JP2006015592A - Hard coat film, its production method, and reflection preventing film using it - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a hard coat film which is improved in flatness by controlling the rapid curing/contraction of a hard coat layer by irradiation with active energy rays, a method for producing the film, and a reflection preventing film with reflection color nonuniformity and breaking reduced when a reflection preventing layer is formed. <P>SOLUTION: In the method for producing the hard coat film, an active energy ray curable layer, after being formed on a resin film 1.4-4 m in width, is passed through a zone irradiated with the active energy rays where the relationship between an irradiation time (t) with the energy rays and the illumination intensity (W) of the rays is adjusted so that (a) the maximum illumination intensity Wmax is 0.1-0.3 (W/cm<SP>2</SP>), and (b) an inclination dW/dt from the start of irradiation to reach the maximum illumination intensity Wmax is 0.1-0.6 (W/cm<SP>2</SP>sec) to be irradiated with the energy rays to be cured. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a hard coat film and a method for producing the same, and an antireflection film using the hard coat film. More specifically, the hard coat film has improved planarity by suppressing rapid curing shrinkage of the hard coat layer caused by active energy ray irradiation and the same. The present invention relates to a production method and an antireflection film having reduced reflection color unevenness and breakage when an antireflection layer is provided.

  In transparent resin films used for optical applications such as polarizing plate protective films for liquid crystal displays, circular polarizing plate protective films used in organic EL displays, etc., several functional thin film layers are provided to give various functions. It is painted. Examples of the functional thin film include an antistatic layer for providing an antistatic function, a hard coat layer for improving surface hardness, an undercoat layer for improving film adhesion, and an anti-layer for preventing curling. A curl layer, an antiglare layer, an antireflection layer, or the like. Of these, the hard coat layer and the antireflection layer are particularly important.

  When forming a hard-coat layer in the said transparent resin film, the hardened | cured material layer normally hardened | cured with active energy rays, such as an ultraviolet-ray, is applied, and an active energy ray is irradiated and hardened. At this time, there is a problem that the hard coat layer undergoes rapid curing shrinkage due to active energy ray irradiation, and the flatness deteriorates, and this improvement has been demanded. This phenomenon was particularly remarkable in a wide transparent resin film. Furthermore, when an antireflection layer is provided on a hard coat film on which a hard coat layer is formed, color unevenness occurs due to the flatness of the substrate, and in severe cases, the portion is discarded, and the productivity is extremely poor. It was a thing. In particular, a polarizing plate or an antireflection film used for the front face of a display device has a strict required performance, and an optical thin film with excellent uniformity without color unevenness has been desired.

Moreover, after apply | coating a crosslinking-curing-type coating material on the resin film base material, it is wound around a heating roll, and it hardens | cures by irradiating an ultraviolet-ray, heating from a back surface, and forms a coating film (for example, refer patent document 1). However, when an antireflection layer is formed on a plastic film having a cured resin layer produced by this method, uneven coating occurs and improvement thereof has been demanded. Furthermore, when forming a thin film, there were many fractures and productivity fell remarkably, and the improvement was calculated | required.
Japanese Patent Laid-Open No. 3-4969

  The present invention has been made in view of the above problems, and its purpose is to provide a hard coat film that suppresses rapid curing shrinkage of the hard coat layer due to irradiation of active energy rays and has improved planarity, a method for producing the same, and an antireflection layer. An object of the present invention is to provide an antireflection film having reduced reflection color unevenness and breakage when provided.

  The above object of the present invention is achieved by the following configurations.

(Claim 1)
After providing an active energy ray-curable resin layer on a resin film having a width of 1.4 to 4 m, the activity in which the relationship between the irradiation time (t) of the active energy ray and the illuminance (W) was adjusted to the following ranges a and b A method for producing a hard coat film, comprising passing through an energy ray irradiation zone and irradiating an active energy ray to cure.

a. Range in which maximum illuminance Wmax is 0.1 to 0.3 (W / cm ² ) b. The slope dW / dt from the start of irradiation until the maximum illuminance Wmax is reached is in the range of 0.1 to 0.6 (W / cm ² · sec).
2. The hardware according to claim 1, wherein the relationship between the irradiation distance (x) from the lamp of the active energy ray to the surface of the active energy ray-curable resin layer and the illuminance (W) is adjusted to the following range c. A method for producing a coated film.

c. dW / dx is in the range of 0.005 to 0.025 (W / cm ² · cm).
The method for producing a hard coat film according to claim 1 or 2, wherein the resin film is a cellulose ester film and the film thickness is in the range of 10 to 60 µm.

(Claim 4)
A hard coat film produced by the method for producing a hard coat film according to claim 1.

(Claim 5)
An antireflection film, comprising an antireflection layer provided on the hard coat film according to claim 4.

  According to the present invention, the hard coat film which improved the flatness by suppressing the rapid curing shrinkage of the hard coat layer due to the active energy ray irradiation, the manufacturing method thereof, and the reflection with reduced reflection color unevenness and breakage when the antireflection layer is provided. A prevention film can be provided.

  The best mode for carrying out the present invention will be described in detail below, but the present invention is not limited thereto.

  In the present invention, after the active energy ray-curable resin layer is provided on the resin film having a width of 1.4 to 4 m, the relationship between the irradiation time (t) of the active energy ray and the illuminance (W) is within the following ranges a and b. It has been found that the above-mentioned problems can be achieved by a method for producing a hard coat film characterized by passing through an adjusted active energy ray irradiation zone and irradiating and curing an active energy ray.

a. Range in which maximum illuminance Wmax is 0.1 to 0.3 (W / cm ² ) b. The slope dW / dt from the start of irradiation to the maximum illuminance Wmax is in the range of 0.1 to 0.6 (W / cm ² · sec). As a result of detailed examination of the cured state of the active energy ray-curable resin layer, conventional active energy ray irradiation is generally performed in the vicinity of the condensing position by a lamp provided with a condensing reflector. Therefore, since the slope from the start of irradiation until reaching the maximum illuminance becomes steep, an analysis result that the active energy ray curable resin layer is likely to cause rapid curing shrinkage is obtained, and the irradiation condition is improved within the above range. Thus, it has been found that the improvement of flatness, which is the first object of the present invention, can be achieved.

  The manufacturing method of the hard coat film of this invention and the apparatus to be used are demonstrated with figures.

