer easily.

In the present invention, as mentioned above, be preferably in from brocken spectrum and do not contain particle the base material, and in cohesive modified resin layer, contain particle, make to form suitable projection on the surface of cohesive modified resin layer.Make the method that contains particle in the cohesive modified resin layer, can enumerate the method for in the coating liquid that forms cohesive modified resin layer, adding particle.

As above-mentioned particle, can enumerate the organic filler of inorganic particulates such as lime carbonate, calcium phosphate, monox, porcelain earth, talcum, titania, aluminium oxide, barium sulphate, calcium fluoride, lithium fluoride, zeyssatite, molybdenum sulfide, bridging property macromolecule particle, calcium oxalate etc.When mainly forming cohesive modified resin layer, in these particles,, can easily obtain high transparent, so be optimum because the refractive index ratio of monox and polyester is more approaching by polyester.

Contain the above-mentioned particle in cohesive modified resin layer, mean grain size is 0.005～1.0 μ m, is preferred from the transparency, operability, scratch-resistant.The higher limit of the mean grain size of particle is seen more preferably 0.5 μ m, most preferably 0.2 μ m from transparency point.The lower limit of the mean grain size of particle in addition is from operability, scratch-resistant more preferably 0.01 μ m, most preferably 0.03 μ m.

Containing the above-mentioned particle in cohesive modified resin layer, for all compositions that constitute cohesive modified resin layer, is 0.1～60 quality %, is preferred from the transparency, operability, scratch-resistant.The amount higher limit of particle is seen more preferably 50 quality %, most preferably 40 quality % from the transparency and cohesive point.The amount lower limit of particle in addition is from operability, scratch-resistant more preferably 0.5 quality %, most preferably 1 quality %.

Above-mentioned particle can and with two or more, but also can cooperate particle particle diameter of the same race different, in a word, all mean grain sizes of particle, and the total amount preferably satisfy above-mentioned scope.

In addition, when coating can form the coating liquid of cohesive modified resin layer,, filter coating liquid with filtering material before being preferably in coating in order to remove thick condensation product of the particle of coating in the liquid and external tramp material.

When secondary filter can form the coating liquid of cohesive modified resin layer, the size of the best filtered particles of employed filtering material was following (the initial stage filtration efficiencies: 95%) of 25 μ m.When the size of filtered particles surpasses 25 μ m, then can not fully remove thick condensation product of particle and external tramp material.For this reason, with the inexpungible thick condensation product of filtering material, after coating coating liquid, drying, film is carried out uniaxial tension or twin shaft when drawing the second month in a season, the thick condensation product of cohesive modified resin layer is to the draw direction expansion of film, sometimes can discern the above condensation product of 100 μ m, its result can produce the defective of optics.

The type of above-mentioned filtering material, so long as have above-mentioned performance just can, do not have special restriction, for example can be long filament type, felt type, screen hole type.

The material of above-mentioned filtering material, so long as have above-mentioned performance, and coating liquid is not had bad influence, just there is not special restriction, for example can enumerate stainless steel, tygon, polypropylene, nylon etc.

In cohesive modified resin layer, only otherwise influencing effect of the present invention also can mix antistatic agent, ultraviolet light absorber, plastifier, light stability agent, and the various adjuvants of lubricant etc.And then, when the coating liquid that forms cohesive modified resin layer being made when water-soluble, only otherwise influence effect of the present invention,, also can in coating liquid, add other water soluble resin, water-dispersed resin and emulsifying agent etc. in order to improve performance.

Form the method for cohesive modified resin layer on base material, the concentration of the solid content when using coating in the coating liquid is preferably below the 30 quality %, more preferably below the 10 quality %.

Among the present invention, the method that forms cohesive modified resin layer on base material does not have special restriction, but the composition of cohesive modified resin layer to be mixed with ormal weight in advance with the solvent of necessary amount, preparation coating liquid will apply liquid again and scrape common coating processs such as the skill in using a kitchen knife in cookery, impregnation coating process and curtain formula coating process and apply on base material with revolving roll coating process, gravure coating method, suitable coating process, roller brush method, the method that is coated with of disputing, air knife method wire brush method, the tubular type of pressing.These methods can be used separately, also can two or more and usefulness.

Cohesive modified resin layer can be provided with on the surface of the base material after biaxial stretch-formed, but be preferably in the manufacturing process of base material film, and the manufacturing of film and the formation of overlay are carried out so simultaneously to being favourable on the productivity.Overlay is coated in stage on the base material film, can all be fine in the assorted petty stage after the manufacturing of unstretching film or after the manufacturing of monadic stretching membrane, after the manufacturing of biaxially-stretched film, but, and then be preferably in a direction and stretch behind coating liquid coating on the film.The more preferably unstretching film before axial tension or vertically monadic stretching membrane, the stage coating liquid coating before crystal orientation is over.Most preferably, follow the method that stretches at cross direction or in the unstretching film coating liquid coating, carry out biaxial stretch-formed method at vertical monadic stretching membrane surface applied coating liquid.

As the method that forms cohesive modified resin layer on the base material film surface, when using the method for coating liquid coating, coating amount, every traveling 1m ²Film, when the sink node after optics is by the overlay film manufacturing is 0.04～5g, see it is desirable from coating homogeneity, anti-sticking property, adaptation, the transparency.The lower limit of coating amount sees it is 0.08g/m from the adaptation and the transparency ², particularly preferably be 0.2g/m ²In addition, the higher limit of coating amount sees it is 4g/m from coating homogeneity and anti-sticking property ², particularly preferably be 2g/m ²Coating amount too after a little while, the adaptation of base material film and cohesive modified resin interlayer reduces easily, the particle in the overlay comes off easily in addition.Coating amount too for a long time, transparent and anti-sticking property not only worsens, and since the coating liquid rerum natura and rheology, add problems such as equipment, be difficult to apply equably.

