JP2006095836A - Method for forming hard coat layer having uneven surface - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for forming a hard coat layer having an uneven surface shape which can possibly be predicted and easily be adjusted. <P>SOLUTION: In the method for forming the hard coat layer having the uneven surface shape, a layer containing an uncured radiation curable resin is irradiated with radiation repeatedly to cure the resin. At least one time in repeated irradiation, the layer is irradiated through a mask having radiation transmitting parts and non-transmitting parts to form parts different in degree of curing of the resin, so that the uneven surface shape can be formed. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for forming a hard coat layer having a concavo-convex shape on the surface, and particularly to a method for forming a hard coat layer that can be suitably used for various display surfaces.

  Various layers such as CRT, liquid crystal panel, plasma display, EL display and the like use various layers in order to improve the surface characteristics. Examples of such a layer include a low refractive index layer that reduces deterioration in display quality due to reflection of external light, an antistatic layer that prevents adhesion of dust due to charging, a hard coat layer that prevents scratches and scratches, A laminate having a plurality of these layers can be used.

  One of such layers is an antiglare layer (antiglare layer) that suppresses glare on the surface by making the surface uneven. As conventional means for providing irregularities on the surface of the antiglare layer, there are a method for providing irregularities by applying an ink containing a filler, a method for providing irregularities by shape transfer using a film having irregularities, and a shape transfer using an uneven plate. There is a method of providing unevenness.

However, according to these methods, the predictability of the surface shape of the antiglare layer is low, the target surface shape cannot be obtained without many trials and errors, and the surface shape cannot be easily adjusted. There is.
JP 2002-331615 A

  The object of the present invention is to solve the above-mentioned problems, that is, the surface shape is highly predictable and the surface shape can be easily adjusted (typically to provide antiglare properties). It is providing the formation method of the hard-coat layer which has this.

  The inventor employs a method of forming a hard coat layer with an ionizing radiation curable resin, and performs ionizing radiation irradiation for resin curing a plurality of times, and at least one of the ionizing radiation transmitting portion and It is found that the above object can be achieved by forming a concavo-convex shape by a curing shrinkage difference by forming a portion having a different degree of curing of the ionizing radiation curable resin, through a mask having a non-transmissive portion. Completed.

  That is, the present invention is a method for forming a hard coat layer by irradiating a layer containing an uncured ionizing radiation curable resin with a plurality of times of ionizing radiation irradiation and curing the ionizing radiation curable resin. At least one of the multiple times of ionizing radiation irradiation is performed through a mask having a transmission part and a non-transmission part of ionizing radiation, and an uneven shape is formed by forming portions with different degrees of curing of the ionizing radiation curable resin This is a method for forming a hard coat layer having a concavo-convex shape on the surface.

  The method for forming a hard coat layer of the present invention is preferably a method in which the final irradiation of the plurality of times of ionizing radiation irradiation is full-surface irradiation without using a mask.

  Moreover, the method for forming a hard coat layer of the present invention is preferably a method in which, in a portion irradiated with ionizing radiation through a mask, the irradiation amount through the mask is 20 to 80% of the total irradiation amount.

  Furthermore, the method for forming a hard coat layer of the present invention is preferably a method in which a polymer having an average molecular weight of 30,000 to 300,000 is added to the uncured ionizing radiation curable resin.

  As another aspect of the present invention, the present invention is a hard coat layer obtained by the above method.

  Moreover, as another aspect of the present invention, the present invention is a laminate having the above hard coat layer.

  As another aspect of the present invention, the present invention is a display having the hard coat layer on the surface.

  According to the present invention, there is provided a simple method for forming a hard coat layer having a concavo-convex shape on the surface, which has high predictability of the surface shape and is easy to adjust the surface shape (typically for imparting antiglare properties). Can be provided.

Hard Coat Layer The hard coat layer in the present invention is a layer for preventing scratches or scratches on the surface of an object and is not particularly limited as long as it has an uneven shape on the surface. Although the hard coat layer in the present invention is not limited to this, it can be laminated on the surface of a display and used as an antiglare film, for example.

Ionizing radiation curable resin The hard coat layer of the present invention is formed from a layer containing an uncured ionizing radiation curable resin. The ionizing radiation means various broadly defined radiations that act to cure the resin, such as ultraviolet rays and electron beams. As the ionizing radiation curable resin, various commercially available resins can be used depending on the use of the hard coat layer. For example, in the case of a hard coat layer using an antiglare film on a display surface, an ionizing radiation curable resin that is colorless and transparent and has high hardness after curing can be used.

  This uncured ionizing radiation curable resin may contain an additional component for adjusting its properties. For example, a polymer (for example, a polymer having an average molecular weight of 30,000 to 300,000) may be contained in advance. Good.