  FIG. 1 is a schematic configuration diagram of an active energy ray irradiation zone of a hard coat film of the present invention. In the figure, the resin film 1 to be conveyed is continuously conveyed in the direction of the arrow, and an active energy ray-curable resin layer is applied onto the resin film by a coating apparatus (not shown), and a solvent is contained in the coated material. In this case, after passing through a drying step (not shown), the resin film is irradiated with an active energy ray using one active ray light source 10 while supporting the back surface with the backup roll 2, and an active energy ray cured product layer is used. To cure. The active energy ray light source 10 has a lamp box 3 in which a reflector 4 and a lamp 5 for generating active energy rays are incorporated. The lamp box preferably has an explosion-proof structure to prevent ignition of the solvent used in the coating process, and preferably has a cooling mechanism. In the present invention, the reflecting plate 4 may be a general condensing type, but in the case of the condensing type, it is preferable to install a glass plate having a diffusing surface on the optical path, and more preferably a diffusing type reflecting plate is used. It is.

  FIG. 2 is another schematic configuration diagram of the active energy ray irradiation zone of the hard coat film of the present invention. Uniform active energy rays can be irradiated by providing two active energy ray irradiation zones.

  FIG. 3 illustrates the relationship between the irradiation time of active energy rays and the illuminance according to the present invention. In the drawing, the illuminance distributions A and B show examples in which the relationship between the irradiation time (t) of the active energy ray and the illuminance (W) according to the present invention satisfies a and b, and the illuminance distribution C of the comparative example is Although the relationship a is satisfied, the inclination expressed by dW / dt is steep beyond the range of the present invention, and therefore the relationship b is not satisfied.

  When the active energy ray is ultraviolet light, the above illuminance measurement can be performed with Eye Graphics Co., Ltd. UV METER UVPF-36, Iida Trading Co., Ltd. ultraviolet intensity meter RMX-3W, VLX-3W, or the like.

In the present invention, a. The maximum illuminance Wmax is in the range of 0.1 to 0.3 (W / cm ² ), and b. It is essential for obtaining the effect of the present invention that the slope dW / dt from the start of irradiation to the maximum illuminance Wmax falls within the range of 0.1 to 0.6 (W / cm ² · sec). If the maximum illuminance Wmax is less than 0.1, it does not cure or tends to vary, and if it exceeds 0.3, the planarity deteriorates due to the shrinkage of the resin layer. When the slope dW / dt is less than 0.1, it takes a long time to obtain the amount of active energy rays necessary for curing, and the production efficiency decreases, for example, the film transport speed becomes extremely slow. When the slope dW / dt exceeds 0.6, as described above, rapid curing shrinkage occurs and flatness deteriorates.

  As a method for adjusting the illuminance and the inclination in such a range, the type of active energy ray irradiation lamp, the type / structure of the reflection plate (condensing type or diffusion type) described later, the installation of the diffusion plate, the transparent resin film It can be adjusted by appropriately changing the conveyance speed, the distance between the lamp and the transparent resin film, and the like.

Further, in the present invention, the relationship between the irradiation distance (x) from the active energy ray lamp to the active energy ray-curable resin layer surface and the illuminance (W) is c. It is preferable that dW / dx is adjusted in the range of 0.005 to 0.025 (W / cm ² · cm). If it is less than 0.005, it takes a long time to obtain the amount of active energy rays required for curing, the film transport speed becomes extremely slow, the size of the irradiation zone becomes extremely large, etc. It is not preferable because it decreases. If it exceeds 0.025, the distance from the lamp to the cured resin layer becomes small, and it becomes difficult to adjust the slope dW / dt from the start of irradiation to the maximum illuminance Wmax within the range of the present invention.

  FIG. 4 is a schematic diagram showing the shapes of the active energy ray irradiation lamp and the reflector used in the present invention, but the present invention is not limited to these.

  4a shows a configuration of an active energy ray irradiation lamp having a condensing reflector, FIG. 4b shows a configuration in which a diffusion plate is installed on the optical axis, and FIG. 4c shows a configuration of an active energy ray irradiation lamp having a diffusion reflector. It is a schematic diagram shown.

  The configuration of the lamp and reflector of the present invention can be either a condensing type or a diffusing type, but for the above reasons, the concentrating type is preferably used at the condensing diffusion point rather than at the condensing point. However, since there is a possibility that the distance between the irradiation lamp and the transparent resin film becomes large and the efficiency is lowered, it is also preferable to install the diffusion plate 6 on the optical path and use it at the condensing point. Further, the diffusion type (also referred to as a parallel light type) is a particularly preferable aspect because it is easy to adjust the relationship between the irradiation time (t) of the active energy ray and the illuminance (W) of the present invention. Even in this case, the diffusion plate 6 can be installed.

  When the active energy ray is ultraviolet light, any light source that generates ultraviolet light can be used. For example, low pressure mercury lamp, medium pressure mercury lamp, high pressure mercury lamp, ultra high pressure mercury lamp, carbon arc lamp, metal halide lamp, xenon lamp, etc. Can be used.

As a material of the reflector, any material may be used as long as the transmittance of the active energy ray is low or the material does not transmit the active energy ray. For example, various materials such as a metal plate, an opaque resin plate and paper are used. I can do it. The reflecting plate is preferably a metal plate from the viewpoint of durability and shielding properties, and examples thereof include iron, copper, aluminum, titanium, chromium, nickel, lead, or an alloy mainly containing any of these. A stainless steel plate or an aluminum plate is preferable, and it is particularly preferable that the active energy ray light source side is mirror-finished. Further, the active ray light source side may be constituted by a cold mirror having a film that absorbs heat rays and reflects ultraviolet rays, for example, a metal oxide vapor deposition film such as TiO ₂ .

  Hereinafter, the material used for this invention is demonstrated in detail.

  The resin film used in the present invention is not particularly limited. For example, polyester film, polyethylene film, polypropylene film, cellophane, cellulose diacetate film, cellulose acetate butyrate film, cellulose acetate propionate film, cellulose as transparent resin film Film made of triacetate or cellulose derivative, polyvinylidene chloride film, polyvinyl alcohol film, ethylene vinyl alcohol film, syndiotactic polystyrene film, polycarbonate film, cycloolefin polymer film, norbornene resin film, polymethylpentene film, polyether ketone Film, polyethersulfone film, polysulfone film Lum, polyether ketone imide film, a polyamide film, a fluororesin film, a nylon film, polymethyl methacrylate film, may be mentioned acrylic film or polyarylate film.