(manufacture method of optical coated film)

In the manufacture method of optical coated film of the present invention, below, as its object lesson, the manufacture method in the time of can enumerating base material and constitute by PET, but the present invention is not limited by these.

After the particle that does not contain the PET of particle in fact carried out abundant vacuum drying, supply in the extruder, under about 280 ℃, melt extrude slabbing, Yi Bian apply static, Yi Bian the PET sheet that do not stretched is solidified in driving fit on the metal chill roll.At this moment, on the about 280 ℃ any molten thread of maintenance, carry out high precision and filter, remove the impurity that is contained in the PET essence.The high precision of fusion PET resin is filtered used filtering material and is not particularly limited, but the filtrate of stainless steel sintered body is for the Sb as the polymerization catalyst of vibrin ₂O ₃The metal Sb that is restored and be good as the agglutinator and the organic performance of removing of high-melting-point of main composition from being aggregated to Si, Ti that the granular stage sneaks into from the outside, Sb, Ge, Cu etc. is so be desirable.

The filtered particles size of above-mentioned filtrate (initial stage filtration efficiency: 95%) preferably below the 15 μ m.For the filtrate of filtered particles size, can not remove the particle of seeing the size that to remove from optical defect above 15 μ m.The secondary filter that the filtrate that has an above-mentioned strainability by use carries out fusion PET resin reduces throughput rate sometimes, but is necessary in order to obtain the few film of optical defect.

The unstretching film that obtains is used the roller that is heated to 80～120 ℃, and (longitudinal direction: the direction of travel when making optical coated film) stretching obtains uniaxial orientation PET film for 2.5～5.0 times at length direction.At this moment, for the fault that prevents film takes place,, should not constitute the vertical and skew that laterally do not have of fault reason defective, (b) film on the surface of the roller of contact on the roller surface that particularly contacts with film (a) on film surface and roller surface.

Above-mentioned defective is meant formed fault, deposit, attachment, impurity etc. on the roller surface, makes the surface of film produce all factors of fine fault when contacting with film, if there are not these faults that just can reduce the film surface to take place.For the generation that prevents above-mentioned defective can be enumerated following method.

When optical coated film is made, the surface roughness of roller is made method below the 0.1 μ m in Ra, for the fault that prevents deposit, attachment, impurity etc. produces the surface sediment of factor to roller, the method for roller washer can be set on the preheating inlet of indulging (MD) operation that stretches and chill roll.

In the optical coated film manufacturing process, have its degree of purification is made method below 1000 grades (the above particle of 0.5 μ m is below 1000 in per 1 cubic feet volume), particularly roller around be below 100 grades, in the curtain coating operation air-supply cooling device that cools off anti-roll surface is preferably also used peace and quiet air below 100 grades.

And then, before optical coated film is made, use abrasive substance to carry out the operation that the defective on the roller is eliminated, the method for carrying out the cleaning of roller.In addition, because the defective that is created on the film absorption dust of static can be enumerated the method that neutralizer is set, make that the carried charge of film is being controlled to be in full operation ± below the 1500V in order to prevent.Operation from the curtain coating to the tentering is the operation that is easy to generate fault, and compactness is arranged in this interval, and its time of passing through was controlled at below 5 minutes, also can suppress generation of defects.

Also can make following structure for roller, promptly form the roller that moisture film makes airflow on the surface of roller, the surface imperfection that makes roller not with the direct contacting structure of film.In addition, will be controlled at below the 1000ppm, can reduce adhering to the surface imperfection of roller from the oligomer amount that film is separated out.

Surface with the end side of the cross direction of the roller squeeze film that has projection (transverse direction: the direction of travel when making meet at right angles direction) with optical film, when this part forms jog, the film that will form this jog with winding mechanism is wound into the roller shape, and then the projection that will have the roller of above-mentioned projection forms the narrow top shape, make round shape at the top of above-mentioned projection, the radius-of-curvature of its end face is set for below the 0.4mm,, also can be made film forming and defective is discontiguous as the collecting device of film.

On the other hand, on the surface of roller, eliminate the method for film skew, for example can enumerate following method.

With the roller pathization, use the driving fit device etc. of suction roll, static driving fit, clamping to strengthen the closing force of film and roller, can suppress to grow the generation of fault.Particularly, make the defect level sectionalization of film, prevent the generation of long fault the roller pathization.In addition, most fault end fault towards the roller cross direction more is long more, and frequency increases, and is difficult to not have the fault part in the end of roller cross direction, so carry out grinding near the central authorities of the roller cross direction that fault is few, can obtain damaging few film.

The fault of longitudinal direction or transverse direction is that the expansion, contraction of the longitudinal direction by film or transverse direction respectively etc. forms.The driving force of this distortion mainly causes the film distortion by temperature variation.For example, suppress the temperature variation of the film on roller surface, can make temperature cause that the film deflection diminishes, and prevents the generation of the fault of longitudinal direction and transverse direction.

Particularly, the temperature variation with the film of each root roller be controlled at below 40 ℃, preferably below 30 ℃, more preferably below 20 ℃ and then preferably below 10 ℃, most preferably below 5 ℃.

As the method for the temperature variation of the film that is suppressed at the roller surface, for example, can enumerate in air cooling between roller, the water and cool off by tank.And then, by increasing the radical of roller, can alleviate the temperature variation of the film on per 1 roller surface.Preferably will make more than 10 at the roller number of MD operation.

