JP2011221131A - Protection film for optical member, laminate containing optical member and method for manufacturing laminate containing optical member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a protection film for an optical member having a fine and uneven pattern, which protection film is excellent in storage stability, does not cause detachment in a post processing process, and is detached without adhesive transfer after use.SOLUTION: There is provided a protection film for an optical member having a functional, fine and uneven pattern provided with optical functionality. The protection film for the optical member has a fine and uneven pattern for protection in an uneven shape which is reverse to the uneven shape of the functional, fine and uneven pattern of the optical member.

Description

  The present invention relates to a protective film used for an optical member having a fine uneven pattern such as a moth-eye type antireflection film, a light guide plate, and a prism sheet.

  In general, a protective film has a pressure-sensitive adhesive layer formed on a substrate, and the protective film pressure-sensitive adhesive layer is adhered to the object to be protected to prevent scratches, contamination, etc. of the object to be protected. It is used for. For example, an optical member such as an antireflection film used in a flat panel display such as a liquid crystal display, a plasma display, and an organic EL display has a protective film bonded through an adhesive layer to protect it from scratches and dirt. Yes. Then, the protective film is peeled off and removed at the stage where the surface protection is no longer necessary, for example, by bonding the optical member to a flat panel display.

The properties required for a protective film with a pressure-sensitive adhesive layer are that it sticks firmly without floating during the process, does not peel off from the protected body, can be easily peeled off from the protected body after use, For example, there is no adhesive residue (residue of adhesive component) on the surface of the object to be protected. As an example of the protective film, Patent Document 1 discloses a surface protective film that suppresses generation of static electricity at the time of peeling, has no contamination due to adhesive residue, and has excellent surface protection performance.
However, if the object to be protected has a fine concavo-convex pattern on the order of μm to nm, the contact area with the protective film becomes small and it becomes difficult to attach the protective film. However, it is not easy and is a big issue. For example, since the adhesiveness is poor, there is a problem that the storage stability is not sufficient, and the film is peeled off in a subsequent water washing step. On the other hand, if it is affixed strongly so that it does not peel off, glue will remain at the time of peeling.

  In addition, as an optical member which has such a fine uneven | corrugated pattern, the antireflection film in which the fine uneven | corrugated pattern by which the period of the unevenness | corrugation was controlled below to the wavelength of visible light was formed on the surface is known, for example. This is based on the principle of the so-called moth-eye structure, by continuously changing the refractive index for light incident on the substrate and eliminating the discontinuous interface of the refractive index. This prevents light reflection. In addition, as another example of the optical member having the concavo-convex pattern described above, a light guide plate having a fine concavo-convex pattern of μm order formed on the light exit surface, a convex portion having a triangular top on the light incident surface, and a triangular groove Examples thereof include a prism sheet on which a prism-shaped fine concavo-convex pattern including a concave portion having a bottom is formed. The light guide plate diffuses light incident from the side surface and emits uniform light from the light output surface. Light from a line light source such as a cold cathode tube or a point light source such as an LED (light emitting diode) is used as a surface light source. And can be converted. The prism sheet is a sheet having a forward light condensing effect, and is installed on the upper surface of the light guide plate of the backlight in order to intensively improve the luminance in the front direction.

Japanese Patent Laid-Open No. 2001-316643

  The present invention has been made in view of the above problems, and is excellent in storage stability for optical members having a fine concavo-convex pattern, does not peel off during post-processing steps, and has no adhesive residue after use. The main object is to provide a peelable protective film for an optical member.

  In order to achieve the above object, in the present invention, a protective film for an optical member used for an optical member having a functional fine uneven pattern having an optical function, wherein the functional fine uneven pattern of the optical member is Provided is a protective film for an optical member, which has a protective fine uneven pattern having an uneven shape opposite to the uneven shape.