  In the present invention, it has excellent curing particularly for a wide resin film, and is particularly preferably applied to a resin film having a width of 1.4 to 4 m. Moreover, the effect excellent especially with respect to the film in which a resin film contains a cellulose ester can be expected. This is because the cellulose ester film has additives such as a plasticizer and is susceptible to dissolution and swelling by the coating solvent. Examples of the cellulose ester film include cellulose acetate film, cellulose acetate butyrate film, cellulose acetate propionate film, and cellulose triacetate (TAC). In particular, the influence is remarkable in a thin film having a film thickness of 10 to 60 μm, and the method of the present invention can exhibit an excellent effect as a method for producing an optical film that requires high flatness.

  Hereinafter, a method for forming a cellulose ester film will be described. Cellulose ester film is generally made by dissolving cellulose ester flake raw material and plasticizer in methylene chloride to form a viscous liquid, and then dissolving the plasticizer into dope. From the extruder die, stainless steel rotating endlessly, etc. It is cast on a metal belt (also referred to as a band), dried, peeled off from the belt in a dry state, dried from both sides by a transport device such as a roll, and wound up. The cellulose ester film used in the production of the optical film of the present invention is a film that is held or stretched by holding the end of the film by a device such as a tenter in the drying process and applying tension in the width direction. It is preferable because higher planarity can be obtained.

  The cellulose ester resin of the cellulose ester film used for the production of the optical film of the present invention is preferably a cellulose lower fatty acid ester resin. The lower fatty acid in the lower fatty acid ester of cellulose is preferably a fatty acid having 6 or less carbon atoms. For example, cellulose acetate, cellulose propionate, cellulose butyrate and the like are particularly preferred examples of the lower fatty acid ester of cellulose.

  In addition to the above, cellulose acetate propionate, cellulose acetate butyrate, cellulose acetate propionate buty described in JP-A Nos. 10-45804, 8-231761, U.S. Pat. No. 2,319,052 and the like. Mixed fatty acid esters such as rate can be used. Among the above description, cellulose triacetate (hereinafter referred to as TAC) and cellulose acetate propionate are the most preferably used lower fatty acid esters of cellulose.

  The number average molecular weight of the cellulose ester according to the present invention is preferably 70,000 to 250,000, which has a high mechanical strength when molded and has an appropriate dope viscosity, and more preferably 80,000 to 150,000. is there.

  The cellulose ester used in the present invention has an acetyl group and / or a propionyl group as a substituent, and when the substitution degree of the acetyl group is X and the substitution degree of the propionyl group is Y, the following formula (I) and Cellulose esters that simultaneously satisfy (II) are particularly preferred.

(I) 2.5 ≦ X + Y ≦ 3.0
(II) 0 ≦ Y ≦ 1.2
The measuring method of the substitution degree of an acyl group can be measured according to the provisions of ASTM-D817-96.

  As the cellulose ester, either a cellulose ester synthesized from cotton linter and a cellulose ester synthesized from wood pulp can be used alone or mixed at an arbitrary ratio. If peelability from the belt or drum becomes a problem, it is preferable to use a large amount of cellulose ester synthesized from a cotton linter that has good peelability from the belt or drum. When a mixture of cellulose esters synthesized from wood pulp is used, the ratio of cellulose esters synthesized from cotton linters is 40% by mass or more, and the effect of releasability becomes remarkable, and more preferably 60% by mass or more. Preferably it is used alone.

  The solvent used in preparing the dope may be any solvent that can dissolve the cellulose ester, and it can be dissolved by mixing with other solvents even if it cannot be dissolved alone. Can be used. In general, a mixed solvent comprising a poor solvent of methylene chloride and cellulose ester, which is a good solvent, is used, and the mixed solvent preferably contains 4 to 30% by mass of the poor solvent.

  Other good solvents that can be used include, for example, methyl acetate, ethyl acetate, amyl acetate, acetone, tetrahydrofuran, 1,3-dioxolane, 1,4-dioxane, cyclohexanone, ethyl formate, 2,2,2-trifluoroethanol, 2,2,3,3-tetrafluoro-1-propanol, 1,3-difluoro-2-propanol, 1,1,1,3,3,3-hexafluoro-2-methyl-2-propanol, 1, 1,1,3,3,3-hexafluoro-2-propanol, 2,2,3,3,3-pentafluoro-1-propanol, nitroethane and the like, and organic halogen compounds such as methylene chloride , Dioxolane derivatives, methyl acetate, ethyl acetate, acetone and the like are preferable organic solvents (ie, good solvents). .

  Examples of the poor solvent for cellulose ester include alcohols having 1 to 8 carbon atoms such as methanol, ethanol, n-propanol, iso-propanol, n-butanol, sec-butanol, and tert-butanol. These poor solvents can be used alone or in combination of two or more.

  Although it does not specifically limit as a plasticizer which can be used by this invention, A phosphate ester plasticizer, a phthalate ester plasticizer, a trimellitic ester plasticizer, a pyromellitic acid plasticizer, a glycolate plasticizer Citric acid ester plasticizers, polyester plasticizers, and the like can be used.

  For phosphate esters, triphenyl phosphate, tricresyl phosphate, cresyl diphenyl phosphate, octyl diphenyl phosphate, diphenyl biphenyl phosphate, trioctyl phosphate, tributyl phosphate, etc.For phthalate esters, diethyl phthalate, dimethoxyethyl phthalate, dimethyl Tributyl trimellitate, triphenyl trimellitate, triphenyl trimellitate, triethyl trimellitate, etc. Tetrabutyl pyrome as a pyromellitic acid ester plasticizer such as melitte Tate, tetraphenylpyromellitate, tetraethylpyromellitate, etc., glycolate ester type, triacetin, tributyrin, ethylphthalylethyl glycolate, methylphthalylethyl glycolate, butylphthalylbutyl glycolate, etc., citrate ester type Examples of plasticizers include triethyl citrate, tri-n-butyl citrate, acetyl triethyl citrate, acetyl tri-n-butyl citrate, acetyl tri-n- (2-ethylhexyl) citrate, or trimethylolpropane tribenzoate. It can be preferably used. As the polyester plasticizer, a copolymer of a dibasic acid such as an aliphatic dibasic acid, an alicyclic dibasic acid, or an aromatic dibasic acid and a glycol can be used. The aliphatic dibasic acid is not particularly limited, and adipic acid, sebacic acid, phthalic acid, terephthalic acid, 1,4-cyclohexyl dicarboxylic acid and the like can be used.

  As the glycol, ethylene glycol, diethylene glycol, 1,3-propylene glycol, 1,2-propylene glycol, 1,4-butylene glycol, 1,3-butylene glycol, 1,2-butylene glycol and the like can be used. These dibasic acids and glycols may be used alone or in combination of two or more. The molecular weight of the polyester is preferably in the range of 500 to 2000 in terms of weight average molecular weight from the viewpoint of compatibility with the cellulose ester.