In addition, with the relation of the relative velocity of many rollers, for film because the deflection that temperature and tension force cause is set nearest speed profiling for, the skew that can lower longitudinal direction.

And then, form in the working procedure of coating of coating liquid of usefulness at cohesive modified resin layer, finish drying by the initial stage between dry section, to the outlet cooling, the film temperature in the drying outlet can be controlled at below 40 ℃, reduce because the skew that temperature variation produces.

Tension force during the traveling of film is crossed when low, and hold descends and produces skew, when too high then stress deformation strengthen and also produce skew, so the speed of setting driven roller by governing mechanism of tension makes optimum tension range be controlled at 4.9～29.4MPa.In addition, film and the friction factor between roller in the serviceability temperature by will make the time makes the skew that can suppress the lip-deep film of roller more than 0.2.

In addition, preferably adopt special bearing that rotational resistance is made below the 19.6N for free roller.To rotate spot for driven roller is controlled at below 0.01%.

Film behind the uniaxial tension during owing to transport membrane, vertically be subjected to stress, and then the distortional stress that generation and Poisson ratio and elastic modulus balance each other on this vertical direction produces horizontal skew.In order to reduce this stress, to reach and reduce the thermal shrinkage stress that film had, do not giving preferably low directional trend in the scope of film bad influence.Concrete is recommends the refringence [(refractive index of the X-direction of monadic stretching membrane)-(refractive index of the X-direction of unstretching film)] of X-direction to make the monadic stretching membrane of 0.01～0.12 low orientation.

And then, use complete biaxial stretch-formed method during stretching without roller, do not contact with the surface imperfection of roller, also can obtain the few film of fault.Can enumerate the method for using linear electric machine or biaxial stretch-formed machine in the past as above-mentioned biaxial stretch-formed method with eidograph.

Prevent the method that above-mentioned fault takes place, can multiple method be used in combination according to the quality requirements of the employed optics of optical coated film of the present invention.

In addition, any stage in the operation that forms base material, the coating liquid of the formation cohesive modified resin layer usefulness that at least one face coating of base material is above-mentioned can form cohesive modified resin layer.

Above-mentioned uniaxial orientation PET film, and then, be imported into stenter for the stretching of cross direction (laterally=direction vertical) and heat fixation with the direction of travel of film, when having applied the coating liquid of cohesive modified resin layer usefulness, be heated at stenter, form stable tunicle by cross-linking reaction, and form cohesive modified resin layer.

Optical coated film of the present invention and then also can have other layer in the scope of not overslaugh effect of the present invention.

Optical coated film of the present invention, the transparency, cohesive, excellent optical performance are so be used for the purposes of near-infrared absorption film that basement membrane that the prism lens board of LCD (LCD) usefulness uses, hard conating use with the breakage-proof panel that shows with transparent and electrically conductive film, plasma with basement membrane, touch screen and electroluminescence on basement membrane, the cathode ray tube (CRT) with basement membrane, diffuser plate with basement membrane, antireflection (AR) and electro-magnetic wave absorption film etc.

Further describe the present invention by the following examples, but the present invention is not limited by these.In addition, each in embodiment and the comparative example is to estimate with following method by film covering characteristics.

(1) detection of fault

Make 16 pieces of the test films of 250mm * 250mm with optical coated film, detect the two sides of this test film, identify the defective of the above size of 50 μ m on the optics with following optical defect detection method.

(optical defect detection method)

As light projector is that fluorescent light with 20W * 2 lamps is configured in 400mm place, XY table below, is arranged on the test film of mounting determination object on the cover in the wide 10mm slit on the XY table.When being 12 ° of ground incident raies with the angle of the tie line of light projector and light-receiving device and test film Surface Vertical direction, if when there is fault in the test film of incoming position, because the brightness of giving out light of this part, the light quantity of this part, be transformed into electric signal with the ccd image sensing camera that is configured in the 500mm place setting of XY table top, this electric signal amplified, behind the differential, compare output optical defect detection signal with comparator and threshold level.In addition, use ccd image sensing camera, input fault image, the camera signal of the image that is transfused to is resolved with the program of setting, and determines the size of optical defect, shows the defective that 50 μ m are above.The detection of optical defect is to carry out on the two sides of test film.

(2) mensuration of fault size

In above-mentioned (1),, select the defective of fault from detected optical defect portion.Above-mentioned test film severing is become suitable size, use the surface of 50 pairs of test films of 3 d shape testing instrument TYPE5 of microdrawing society system to observe, measure the size of fault from vertical direction.To test film, be the surface of film when vertical direction is observed, adjacent 50 μ m consider as same fault so that interior fault is concavo-convex, cover the rectangular length of outermost minimum area of these faults and width length and the width as fault.And, in this rectangular length direction, to be offset vertically (direction of travel when optical film is made) ± 45 ° with interior fault as vertical fault, skew laterally (with vertical vertical direction) ± 45 ° with interior fault as horizontal fault, determine the degree of depth (difference in height of fault highest point and lowest part) and length.From this result, can determine the degree of depth 1 μ m is above and length 3mm is above vertical fault, laterally fault and all fault number are (individual/m ²).