  According to the present invention, the protective film for an optical member has a protective fine concavo-convex pattern having a concavo-convex shape opposite to the concavo-convex shape of the functional fine concavo-convex pattern of the target optical member. By forming an optical member formed with a fine concavo-convex pattern for protecting a film on the protective film for an optical member, the fine concavo-convex patterns of the optical member and the protective film for the optical member are fitted to each other, and the functional fine concavo-convex pattern is formed. The optical member and the protective film for the optical member can be firmly adhered without any gap. Therefore, it can be set as the protective film which is excellent in storage stability and does not peel even in a post-processing process. In addition, by using a resin material having excellent releasability and having a protective film that does not have an adhesive layer, the protective film for optical members can be easily peeled off from the optical member. Furthermore, there is no adhesive residue on the protected surface of the optical member.

  In the said invention, it is preferable that the said protective fine uneven | corrugated pattern is an original of the said functional fine uneven | corrugated pattern. By manufacturing the optical member using the protective film for an optical member of the present invention as an original plate of the optical member, the optical member and the protective film for the optical member are integrated so as to protect the functional fine uneven pattern of the optical member. The laminated body, that is, the optical member protected by the protective film for the optical member can be easily produced.

  In the said invention, it is preferable that the protective film for optical members of this invention consists of a polypropylene or polyethylene. This is because it has releasability, is inexpensive and highly versatile.

  Further, in the present invention, an optical member laminate comprising an optical member having a functional fine concavo-convex pattern having an optical function and a protective film for an optical member protecting the functional fine concavo-convex pattern, wherein the optical The member protective film has a protective fine uneven pattern having an uneven shape opposite to the uneven shape of the functional fine uneven pattern of the optical member, and the protective fine uneven pattern of the protective film for the optical member; Provided is an optical member laminate in which the optical member protective film and the optical member are laminated by being detachably fitted to the functional fine uneven pattern of the optical member. To do.

  According to the present invention, the protective film for an optical member has a protective fine concavo-convex pattern having a concavo-convex shape opposite to the concavo-convex shape of the functional fine concavo-convex pattern of the target optical member, and protects the protective film for an optical member Since the fine concavo-convex pattern for use and the functional fine concavo-convex pattern of the optical member are fitted to each other, the two can be adhered to each other without a gap. Therefore, the optical member and the protective film for the optical member are integrated so as to protect the functional fine concavo-convex pattern serving as the protected surface of the optical member, and it has excellent storage stability and does not peel off during the post-processing step. It can be a body. In addition, the optical member and the protective film for the optical member can be peeled, and the optical member can be peeled cleanly from the protective film for the optical member, so that the protected surface of the optical member is not contaminated. It is possible to easily incorporate the peeled optical member into another member without performing a process for converting into other members.

  Moreover, in this invention, the manufacturing method of the optical member laminated body formed by laminating | stacking the optical member which has a functional fine concavo-convex pattern which has an optical function, and the protective film for optical members which protects the said functional fine concavo-convex pattern An optical member protective film for forming an original plate having the same fine uneven pattern as the functional fine uneven pattern and forming the optical member protective film on the fine uneven pattern of the original plate. A protective film for an optical member that forms the protective film for an optical member having a concave / convex pattern for protection having a concave / convex shape opposite to the concave / convex shape of the functional fine concave / convex pattern by arranging and shaping the resin material for the optical member Forming a concave and convex layer for forming the concave and convex layer of the optical member on the protective fine concave and convex pattern of the protective film for the optical member; An optical member comprising an optical member forming step of forming an uneven layer having the functional fine uneven pattern by arranging and shaping a layer forming resin material, thereby forming the optical member. A method for producing a member laminate is provided.

  According to the present invention, a protective film for an optical member having a protective fine concavo-convex pattern having a concavo-convex shape opposite to the concavo-convex shape of the functional fine concavo-convex pattern of the target optical member is prepared in advance, and this protective fine concavo-convex pattern By forming an optical member having a functional fine concavo-convex pattern formed by molding on the protective film for optical member, both the optical member and the fine concavo-convex pattern of the protective film for optical member are fitted together. Can be adhered without gaps. Therefore, the optical member and the protective film for the optical member are integrated so as to protect the functional fine concavo-convex pattern serving as the protected surface of the optical member, and it has excellent storage stability and does not peel off during the post-processing step. You can get a body. Moreover, the optical member protected by the protective film for optical members can be easily obtained while manufacturing the optical member.