  Further, it is preferable to use a plasticizer having a vapor pressure of less than 1333 Pa at 200 ° C., more preferably a compound having a vapor pressure of 666 Pa or less, and more preferably 1 to 133 Pa. The non-volatile plasticizer is not particularly limited, and examples thereof include arylene bis (diaryl phosphate) ester, tricresyl phosphate, trimellitic acid tri (2-ethylhexyl), and the above polyester plasticizer.

  These plasticizers can be used alone or in combination of two or more.

  In consideration of dimensional stability and processability, the amount of the plasticizer used can be added in an amount of 1 to 40% by weight, preferably 3 to 20% by weight, based on the cellulose ester. Preferably it is 4-15 mass%. If the amount is less than 3% by mass, a smooth cut surface cannot be obtained when slitting or punching, resulting in increased generation of chips.

  It is preferable to add an antioxidant or an ultraviolet absorber to the cellulose ester film of the present invention.

  As the antioxidant, a hindered phenol compound is preferably used, and 2,6-di-t-butyl-p-cresol, pentaerythrityl-tetrakis [3- (3,5-di-t-butyl). -4-hydroxyphenyl) propionate], triethylene glycol-bis [3- (3-tert-butyl-5-methyl-4-hydroxyphenyl) propionate], 1,6-hexanediol-bis [3- (3 5-di-t-butyl-4-hydroxyphenyl) propionate], 2,4-bis (n-octylthio) -6- (4-hydroxy-3,5-di-t-butylanilino) -1,3,5 -Triazine, 2,2-thiodiethylenebis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionate], octadecyl-3- (3 -Di-t-butyl-4-hydroxyphenyl) propionate, N, N'-hexamethylenebis (3,5-di-t-butyl-4-hydroxyhydrocinnamamide), 1,3,5-trimethyl- 2,4,6-tris (3,5-di-t-butyl-4-hydroxybenzyl) benzene, tris- (3,5-di-t-butyl-4-hydroxybenzyl) isocyanurate . In particular, 2,6-di-t-butyl-p-cresol, pentaerythrityl-tetrakis [3- (3,5-di-t-butyl-4-hydroxyphenyl) propionate], triethylene glycol-bis [3- (3-t-butyl-5-methyl-4-hydroxyphenyl) propionate] is preferred. Further, for example, hydrazine-based metal deactivators such as N, N′-bis [3- (3,5-di-t-butyl-4-hydroxyphenyl) propionyl] hydrazine and tris (2,4-di-t A phosphorus-based processing stabilizer such as -butylphenyl) phosphite may be used in combination. The amount of these compounds added is preferably 1 ppm to 1.0%, more preferably 10 to 1000 ppm in terms of mass ratio with respect to the cellulose ester.

  In addition, thermal stabilizers such as kaolin, talc, diatomaceous earth, quartz, calcium carbonate, barium sulfate, titanium oxide, alumina and other inorganic fine particles, and alkaline earth metal salts such as calcium and magnesium may be added. .

  The cellulose ester film of the present invention is used for a polarizing plate or a liquid crystal display member because of its high dimensional stability, but an ultraviolet absorber is preferably used from the viewpoint of preventing deterioration of the polarizing plate or the liquid crystal.

  As the ultraviolet absorber, those excellent in the ability to absorb ultraviolet rays having a wavelength of 370 nm or less and having little absorption of visible light having a wavelength of 400 nm or more are preferably used from the viewpoint of good liquid crystal display properties. Specifically, the transmittance at 380 nm is preferably less than 10%, more preferably less than 5%.

  Specific examples of the ultraviolet absorber preferably used in the present invention include oxybenzophenone compounds, benzotriazole compounds, salicylic acid ester compounds, benzophenone compounds, cyanoacrylate compounds, nickel complex compounds, and the like. Moreover, the polymeric ultraviolet absorbers described in JP-A-6-148430 and JP-A-2002-47357 are also preferably used. Or the ultraviolet absorber described in Unexamined-Japanese-Patent No. 10-152568 can also be used.

  As the benzotriazole ultraviolet absorber, a compound represented by the following general formula [1] is preferably used.

In the formula, R ₁ , R ₂ , R ₃ , R ₄ and R ₅ may be the same or different, and are a hydrogen atom, halogen atom, nitro group, hydroxyl group, alkyl group, alkenyl group, aryl group, alkoxyl group, acyloxy Represents a group, aryloxy group, alkylthio group, arylthio group, mono- or dialkylamino group, acylamino group or 5- to 6-membered heterocyclic group, and R ₄ and R ₅ are closed to form a 5- to 6-membered carbocyclic ring May be.

  Moreover, these groups described above may have an arbitrary substituent.

  Although the specific example of the ultraviolet absorber which concerns on this invention is given to the following, it is not limited to these.

UV-1: 2- (2'-hydroxy-5'-methylphenyl) benzotriazole UV-2: 2- (2'-hydroxy-3 ', 5'-di-tert-butylphenyl) benzotriazole UV-3 : 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) benzotriazole UV-4: 2- (2'-hydroxy-3 ', 5'-di-tert-butylphenyl)- 5-Chlorobenzotriazole UV-5: 2- (2'-hydroxy-3 '-(3 ", 4", 5 ", 6" -tetrahydrophthalimidomethyl) -5'-methylphenyl) benzotriazole UV-6: 2,2-methylenebis (4- (1,1,3,3-tetramethylbutyl) -6- (2H-benzotriazol-2-yl) phenol)
UV-7: 2- (2'-hydroxy-3'-tert-butyl-5'-methylphenyl) -5-chlorobenzotriazole UV-8: 2- (2H-benzotriazol-2-yl) -6 (Linear and side chain dodecyl) -4-methylphenol (TINUVIN171, manufactured by Ciba Specialty Chemicals)
UV-9: Octyl-3- [3-tert-butyl-4-hydroxy-5- (chloro-2H-benzotriazol-2-yl) phenyl] propionate and 2-ethylhexyl-3- [3-tert-butyl- Mixture of 4-hydroxy-5- (5-chloro-2H-benzotriazol-2-yl) phenyl] propionate (TINUVIN109, manufactured by Ciba Specialty Chemicals)
Specific examples of the benzophenone-based ultraviolet absorber are shown below, but the present invention is not limited thereto.