(3) cohesive

Sample film by overlay film on use #8 wire brush coating photo-hardening type acrylic acid series hard coating agent (the big day system of refining, fork clip are than nurse EXF01 (B)).Descend dry 1 minute except that after desolvating, under high-pressure mercury-vapor lamp, at 70 ℃ at 200mJ/cm ², irradiation distance 15cm, traveling speed 5m/ minute condition under form the hard conating of thickness 3 μ m.The hard coating film that obtains is obtained the cohesive between the coating of hard conating and sample film according to the test method of the 8.5.1 record of JIS-K5400.Particularly, use the knife rest perforation coating ground of gap 2mm that base material film is cut into 100 grid-like cut channels.Then, with Sai Lufen adhesive tape (No. 405, day kind society's system; 24mm is wide) be attached to grid-like cut channel face, adhere to fully with rubber friction after, vertically peel off, obtain cohesive with visual from following formula.In addition, as long as there is part to peel off in 1 grid, it is also as the grid of being stripped from.

Cohesive (%)=(number of the number/grid of the grid that 1-is stripped from) * 100

(4) moisture-proof adaptation

Under 60 ℃, the atmosphere of 90RH%, leave standstill the hard coating film that the method with above-mentioned (3) obtains.After 500 hours, take out film, under 23 ℃, the atmosphere of 60RH%, place more than 12 hours.For this film, according to the test method repeatable operation bond test of the 8.5.1 of JIS-K5400 record 3 times, obtain cohesive same as described abovely.

(5) haze value

According to JIS-K7105, use haze value meter (Tokyo electricity look industry society system, pattern TC-H3DP) to measure.

(6) intrinsic viscosity of polyester

In phenol 60 quality % and 1,1,2, dissolved polyester in the mixed solvent of 2-tetrachloroethane 40 quality % is measured under 30 ℃.

(7) ultimate analysis

Carry out ultimate analysis with the method shown in following, quantitatively each amount of element in the polyester.

(a) analysis of Mg

With platinum crucible ashing decomposition samples, add the evaporation of 6mol/L hydrochloric acid and do solid.Use the 1.2mol/L dissolving with hydrochloric acid, with the quantitative Mg of ICP luminesceence analysis (Shimadzu Seisakusho Ltd.'s system, ICPS-2000).

(b) analysis of P

Dry incineration decomposition samples under sodium carbonate coexistence, or in sulfuric acid, nitric acid, perchloric acid system or sulfuric acid, hydrogen peroxide water system the wet type decomposition samples, phosphorus is made orthophosphoric acid.Then, in the 1mol/L sulfuric acid solution, make itself and molybdic acid reaction make phosphomolybdic acid, after it was reduced with hydrazine sulfate, (Shimadzu Seisakusho Ltd.'s system, the absorbance of the 830nm of the poly-orchid of mixing that UV-150-02) mensuration generates was as colorimetric assay with the absorbance meter.

(c) analysis of Sb

Wet type decomposition samples in sulfuric acid, hydrogen peroxide water system makes Sb behind the adding sodium nitrite ⁵⁺After adding the bright green toner, the blue complex of formation and Sb, after the toluene extraction, (Shimadzu Seisakusho Ltd.'s system, the UV-150-02) absorbance of mensuration 625nm is as colorimetric assay with the absorbance meter.

(8) resistance is compared in the polyester fusion

2 electrodes (stainless pin) are set in the polyester of 275 ℃ of fusions, measure the electric current (i when applying 120V voltage ₀), with its substitution following formula, obtain than resistance Si (Ω cm).

Si(Ω·cm)＝(A/L)×(V/i ₀)

Wherein, A is the area (cm of electrode ²), L is that interelectrode distance (cm), V are voltage (V).

(9) tone of polyester

Use colour difference meter (Tokyo electricity look (strain) system, MODEL TC-1500MC-88) to measure L value and b value.

Embodiment

Embodiment 1

Raw material as base material film, be that the particle of 0.62dl/g, the PET resin that does not contain particle is at 135 ℃ of following drying under reduced pressure after 6 hours (1Torr) with intrinsic viscosity, supply with extruder, under about 280 ℃, melt extrude membranoid substance, remain in surface temperature that chilling solidifies on 20 ℃ the metallic roll, obtain the cast film of thickness 1400 μ m.During fusion, as the impurity filter material of removing in the molten resin, using filtered particles size (initial stage filtration efficiency 95%) is the stainless steel sintering filter material of 15 μ m, carries out accurate filtration.Then, with the above-mentioned cast film to 100 of warmed-up one group of roller and infrared heater heating ℃, then, in the differentiated one group of roller of peripheral speed, vertically (direction of travel) stretches 3.5 times, obtains uniaxial orientation PET film.

Employed roller during for thin film fabrication, the surface roughness Ra that control roll are below the 0.1 μ m, and the washer of roller is set on the preheating mouth of longitudinal stretching operation and chill roll.The roller of longitudinal stretching operation directly is 150mm, adopts the packoff of suction roll, static driving fit, product nip rolls to make roller and film driving fit.

On the other hand, as cohesive modified resin layer coating liquid, be in the mixed solvent of 60 quality % water and 40 quality % isopropyl alcohols formation, copolymer polyester resin dispersion liquid (Japan's weaving (strain) system that cooperates 4 mass parts for total amount 100 mass parts of mixed solvent and resin dispersion liquid, MD-1200), 4 mass parts of colloid silicon (daily output chemical industry (strain) system, this 20L of this slow Plutarch cooperate to(for) the solid content of total amount 100 mass parts, average SEM particle diameter: 45nm), make dispersing and mixing liquid.With this dispersing and mixing liquid with filtered particles size (initial stage filtration efficiency: be that the filter material of 25 μ m felt type polypropylene systems carries out secondary filter 95%), be coated on the face of above-mentioned uniaxial orientation PET film with contrary roller method.