Multiple times of ionizing radiation irradiation In the method for forming a hard coat layer of the present invention, ionizing radiation irradiation for resin curing is performed a plurality of times. Then, at least one of the plurality of times of ionizing radiation irradiation is performed through a mask having an ionizing radiation transmitting portion and a non-transmitting portion, thereby forming portions having different degrees of curing of the ionizing radiation curable resin. Thus, by changing the irradiation amount depending on the location of the hard coat layer, typically, a difference in curing shrinkage can be produced depending on the location of the hard coat layer, and irregularities can be formed on the surface.

  Regarding the difference in the irradiation amount, it is preferable that the irradiation amount through the mask in the portion irradiated with the ionizing radiation through the mask is 20 to 80% of the total irradiation amount. By adjusting the irradiation amount through the mask and the total irradiation amount, the height of the unevenness can be easily adjusted.

  Further, by changing the shape and interval of the ionizing radiation transmitting portion (mask opening), the shape and interval of the unevenness viewed from the upper surface of the hard coat layer can be easily set. In the case of using a mask in which the ionizing radiation transmitting portion has, for example, a hole shape, the hole diameter is not limited to this. For example, the hole diameter is 20 to 1000 μm, preferably 50 to 200 μm, and the hole interval is 20 for example. The thing of -2000 micrometers, Preferably it is 100-500 micrometers can be used.

Uneven shape The shape of the unevenness formed on the surface of the hard coat layer of the present invention is not particularly limited. For example, various shapes such as a cylinder, a prism, a cone, a pyramid, a part of a spherical surface (such as a hemisphere), a donut, and a lattice frame shape can be used.

  In addition, the size of the unevenness is not particularly limited, but the height of the unevenness is, for example, 0.01 to 100 μm, preferably 0.1 to 10 μm, and the width of the protruding portion or the recessed portion, for example, in order to develop antiglare properties. The thickness can be 1 to 500 μm, preferably 10 to 200 μm.

Product As a product targeted by the present invention, firstly, a hard coat layer obtained by the above-mentioned method is mentioned.

  Moreover, the laminated body which has this hard-coat layer is also mentioned as a product made into the object of this invention. Examples of the laminate include a laminate in which a low refractive index layer and / or an antistatic layer are combined in addition to the hard coat layer of the present invention.

  Furthermore, the product which is the subject of the present invention includes a display having this hard coat layer (or a laminate having this hard coat layer) on the surface. Examples of the display include various displays such as a CRT, a liquid crystal panel, a plasma display, and an EL display.

  As described below, the uncured ultraviolet curable resin layer was irradiated with ultraviolet rays a plurality of times to form a hard coat layer having an uneven shape on the surface.

1. An uncured UV curable resin for clearing was applied onto a substrate and dried (film thickness after drying: about 7 μm).
2. A shadow mask is placed on the substrate with a clearance of 0.2 mm, and exposure is performed with ultraviolet rays (100 mj / cm2) perpendicular to the substrate and the mask. Only the area opposite the mask hole was cured. Ultraviolet exposure was performed without N2 purge (in the atmosphere).
3. Next, the mask was removed, and the entire surface of the substrate was exposed to ultraviolet rays (100 mj / cm 2). The masked part was also cured.
4). The surface irregularity shape was evaluated.

  As a mask, a shadow mask (a thin metal plate in which holes used in a CRT are arranged in a staggered pattern) having a hole array with a hole diameter of 100 μm and an XY pitch of 300 μm was used.

  The results of evaluating the irregularities on the surface of the obtained hard coat layer were as follows.

a. The entire mask exposure area was not convex or concave.
b. Convex portions were formed only in the periphery of the mask exposure region.
c. The convex part was about 1000 nm higher than the peripheral part.
d. The hole size of the mask was 100 μm, and as a result, a donut-shaped convex part having a height of about 1000 nm and a width of about 25 μm was formed on the hard coat layer.
e. According to the visual test, sufficient antiglare property was also recognized.

Claims (7)

For a layer containing an uncured ionizing radiation curable resin, a method of performing a plurality of times of ionizing radiation irradiation and curing the ionizing radiation curable resin to form a hard coat layer,
At least one of the plurality of times of ionizing radiation irradiation is performed through a mask having a transmission part and a non-transmission part of ionizing radiation, and the uneven shape is formed by forming portions with different degrees of curing of the ionizing radiation curable resin. A method for forming a hard coat layer having a concavo-convex shape on a surface, wherein   The formation method of the hard-coat layer of Claim 1 whose last irradiation is the whole surface irradiation which does not use a mask among the said multiple times of ionizing radiation irradiation.   2. The method of forming a hard coat layer according to claim 1, wherein in the portion irradiated with ionizing radiation through the mask, the irradiation amount through the mask is 20 to 80% of the total irradiation amount.   The method for forming a hard coat layer according to claim 1, wherein a polymer having an average molecular weight of 30,000 to 300,000 is added to the uncured ionizing radiation curable resin.   A hard coat layer obtained by the method according to claim 1.   A laminate having the hard coat layer according to claim 5.   A display having the hard coat layer according to claim 5 on a surface thereof.