UV-10: 2,4-dihydroxybenzophenone UV-11: 2,2'-dihydroxy-4-methoxybenzophenone UV-12: 2-hydroxy-4-methoxy-5-sulfobenzophenone UV-13: Bis (2-methoxy -4-hydroxy-5-benzoylphenylmethane)
In the cellulose ester film used for this invention, it is preferable to add microparticles | fine-particles in order to provide slipperiness to a film and to prevent blocking of a roll-shaped film.

  The fine particles according to the present invention include inorganic compound fine particles or organic compound fine particles.

  Inorganic compounds include silicon-containing compounds, silicon dioxide, aluminum oxide, zirconium oxide, calcium carbonate, talc, clay, calcined kaolin, calcined calcium silicate, hydrated calcium silicate, aluminum silicate, magnesium silicate, calcium phosphate, etc. More preferred are silicon-containing inorganic compounds and zirconium oxide, but silicon dioxide is particularly preferably used because the turbidity of the cellulose ester laminated film can be reduced.

  As the fine particles of silicon dioxide, for example, commercially available products such as Aerosil R972, R972V, R974, R812, 200, 200V, 300, R202, OX50, TT600 (above Nippon Aerosil Co., Ltd.) can be used.

  As the fine particles of zirconium oxide, commercially available products such as Aerosil R976 and R811 (manufactured by Nippon Aerosil Co., Ltd.) can be used.

  As the organic compound, for example, polymers such as silicone resin, fluorine resin and acrylic resin are preferable, and among them, silicone resin is preferably used.

  Among the above-described silicone resins, those having a three-dimensional network structure are particularly preferable. For example, Tospearl 103, 105, 108, 120, 145, 3120 and 240 (above Toshiba Silicone Co., Ltd.) ) Etc. can be used.

  The primary average particle diameter of the fine particles is preferably 20 nm or less, more preferably 5 to 16 nm, and particularly preferably 5 to 12 nm, from the viewpoint of keeping the haze low. For example, they are commercially available under the trade names of Aerosil 200V and Aerosil R972V (manufactured by Nippon Aerosil Co., Ltd.) and can be preferably used.

<< Preparation Method A >>
After stirring and mixing the solvent and the fine particles, dispersion is performed with a disperser. This is a fine particle dispersion. The fine particle dispersion is added to the dope solution and stirred.

<< Preparation Method B >>
After stirring and mixing the solvent and the fine particles, dispersion is performed with a disperser. This is a fine particle dispersion. Separately, a small amount of cellulose ester is added to the solvent and dissolved by stirring. As the cellulose ester added here, it is particularly preferable to add the solid material of the present invention.

  The fine particle dispersion is added to this and stirred. This is a fine particle addition solution. The fine particle additive solution is sufficiently mixed with the dope solution using an in-line mixer.

<< Preparation Method C >>
Add a small amount of cellulose ester to the solvent and dissolve with stirring. Fine particles are added to this and dispersed by a disperser. This is a fine particle addition solution. The fine particle additive solution is sufficiently mixed with the dope solution using an in-line mixer.

  Preparation method A is excellent in dispersibility of silicon dioxide fine particles, and preparation method C is excellent in that silicon dioxide fine particles are difficult to re-aggregate. Among them, the preparation method B described above is a preferable preparation method that is excellent in both dispersibility of the silicon dioxide fine particles and that the silicon dioxide fine particles are less likely to reaggregate.

《Distribution method》
The concentration of silicon dioxide when the silicon dioxide fine particles are mixed with a solvent and dispersed is preferably 5 to 30% by mass, more preferably 10 to 25% by mass, and most preferably 15 to 20% by mass. A higher dispersion concentration is preferable because liquid turbidity with respect to the added amount tends to be low, and haze and aggregates are improved.

  The solvent used is preferably lower alcohols such as methyl alcohol, ethyl alcohol, propyl alcohol, isopropyl alcohol, butyl alcohol and the like. Although it does not specifically limit as solvents other than a lower alcohol, It is preferable to use the solvent used at the time of film forming of a cellulose ester.

  The amount of silicon dioxide fine particles added to cellulose ester is preferably 0.01 to 0.3 parts by mass, more preferably 0.05 to 0.2 parts by mass, and more preferably 0.0 to 0.2 parts by mass with respect to 100 parts by mass of cellulose ester. Most preferred is 08 to 0.12 parts by mass. The larger the added amount, the better the dynamic friction coefficient, and the smaller the added amount, the lower the haze and the fewer agglomerates.

  As the disperser, a normal disperser can be used. Dispersers can be broadly divided into media dispersers and medialess dispersers. For dispersing silicon dioxide fine particles, a medialess disperser is preferred because of its low haze.

  Examples of the media disperser include a ball mill, a sand mill, and a dyno mill.

  Examples of the medialess disperser include an ultrasonic type, a centrifugal type, and a high pressure type. In the present invention, a high pressure disperser is preferable. The high pressure dispersion device is a device that creates special conditions such as high shear and high pressure by passing a composition in which fine particles and a solvent are mixed at high speed through a narrow tube. When processing with a high-pressure dispersion apparatus, for example, the maximum pressure condition inside the apparatus is preferably 9.807 MPa or more in a thin tube having a tube diameter of 1 to 2000 μm. More preferably, it is 19.613 MPa or more. Further, at that time, those having a maximum reaching speed of 100 m / second or more and those having a heat transfer speed of 420 kJ / hour or more are preferable.

  The high-pressure dispersing apparatus as described above includes an ultra-high pressure homogenizer (trade name: Microfluidizer) manufactured by Microfluidics Corporation or a nanomizer manufactured by Nanomizer. Examples include UHN-01 manufactured by Wako Machine Co., Ltd.

  Further, these fine particles may be uniformly distributed in the thickness direction of the film, but more preferably distributed so as to be mainly present in the vicinity of the surface, for example, by co-casting method, It is preferable to add fine particles mainly to the dope arranged on the surface layer side using two or more kinds of dopes because a film having high slipperiness and low haze can be obtained. Preferably, it is desirable to add fine particles mainly to at least one dope on the surface layer side or two dopes on the surface layer side using three kinds of dopes, and the dope forming the central layer contains almost no fine particles. , Preferably not included at all. Additives that may cause bleed-out, such as plasticizers or UV absorbers, are mainly added to the dope forming the center layer, and the two dopes on the surface layer side are added to the dope forming the center layer. The addition amount is preferably less than 80% by mass, more preferably less than 50% by mass, and it is more preferable to add little or no addition in terms of preventing process contamination.

  After the cellulose ester film obtained in such a film forming process is wound up once or continuously without being wound up, the coating layer can be provided by the method for producing a hard coat film of the present invention.