After the coating, then the end of controlling film with clip imports to the hot blast district that is heated to 70 ℃, after dry 15 seconds, under 115 ℃, stretch 4.0 times at cross direction (vertical) with direction of travel, then at 230 ℃ of following heat fixations, obtain thickness 100 μ m, final coating amount is 0.25g/m ²Single face have the biaxial stretch-formed PET film of cohesive modified resin layer.The 1.3m of the full width of this biaxial stretch-formed PET film of cutting central authorities obtains the optical coated film of embodiment 1.The result who obtains is illustrated in the table 1.

Embodiment 2

Except following difference, other uses the method identical with embodiment 1 to obtain optical coated film.The result who obtains is illustrated in the table 1.

The full roller that uses when making for film, the surface roughness Ra that does not use control roll are the following roller of 0.1 μ m, and the washer of roller is not set yet.And then the roller of longitudinal stretching operation directly is 300mm, does not adopt the packoff of suction roll, static driving fit, product nip rolls etc.

In addition, the thickness of casting films is 1750 μ m, and the thickness of biaxial stretch-formed PET film is 125 μ m.For the cleanliness factor in the film manufacturing process, for being below 100 grades around the roller, for the peace and quiet air of air blast cooling device use below 100 grades of the cooling of cooling off anti-roll surface in the curtain coating operation.Before making film, the abrasive substance of use roller is removed the operation of the defective on roller surface.In addition, by the aerial cooling between roller, the temperature variation of the film on the roller is suppressed at below 10 ℃.And then, in vertical stretching process, the roller radical is taken as 12, the temperature variation of 1 roller is reduced.

Embodiment 3

Except following difference, use the method identical to obtain optical coated film with embodiment 1.The result who obtains is as shown in table 1.

The full roller that uses when making for film, the surface roughness Ra that does not use control roll are the following roller of 0.1 μ m, and the washer of roller is not set yet.And then the roller of vertical stretching process directly is 300mm, does not adopt packoffs such as suction roll, static driving fit, product nip rolls.

In addition, the thickness of casting films is 2632 μ m, and the thickness of biaxial stretch-formed polyethylene terephthalate film is 188 μ m.In the full operation when film is made, Destaticizing device is set, make film carried charge ± below the 1500V.The time of passing through to tentering device inlet after the curtain coating is 4 minutes, and each roller speed setting of a plurality of rollers becomes about identical speed, so that the deflection that causes for the temperature and the tension force of film reaches the most approaching, suppresses the fault of the longitudinal direction of film.The cohesive modified resin drying condition of the working procedure of coating of coating liquid, the initial stage drying between dry section is over, and the film temperature of controlling dry outlet to outlet cooling ground is 29 ℃.Carry out the speed adjustment of driving shaft and the adjustment of tension adjusting device in addition, so that the tension force during the film traveling reaches 11.8Mpa.

Embodiment 4

Except following difference, use the method identical to obtain optical coated film with embodiment 1.The result who obtains is as shown in table 1.

The full roller that uses when making for film, the surface roughness Ra that does not use control roll are the following roller of 0.1 μ m, and the washer of roller is not set yet.And then the roller of vertical stretching process directly is 300mm, does not adopt packoffs such as suction roll, static driving fit, product nip rolls.

In addition, as the molten resin that forms base material remove the impurity filter material, (the initial stage filtration efficiency: be the stainless steel sintering filter material of 10 μ m 95%), the thickness of biaxial stretch-formed polyethylene terephthalate film is 125 μ m to use filtered particles size.In addition, all rollers of film manufacturing process are all made the air-flow forming roll, can make on the film surface not the directly structure of the defective on touch roll surface.Select stretching condition, so that the degree of orientation of the film behind the uniaxial tension (Δ N _x) be 0.055.Use roller and intermembranous coefficient of static friction are 0.42 roller under 65 ℃.In addition, adopt specific bearing, make the spin moment of 2.9N, will rotate spot for driven roller and be controlled at below 0.008% for free roller.With the film surface of end side of the cross direction of the roller squeeze film of band projection, when its film surface formed jog, the film that will form above-mentioned jog with winding mechanism was wound into roller shape ground formation.Projection with the roller of above-mentioned projection forms the narrow shape of head, becomes round shape at the top of above-mentioned projection, and the radius-of-curvature of its end face is made 0.3mm, does not contact with the defective on film when film is reeled and roller surface.

Embodiment 5

Raw material as base material film, be that the particle of 0.62dl/g, the PET resin that does not contain particle is at 135 ℃ of following drying under reduced pressure after 6 hours (1Torr) with intrinsic viscosity, supply with extruder, under about 280 ℃, melt extrude membranoid substance, remain in surface temperature that chilling solidifies on 20 ℃ the metallic roll, obtain the cast film of thickness 1400 μ m.During fusion, as the impurity filter material of removing in the molten resin, using filtered particles size (initial stage filtration efficiency 95%) is the stainless steel sintering filter material of 15 μ m.The cohesive modified resin layer that coating embodiment 1 uses on a face of above-mentioned cast film is with coating liquid, so that the final coating amount when making film is 0.20g/m ²

After the coating, in the preheating zone 105 ℃ dry 30 seconds down, simultaneously in biaxial stretch-formed device 100 ℃ of heating 45 seconds down, biaxial stretch-formed 3.6 times simultaneously of length directions, stretch 4.1 times at cross direction.Then, carrying out heat fixation under 22 ℃ handles, and then carry out 5% at cross direction, carry out 3.8% relaxation processes at length direction, obtain the optical coated film that biaxial stretch-formed PET film thickness 125 μ m, have cohesive modified resin layer on a face constitutes.The result who obtains is as shown in table 1.

Embodiment 6

Except following difference, use the method identical to obtain optical coated film with embodiment 1.The result who obtains is as shown in table 1.

Raw material as base material film, be to use intrinsic viscosity be 0.65dl/g, do not contain particle poly-2, the particle of 6-naphthoic acid glycol ester resin is altered to 300 ℃, vertical draft temperature with extrusion temperature and becomes 145 ℃, horizontal draft temperature and become 160 ℃, heat fixation temperature and become 260 ℃.

Embodiment 7

Except following difference, use the method identical to obtain optical coated film with embodiment 1.The result who obtains is as shown in table 1.

In extruding operation, maximum temperature was controlled at 270 ℃, mean residence time at 3.5 minutes, the generation of the oligomer among the may command PET.The oligomer amount of separating out on the film surface behind the system film is 110ppm.On the other hand, employed full roller during for the system film, the surface roughness Ra that does not use control roll is the following roller of 0.1 μ m, and the washer of roller is not set.And then the roller of vertical stretching process directly is 300mm, does not adopt packoffs such as suction roll, static driving fit, product nip rolls.In addition, before the final roller of the preheating procedure before vertical the stretching, make and on roller, form moisture film, the structure that the roller surface is not directly contacted with face.In the refrigerating work procedure after vertical the stretching, after vertical the stretching, film immersion is cooled off in tank, the temperature variation maximum on the later roller is controlled at 9 ℃.

Comparative example 1

Except following difference, use the method identical to obtain biaxial stretch-formed by coated with PET film with embodiment 1.The result who obtains is as shown in table 1.

The full roller that uses when making for film, the surface roughness Ra that does not use control roll are the following roller of 0.1 μ m, and the washer of roller is not set.And then the roller of vertical stretching process directly is 300mm, does not adopt packoffs such as suction roll, static driving fit, product nip rolls.

Comparative example 2

Except following difference, use the method identical to obtain biaxial stretch-formed by coated with PET film with embodiment 2.The result who obtains is as shown in table 1.

The cleanliness factor of film manufacturing process is controlled at 5000 grades, before the system film, does not use and grind the operation that material is removed the roller surface imperfection.And then the film temperature maximum on the roller controlled to 50 ℃, the radical of getting roller in vertical stretching process is 8.

Comparative example 3

Except following difference, use the method identical to obtain biaxial stretch-formed by coated with PET film with embodiment 3.The result who obtains is as shown in table 1.

The speed of the preheat roll before vertical the stretching for 5 rollers, is set with all generations 3.5% with stretching.And then, the film temperature of the outlet of coating operation is set for 63 ℃, set the speed of driven roller, so that the tension force during traveling reaches 4.9Mpa.

Comparative example 4

With intrinsic viscosity is that the particle of 0.65dl/g, moisture rate 30ppm, as not contain particle PET resin melt extrudes under 250 ℃, be after forming film on 40 ℃ the chill roll in surface temperature, stretch 2.8 times down at 93 ℃ at length direction, make uniaxial tension PET film.And, with added 0.02 quality % surfactant (mutual induction chemistry society system, not draw skot RY-2) water-soluble polyester system altogether resin be coated on the face and carry out drying.

Then, stretch 3 times down at 115 ℃ at cross direction, the film that will come out from amplifier, between the tension force cutting roller that the niproll of the hard chrome plating roller of drawing 1.015, silica gel system constitutes, anchor clamps for the cross direction drawing machine apply pulling force equably, after 5 hard chrome plating rollers are passed through, obtain the biaxial stretch-formed of thickness 188 μ m by coated with PET film with the up-coiler coiling.In addition, with ethanol wash-coated laminar surface, during surfactant, be 0.001g/10m quantitatively ²This comparative example 4 is the embodiment that are equivalent to the embodiment 1 of No. 183201/1997 patent disclosure communique of Japan.The result who obtains is as shown in table 1.

Embodiment 8

(the base material film manufacturing of PET resin)

Esterification reaction tank is heated up, when reaching 200 ℃, add the slurries of forming by terephthalic acid (TPA) 86.4 mass parts and ethylene glycol 64.4 mass parts, while stir antimony trioxide 0.017 mass parts and triethylamine 0.16 mass parts that adds as catalyzer.Then, carry out heat temperature raising, the esterification of under gauge pressure 0.34Mpa, 240 ℃ condition, pressurizeing.

Then, will become normal pressure in the esterification reaction tank, add magnesium acetate 4 hydrates 0.071 mass parts, then add trimethyl phosphate 0.014 mass parts.And then, be warmed up to 260 ℃ at 15 minutes, add trimethyl phosphate 0.012 mass parts, add sodium acetate 0.0036 mass parts then.The esterification reaction product that obtains is moved on to the polycondensation reaction jar, under reduced pressure slowly be warmed up to 280 ℃ from 260 ℃, carry out polycondensation reaction at 285 ℃.After polycondensation reaction ended, (the initial stage filtration efficiency: nylon filter made device 95%) carried out filtration treatment with aperture 5 μ m.

Then, with the PET resin particleization of above-mentioned polycondensation reaction product, above-mentioned confined chamber reduces with helping filtrator will be present in the above impurity of airborne diameter 1 μ m in confined chamber.Granulating is undertaken by following, Yi Bian flow through carry out filtration treatment (aperture: 1 μ m following) in advance chilled water, in bosh, extrude fusion PET resin on one side, with the method for the multiply shape PET resin cut-out that obtains from the mouth of disputing of extruder.The intrinsic viscosity of the PET resin particle that obtains is that 0.62dl/g, Sb content are that 144ppm, Mg content are that 5 8ppm, P content are that 40ppm, look L value are 56.2, look b value is 1.6, the fusion under 275 ℃ is 0.23 * 10 than resistance ⁸Ω cm, do not contain inert particle and inner precipitation particles in fact.