  The active energy ray-curable resin layer according to the present invention will be described. The active energy ray-curable resin layer refers to a layer mainly composed of a resin that is cured through a crosslinking reaction or the like by irradiation with active energy rays such as ultraviolet rays or electron beams. Typical examples of the active energy ray curable resin include an ultraviolet curable resin and an electron beam curable resin, but a resin that is cured by irradiation with an active energy ray other than an ultraviolet ray or an electron beam may be used. Examples of the ultraviolet curable resin include an ultraviolet curable acrylic urethane resin, an ultraviolet curable polyester acrylate resin, an ultraviolet curable epoxy acrylate resin, an ultraviolet curable polyol acrylate resin, and an ultraviolet curable epoxy resin. I can do it.

  UV curable acrylic urethane resins generally include 2-hydroxyethyl acrylate and 2-hydroxyethyl methacrylate (hereinafter referred to as acrylates) in addition to products obtained by reacting polyester polyols with isocyanate monomers or prepolymers. It can be easily obtained by reacting an acrylate monomer having a hydroxyl group such as 2-hydroxypropyl acrylate (for example, JP-A-59-151110).

  The UV curable polyester acrylate resin can generally be easily obtained by reacting a polyester polyol with 2-hydroxyethyl acrylate or 2-hydroxy acrylate monomer (for example, JP-A-59-151112).

  Specific examples of the ultraviolet curable epoxy acrylate resin include those obtained by reacting epoxy acrylate with an oligomer, a reactive diluent and a photoinitiator added thereto (for example, JP-A-1- No. 105738). As this photoreaction initiator, one or more kinds selected from benzoin derivatives, oxime ketone derivatives, benzophenone derivatives, thioxanthone derivatives and the like can be selected and used.

  Specific examples of ultraviolet curable polyol acrylate resins include trimethylolpropane triacrylate, ditrimethylolpropane tetraacrylate, pentaerythritol triacrylate, pentaerythritol tetraacrylate, dipentaerythritol hexaacrylate, alkyl-modified dipentaerythritol pentaacrylate. Etc. can be mentioned. These resins are usually used together with known photosensitizers. Moreover, the said photoinitiator can also be used as a photosensitizer. Specific examples include acetophenone, benzophenone, hydroxybenzophenone, Michler's ketone, α-amyloxime ester, tetramethyluram monosulfide, thioxanthone, and derivatives thereof. Further, when using an epoxy acrylate photoreactant, a sensitizer such as n-butylamine, triethylamine, or tri-n-butylphosphine can be used. The photoreaction initiator or photosensitizer used in the ultraviolet curable resin composition is 0.1 to 15 parts by weight, preferably 1 to 10 parts by weight, based on 100 parts by weight of the composition.

Examples of the active energy rays include electron beams, X-rays, radiation, visible light, and ultraviolet rays. In particular, ultraviolet rays are preferably used. In this case, any light source that generates ultraviolet rays can be used. For example, the low-pressure mercury lamp, medium-pressure mercury lamp, high-pressure mercury lamp, ultrahigh-pressure mercury lamp, carbon arc lamp, metal halide lamp, xenon lamp, etc. can be used. The irradiation conditions vary depending on individual lamps, but the amount of light irradiated may be any degree 20~10000mJ / cm ^2, preferably from 50~2000mJ / cm ^2. From the near ultraviolet region to the visible light region, it can be used by using a sensitizer having an absorption maximum in that region.

  Moreover, when irradiating actinic radiation, it is preferable to carry out while applying tension | tensile_strength in the conveyance direction of a film, More preferably, it is performing applying tension | tensile_strength also in the width direction. The tension to be applied is preferably 30 to 300 N / m. The method for applying the tension is not particularly limited, and the tension may be applied in the conveying direction on the back roll, or the tension may be applied in the width direction or the biaxial direction by a tenter. This makes it possible to obtain a film having further excellent flatness.

  Furthermore, it is preferable that the ambient temperature when irradiating with active rays is in the range of 15 to 45 ° C. If it exceeds 45 ° C., the flatness tends to deteriorate due to heat. In order to make it the said temperature range, the air blower which can be temperature-controlled can be integrated in an active energy ray irradiation zone.

  In order to provide the active energy ray-cured resin layer with an antiglare property on the surface of the display device panel, to prevent adhesion with other substances, or to provide scratch resistance, inorganic or organic fine particles Can also be added. Examples of inorganic particles include silicon oxide, titanium oxide, aluminum oxide, zirconium oxide, tin oxide, zinc oxide, calcium carbonate, barium sulfate, talc, kaolin, calcium sulfate, and the like. Methyl methacrylate resin powder, acrylic styrene resin powder, polymethyl methacrylate resin powder, silicon resin powder, polystyrene resin powder, polycarbonate resin powder, benzoguanamine resin powder, melamine resin powder, polyolefin resin powder, polyester It can be added to an ultraviolet curable resin composition such as a resin resin powder, a polyamide resin powder, a polyimide resin powder, or a polyfluorinated ethylene resin powder. The average particle diameter of these particle powders is 0.01 μm to 10 μm, and the ratio of the ultraviolet curable resin composition to the fine particle powder is 0.1 to 20 parts by mass with respect to 100 parts by mass of the resin composition. It is desirable to blend so that. In order to impart an antiglare effect, the average particle size is preferably 0.1 to 3 μm, and 1 to 15 parts by mass with respect to 100 parts by mass of the resin composition.

  Furthermore, the particles having a volume average particle size of 0.005 to 0.1 μm are added to 100 parts by mass of the resin composition with the same components as those described above in order to perform the blocking prevention function or to form fine irregularities. 0.1-5 mass parts can also be used together.

  Since the organic solvent contained in the coating solution is evaporated before the ultraviolet irradiation, a drying process is required.

  Examples of organic solvents that can be used as the coating solution include alcohols such as methanol, ethanol, propanol, n-butanol, 2-butanol, tert-butanol, and cyclohexanol, ketones such as methyl ethyl ketone, methyl isobutyl ketone, and acetone, ethyl acetate, Esters such as methyl acetate, ethyl lactate, isopropyl acetate, amyl acetate, ethyl butyrate, glycol ethers (propylene glycol mono (C1-C4) alkyl ethers (specifically, propylene glycol monomethyl ether (PGME), propylene glycol monoethyl) Ether, propylene glycol mono-n-propyl ether, propylene glycol monoisopropyl ether, propylene glycol monobutyl ether, etc.), propylene glycol Mono (C1 -C4) alkyl ester (propylene glycol monomethyl ether acetate, propylene glycol monoethyl ether acetate)), toluene, benzene, cyclohexane, and other solvents hydrocarbons such as n- hexane. Although not particularly limited to these, a solvent in which these are appropriately mixed is preferably used.