(by the manufacturing of overlay film)

Under 135 ℃, above-mentioned base material film after 6 hours, is supplied with extruder with PET resin particle drying under reduced pressure (133Pa), melt extrude slabbing at about 280 ℃, chilling on the metallic roll that keeps 20 ℃ of surface temperatures, limit add the driving fit of static limit and solidify, and obtain the casting films of thickness 1400 μ m.At this moment, as the impurity filter material of removing fusion PET resin, using filtrable particle size is that (the initial stage filtration efficiency: stainless steel sintering filtrate 95%) carries out secondary filter to 15 μ m.

Roller group and infrared heater with heating are being heated to 100 ℃ with this casting films, obtain uniaxial orientation PET film for 3.5 times in the length direction stretching then in the differentiated roller group of peripheral speed.In addition, the surface roughness of the roller of full operation is controlled at below the 0.1 μ m by Ra, on the preheating inlet of indulging stretching process and chill roll the roller washer is set.Adopting the roller of vertical stretching process directly is the driving fit device of 150mm, suction roll, static driving fit, product nip rolls, with the film driving fit on roller.

In addition, as cohesive modified resin layer coating liquid, be in the mixed solvent of 60 quality % water and 40 quality % isopropyl alcohols formation, the copolymer polyester resin dispersion liquid (Japan weaving society system, MD-1200) that cooperates 4 mass parts for total amount 100 mass parts of mixed solvent and copolymer polyester resin, colloid silicon (daily output chemical industry (strain) system that cooperates 5 mass parts for the solid content of total amount 100 mass parts, this OL of this slow Plutarch, average SEM particle diameter: 40nm), make dispersing and mixing coating liquid.

Then, but be that (the initial stage filtration efficiency: the filter material of felt type polypropylene system 95%) carries out secondary filter to 25 μ m, is coated on the face of above-mentioned uniaxial orientation PET film with contrary roller method, carries out drying with above-mentioned coating liquid with the filtered particles size.The coating amount of this moment is 0.20g/m ²After the coating, the end of controlling film with clip obtains stretching 4.0 times the film of thickness 100 μ m at cross direction after importing to the hot blast district that is heated to 130 ℃, drying.And then the 1.5m of cutting full width central authorities, obtain optical coated film.The acrylic acid series hard conating and by the cohesive of the lining aspect of overlay film be 15%, the moisture-proof adaptation is 0%.Its result is illustrated in the table 1.

Embodiment 9

Except cohesive modified resin layer is altered to the following coating liquid with coating liquid, other and embodiment 8 obtain optical coated film in the same manner.The acrylic acid series hard conating is 100% with the cohesive of the lining aspect of the film that obtains, and be good, but the moisture-proof adaptation is 40%, is poor.Its result is illustrated in the table 1.

In reactor, add terephthalic acid (TPA) diformazan alcohol ester, the m-phthalic acid diformazan alcohol ester of 95 mass parts, the ethylene glycol of 35 mass parts, the neopentyl glycol of 145 mass parts, the zinc acetate of 0.1 mass parts and the antimony oxide of 0.1 mass parts of 95 mass parts, under 180 ℃, carry out transesterification 3 hours.

Then, add Sodium Benzoate 6.0 mass parts between the 5-sulfo group, carrying out transesterification under 240 ℃ after 1 hour, down under the decompression (13.3～0.26hPa) carried out polycondensation reaction 2 hours, obtained the copolymer polyester resin (A) of 60 ℃ of molecular weight 19500, softening point at 250 ℃.

Aqueous dispersions 6.7 mass parts of mixing 30 quality % of the copolymer polyester resin that obtains respectively, contain useful sodium bisulfite end-blocking aqueous solution (the first industrial pharmacy system of 20 quality % of self-crosslinking type polyurethane resin (B) of isocyanate group, the special grand H-3 in dust Lars) 40 mass parts, the dust Lars is special grand with catalyzer (the first industrial pharmacy system, Cat64) 0.5 mass parts, water 44.3 mass parts and isopropyl alcohol 5 mass parts, and then, the aqueous solution 0.6 quality % of interpolation anionic surfactant's 10 quality %, particle A (daily output chemical industry (strain) system, this OL of this slow Plutarch, average SEM particle diameter 40nm) aqueous dispersions 1.8 mass parts of 20 quality %, particle B (Japanese A Jier society system, A Jier 50, average SEM particle diameter: 4% aqueous dispersions 1.1 mass parts 200nm) make coating liquid.

Embodiment 10

Except cohesive modified resin layer is altered to the following coating liquid with coating liquid, other and embodiment 8 obtain optical coated film in the same manner.The cohesive of the lining aspect of the film that obtains and moisture-proof adaptation all are 100%, and its result is illustrated in the table 1.

(1) modulation of copolymer polyester resin

In having the stainless steel autoclave that stirring machine, temperature take into account partial reflux formula refrigeratory, add terephthalic acid (TPA) diformazan alcohol ester, 163 mass parts of 163 mass parts m-phthalic acid diformazan alcohol ester, 169 mass parts 1, the tetra-n-butyl titanate esters of the ethylene glycol of 4 butylene glycols, 324 mass parts and 0.5 mass parts was carried out transesterification 4 hours from 160 ℃ to 220 ℃.

Then, add fumaric acid 14 mass parts and certain herbaceous plants with big flowers diacid 203 mass parts, after heating up 1 hour from 200 ℃ to 220 ℃, carry out esterification.Then, be warmed up to 255 ℃, after reactive system was slowly reduced pressure, reaction was 1 hour 30 minutes under the decompression of 29Pa, obtains copolymer polyester resin.The copolymer polyester resin that obtains is faint yellow transparency.

(2) manufacturing of graft resin

The copolymer polyester resin, the MEK of 56 mass parts and the isopropyl alcohol of 19 mass parts that in reactor, add 75 mass parts with stirring machine, thermometer, reflux and quantitative dripping device, heating, stirring and dissolving resin under 65 ℃.After resin dissolves fully, maleic anhydride 15 mass parts are added in the polyester liquid.

Then, styrene 10 mass parts and azo dimethyl certain herbaceous plants with big flowers nitrile 1.5 mass parts are dissolved in the solution of MEK 12 mass parts, splash in the polyester liquid with 0.1ml/ minute, and then continue to stir 2 hours.From reaction solution, analyze with after the sampling, add methyl alcohol 5 mass parts.Then water 300 mass parts and triethylamine 15 mass parts are joined in the reaction solution, stirred 1 hour.

Then,, distill out MEK, isopropyl alcohol, excessive triethylamine, obtain water dispersible graft polymerization resin by distillation with the interior temperature rise to 100 of reactor ℃.This water dispersible graft polymerization resin is faint yellow transparency.The oxygen value of this graft is 1400eq/t.

(3) modulation of coating liquid

Aqueous dispersions 40 mass parts, water 24 mass parts and isopropyl alcohol 36 mass parts of mixing 25 quality % of the water dispersible graft resin that obtains respectively, and then liquid adds propionic acid and negative ion is surfactant 1 quality %, (daily output chemical industry (strain) system, this OL of this slow Plutarch, average SEM particle diameter: aqueous dispersions 5 quality % 40nm) make coating liquid to add the silicon body glue particulate for the resin solid content as monox for applying respectively.

Table 1

	The number of fault is (individual/m 2)			Haze value (%)	Thickness (μ m)	Base material film
							Vertically	Laterally	Amount to
	Embodiment 1	2	4							6	0.9	100	PET
Embodiment 2				3	3	6	0.9	125	PET
	Embodiment 3	5	3							8	1.0	188	PET
Embodiment 4				19	7	26	0.9	125	PET
	Embodiment 5	24	3							27	0.9	125	PET
Embodiment 6				12	3	15	0.9	100	PEN
	Embodiment 7	12	14							26	0.9	100	PET
Comparative example 1				83	102	185	1.0	100	PET
	Comparative example 2	156	336							492	1.1	125	PET
Comparative example 3				130	203	333	1.2	188	PET
	Comparative example 4	359	83							442	2.0	188	PET
Embodiment 8				2	5	7	0.8	100	PET
	Embodiment 9	1	4							6	0.7	100	PET
Embodiment 10				1	5	7	0.5	100	PET

The optical coated film that the present invention relates to can suppress to have the above fault of specific dimensions and take place, and results from the optical defect of above-mentioned fault owing to can reduce.So the basement membrane, touch screen and the electroluminescence that are suitable for use in the near infra red film absorbing film that the panel that shows with basement membrane, plasma of the prism lens board, antireflection, hard conating etc. of LCD (LCD) usefulness uses are with the breakage-proof basement membrane of using on the basement membrane of transparent and electrically conductive film or the cathode ray tube (CRT).

Claims (9)

1. optical coated film, with the biaxial oriented polyester film more than the thickness 50 μ m as base material, on at least one face of above-mentioned base material, has cohesive modified resin layer, the resin composition of this cohesive modified resin layer serves as mainly to constitute with at least a in copolymer polyester resin, polyurethane series resin, the acrylic resin

It is characterized in that the above-mentioned particle that do not contained in fact in the base material of overlay film only contains particle in cohesive modified resin layer,

Be present in above-mentioned by more than the lip-deep degree of depth 1 μ m of overlay film and the full fault more than the length 3mm at 100/m ²Below.

2. optical coated film according to claim 1 is characterized in that the number of above-mentioned fault is at 30/m ²Below.

3. optical coated film according to claim 1 is characterized in that the number of above-mentioned fault is at 10/m ²Below.

4. according to each described optical coated film in the claim 1～3, it is characterized in that the haze value of above-mentioned optical coated film is below 1.0%.

5. optical coated film according to claim 1 is characterized in that, the amount that is included in the particle in the above-mentioned cohesive modified resin layer is 0.1～60 quality % with respect to all compositions of cohesive modified resin layer.

6. optical coated film according to claim 1 is characterized in that, the mean grain size that is included in the particle in the above-mentioned cohesive modified resin layer is 0.005～1.0 μ m.

7. optical coated film according to claim 1 is characterized in that, the particle that is included in the above-mentioned cohesive modified resin layer is a monox.

8. optical coated film according to claim 1, it is characterized in that, contain the magnesium compound of 40～70ppm and the phosphorus compound of 10～55ppm in the polyester of above-mentioned base material, and the fusion of above-mentioned vibrin under 275 ℃ is 0.10～0.45 * 10 than resistance value ⁸Ω cm.

9. optical coated film according to claim 1 is characterized in that, the vibrin that constitutes above-mentioned base material is with polyethylene terephthalate or poly-2, and 6-naphthoic acid glycol ester is a Main Ingredients and Appearance.