  As a coating method of the coating liquid containing the active energy ray curable resin, a known method such as a gravure coater, a spinner coater, a wire bar coater, a roll coater, a reverse coater, an extrusion coater, an air doctor coater can be used. The coating amount is suitably 0.1 to 30 μm, preferably 0.5 to 15 μm in terms of wet film thickness.

  The coating solution containing the active energy ray-curable resin is applied and dried, and then irradiated with active rays such as ultraviolet rays. The irradiation conditions are as described above. Although there is no restriction | limiting in particular in irradiation time, 0.1 second-5 minutes are preferable, and 0.1 second-1 minute are more preferable from the hardening efficiency of a curable resin, work efficiency, etc.

  An organic solvent is preferably used for the coating solution containing the active energy ray-curable resin of the present invention. At this time, it is preferable to use a solvent having a property of dissolving or swelling the resin film because the adhesiveness between the coated layer and the resin film is excellent. As the solvent, the above-mentioned solvents are used.

  An optical film can be formed by coating an antireflective layer such as a high refractive index layer or a low refractive index layer on the hard coat layer produced by the method for producing a hard coat film of the present invention. An optical film with significantly improved is obtained.

Although the following example is mentioned as a layer structure of the optical film obtained by the manufacturing method of this invention, It does not specifically limit to these. Among these, at least one of the clear hard coat layer, the antiglare hard coat layer, the medium refractive index layer, the high refractive index layer, and the low refractive index layer is a layer that is cured by irradiation with active rays after coating and drying. I can do it. The antireflection layer may be formed by a sol-gel method using any metal alkoxide of Ti or Si, and a composition containing metal oxide fine particles such as Zr, Zn, Ti, Si, Sn, and In and a binder is coated. May be.
Back coat layer / resin film / clear hard coat layer / high refractive index layer / low refractive index layer back coat layer / resin film / clear hard coat layer / medium refractive index layer / high refractive index layer / low refractive index layer antistatic layer / Resin film / Clear hard coat layer / Medium refractive index layer / High refractive index layer / Low refractive index layer Back coat layer / Resin film / Anti-glare hard coat layer / High refractive index layer / Low refractive index layer Back coat layer / Resin film / Anti-glare hard coat layer / Medium refractive index layer / High refractive index layer / Low refractive index layer Antistatic layer / Resin film / Anti-glare hard coat layer / Medium refractive index layer / High refractive index layer / Low refractive index Rate layer Since the optical film obtained by the present invention is excellent in flatness, an antireflection film or an antiglare film used in front of a liquid crystal display device, an organic EL display or a plasma display, or a clear film. It is useful as a hard coat film, can provide excellent visibility, and can provide a polarizing plate or a display device using these as a polarizing plate protective film.

  EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited to this Example.

<< Preparation of transparent resin film >>
(Dope composition)
Cellulose triacetate (acetyl substitution degree 2.88) 100 parts by weight Ethylphthalyl ethyl glycolate 5 parts by weight Tinuvin 109 (manufactured by Ciba Specialty Chemicals) 1 part by weight Tinuvin 171 (manufactured by Ciba Specialty Chemicals) 1 part by weight Silicon oxide fine particles (Aerosil 200V) 0.1 parts by weight Methylene chloride 430 parts by weight Methanol 90 parts by weight The above composition was put into a sealed container, kept at 80 ° C. under pressure and completely dissolved while stirring.

  Next, the dope composition was filtered, cooled and kept at 33 ° C., and evenly cast on a stainless steel band. After the solvent was evaporated until peeling became possible, the width was removed by a tenter after peeling from the stainless steel band. The film was dried while being gripped, stretched to 1.1 times in the width direction, and further dried while being conveyed by a number of rolls to obtain a transparent resin film having a thickness of 40 μm and a width of 1.5 m.

  At this time, the surface in contact with the stainless steel band is defined as b surface, and the other surface is defined as a surface.

<< Formation of Back Coat Layer (BC Layer) >>
(Backcoat layer (BC layer) coating composition)
Acetone 72 parts by mass Methanol 18 parts by mass Propylene glycol monomethyl ether 10 parts by mass Diacetyl cellulose 0.5 parts by mass 2% acetone-dispersed ultrafine silica (Aerosil 200V manufactured by Nippon Aerosil Co., Ltd.)
0.1 part by mass The backcoat layer coating composition was applied to the surface of the transparent resin film a so as to have a wet film thickness of 13 μm, and dried in a drying unit set at 80 ° C. to provide a BC layer. .

<< Formation of clear hard coat layer (CHC layer) >>
(Clear hard coat layer (CHC layer) coating composition)
Dipentaerythritol hexaacrylate monomer 60 parts by mass Dipentaerythritol hexaacrylate dimer 20 parts by mass Dipentaerythritol hexaacrylate trimer or higher component 20 parts by mass Irgacure 184 (manufactured by Ciba Specialty Chemicals) 2 parts by mass Isopropyl alcohol 50 parts by weight Ethyl acetate 50 parts by weight Methyl ethyl ketone 50 parts by weight The clear resin layer coating composition was extrusion coated on the b-side of the prepared transparent resin film, and then dried in a drying part set at 80 ° C. Thereafter, ultraviolet rays were irradiated using the ultraviolet irradiation equipment shown in FIG. 1 under the following conditions. As shown in Table 1, the illuminance is adjusted by changing the lamp power, the shape of the lamp and the diffusion plate, or the transport speed of the transparent resin film, and having a clear hard coat layer (CHC layer) with a thickness of 7 μm. 1-21 were obtained.

  Ultraviolet irradiation device: The configuration shown in FIG. 1, a 600φ backup roll 2 is used, the surface temperature is set to 25 ° C., and the range of 180 degrees where the backup roll 2 and the transparent resin film 1 are in contact with each other. The active ray light source 10 was disposed at a position 50 mm away from the surface of the transparent resin film 1 so that the light source could be illuminated with a light source.

Actinic ray light source: UV lamp output 3 kW (High-pressure mercury type manufactured by Eye Graphic Co., Ltd.)
The following evaluation was performed using the produced hard coat film, and the results are shown in Table 1 below.

<Evaluation of clear hard coat layer>
(Flatness)
Cut each sample into a size of 90cm in width and 100cm in length, and arrange five 50W fluorescent lamps at a height of 1.5m so that the sample stage can be illuminated from a 45 ° angle. Each film sample was placed, and the unevenness that appeared to be reflected on the film surface was visually observed and judged as follows. By this method, it is possible to determine “tsun” and “wrinkle”.

◎: All five fluorescent lights look straight ○: Some fluorescent lights appear to be bent slightly △: Fluorescent lights appear slightly bent as a whole ×: Fluorescent lights appear to swell greatly

  Furthermore, the following antireflection layer was formed using the produced hard coat film, and the antireflection film was produced.

<Formation of multilayer antireflection layer>
(Medium refractive index layer coating composition)
Tetra (n) butoxytitanium 250 parts by mass Terminal reactive dimethyl silicone oil (L-9000, manufactured by Nihon Unicar)
0.48 parts by mass Aminopropyltrimethoxysilane (KBE903 manufactured by Shin-Etsu Chemical Co., Ltd.)
22 parts by mass UV curable epoxy resin (KR500 manufactured by Asahi Denka Co., Ltd.) 21 parts by mass Propylene glycol monomethyl ether 4900 parts by mass Isopropyl alcohol 4840 parts by mass (High refractive index layer coating composition)
Tetra (n) butoxytitanium 310 parts by mass Terminal reactive dimethyl silicone oil (L-9000, manufactured by Nihon Unicar Company)
0.4 parts by mass Aminopropyltrimethoxysilane (KBE903 manufactured by Shin-Etsu Chemical Co., Ltd.)
4.8 parts by mass UV curable epoxy resin (KR500 manufactured by Asahi Denka Co., Ltd.) 4.6 parts by mass Propylene glycol monomethyl ether 4900 parts by mass Isopropyl alcohol 4800 parts by mass (Preparation of tetraethoxysilane hydrolyzate A)
580 g of tetraethoxysilane and 1144 g of ethanol were mixed, and after adding an aqueous citric acid solution (in which 5.4 g of citric acid monohydrate was dissolved in 272 g of water), the mixture was stirred at 25 ° C. for 1 hour. Ethoxysilane hydrolyzate A was prepared.

(Low refractive index layer coating composition)
Tetraethoxysilane hydrolyzate A 1020 parts by mass Terminal reactive dimethyl silicone oil (L-9000, manufactured by Nihon Unicar Company)
0.42 parts by mass Propylene glycol monomethyl ether 2700 parts by mass Isopropyl alcohol 6300 parts by mass On the transparent resin films 1 to 21 having the above CHC layer, the medium refractive index layer, the high-order refractive index layer, and the low refractive index layer in the order CHC After coating with a die using a die and drying at 120 ° C., each antireflection layer is cured by irradiating with ultraviolet rays under the same conditions as in the formation of the CHC layer (the conditions described in Table 1), and multilayer reflection is performed. A prevention layer was formed. The flow rate condition was controlled while measuring the thickness of the formed layer online. In this way, a middle refractive layer (thickness: 0.075 μm), a high refractive layer (thickness: 0.070 μm), and a low refractive index layer (thickness: 0.093 μm) are formed. The antireflection films 1 to 21 were prepared.

  The refractive index and film thickness of each layer are determined from the measurement result of the spectral reflectance of the spectrophotometer for the sample coated with each layer alone. The spectrophotometer is U-4000 type (manufactured by Hitachi, Ltd.), and after roughening the back surface of the sample, it is light-absorbed with a black spray to prevent reflection of light on the back surface, and is 5 degrees positive. The reflectance measurement in the visible light region (400 to 700 nm) is performed under the conditions of reflection. The refractive index of each completed layer was medium refractive index layer 1.65, high refractive index layer 1.90, and low refractive index layer 1.45.

<Evaluation of antireflection film>
(Evaluation of uneven color)
A black acrylic plate is attached to the surface opposite to the antireflection layer coated on each of the antireflection films prepared above, and the antireflection layer coating surface side surface is irradiated with a strong white light source to visually observe color unevenness. The presence or absence of occurrence was confirmed, the acrylic plate was removed, the presence or absence of color unevenness due to transmitted light was confirmed, and color unevenness was evaluated according to the following criteria.

◎: No color unevenness is observed even with a black acrylic plate affixed ○: Extremely weak color unevenness is observed with a black acrylic plate affixed, but no color unevenness is observed by observation with transmitted light △: Black acrylic plate Color unevenness is observed in a part of the patch, but it is in a practically acceptable range. ×: Color unevenness is clearly recognized by observation with a black acrylic plate patch and transmitted light, and there is a problem in practical use. The results are shown in Table 1 above.

  As is apparent from Table 1, the optical film produced using the active irradiation conditions defined in the present invention has good flatness in the state where the clear hard coat layer is applied to the comparative example. It can be seen that even in the state where the antireflection layer is coated, color unevenness does not occur and the uniformity of the coating film is excellent. Furthermore, the optical film was not easily broken when an optical thin film was formed.

It is a schematic block diagram of the manufacturing apparatus of the optical film of this invention. It is another example of the schematic block diagram of the manufacturing apparatus of the optical film of this invention. The relationship between the irradiation time of the active energy ray which concerns on this invention, and illumination intensity is illustrated. It is the schematic diagram showing the shape of the active energy ray irradiation lamp and reflector used for this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transparent resin film 2 Backup roll 3 Lamp box 4 Reflecting plate 5 Lamp 6 Diffusing plate 10 Active line light source

Claims (5)

After providing an active energy ray-curable resin layer on a resin film having a width of 1.4 to 4 m, the activity in which the relationship between the irradiation time (t) of the active energy ray and the illuminance (W) was adjusted to the following ranges a and b A method for producing a hard coat film, comprising passing through an energy ray irradiation zone and irradiating an active energy ray to cure.
a. Range in which maximum illuminance Wmax is 0.1 to 0.3 (W / cm ² ) b. The slope dW / dt from the start of irradiation to the maximum illuminance Wmax is in the range of 0.1 to 0.6 (W / cm ² · sec) 2. The hardware according to claim 1, wherein the relationship between the irradiation distance (x) from the lamp of the active energy ray to the surface of the active energy ray-curable resin layer and the illuminance (W) is adjusted to the following range c. A method for producing a coated film.
c. dW / dx is in the range of 0.005 to 0.025 (W / cm ² · cm) The method for producing a hard coat film according to claim 1 or 2, wherein the resin film is a cellulose ester film and the film thickness is in the range of 10 to 60 µm. A hard coat film produced by the method for producing a hard coat film according to claim 1. An antireflection film, comprising an antireflection layer provided on the hard coat film according to claim 4.

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