  Moreover, in this invention, the optical member laminated body incorporating process which incorporates the optical member laminated body obtained by the manufacturing method of the optical member laminated body mentioned above in the member which requires an optical function, and for optical members from an optical member The manufacturing method of the member which has an optical function characterized by having the peeling process which peels a protective film.

  According to the present invention, by incorporating the optical member laminate described above into a member that requires an optical function, any post-process can be appropriately performed as necessary while protecting the optical member. In addition, after the process, in the assembled optical member laminate, the optical member having a fine uneven pattern in which the optical function member is free from contamination such as adhesive residue by peeling off the protective film for the optical member from the optical member Therefore, a member having a good optical function can be obtained.

  In the present invention, the optical member and the protective film for the optical member are integrated so as to protect the functional fine uneven pattern of the optical member by manufacturing the optical member using the protective film for the optical member for the original plate of the optical member. It is possible to easily produce a laminated body, that is, an optical member protected by a protective film for an optical member. According to the present invention, even when used for an optical member having a fine unevenness pattern on the order of μm to nm, it is excellent in storage stability, does not peel off during the post-processing step, and can be peeled off without any adhesive residue after use. There exists an effect that the protective film for members is obtained.

It is a schematic sectional drawing which shows an example of the optical member which has a functional fine concavo-convex pattern which has a protective film for optical members of this invention, and an optical function. It is the schematic explaining the parameter which specifies the fine uneven | corrugated pattern for protection in the protective film for optical members. It is a schematic sectional drawing which shows an example of the optical member laminated body of this invention. It is a schematic sectional drawing which shows an example of the antireflection film used as an optical member in the optical member laminated body of this invention. It is the schematic explaining the parameter which specifies the fine uneven | corrugated pattern in an antireflection film. It is a perspective view which shows an example of the light-guide plate used as an optical member in the optical member laminated body of this invention. It is the XX sectional view taken on the line of FIG. It is a perspective view which shows an example of the prism sheet used as an optical member in the optical member laminated body of this invention. It is process drawing which shows an example of the manufacturing method of the optical member laminated body of this invention. It is process drawing which shows the other example of the manufacturing method of the optical member laminated body of this invention.

  Hereinafter, the protective film for optical members, the optical member laminate, the method for producing the optical member laminate and the method for producing a member having an optical function according to the present invention will be described in detail.

A. First, the protective film for optical members of the present invention will be described. The protective film for an optical member of the present invention is a protective film for an optical member used for an optical member having a functional fine uneven pattern having an optical function, and the uneven shape of the functional fine uneven pattern of the optical member It is characterized by having a protective fine concavo-convex pattern having a reverse concavo-convex shape.

  The protective film for optical members of the present invention will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view showing an example of the protective film for an optical member of the present invention and an optical member having a functional fine concavo-convex pattern having an optical function. The protective film 1 for an optical member illustrated in FIG. 1 has a protective fine uneven pattern 1a on the surface, and the protective fine uneven pattern 1a has functional fine unevenness on the surface of the target optical member 2. The uneven shape is reversed with respect to the pattern 2a. Here, “the concavo-convex shape is reversed” means that the convex portion of one fine concavo-convex pattern and the concave portion of the other fine concavo-convex pattern can be fitted to each other.

According to the present invention, the protective film for an optical member has the protective fine concavo-convex pattern having the concavo-convex shape opposite to the concavo-convex shape of the functional fine concavo-convex pattern of the target optical member. By arranging the optical member on the protective film for an optical member so that the fine uneven patterns of the protective film for the optical member are fitted to each other, both can be brought into close contact with each other.
Furthermore, by using an optical member having a functional fine concavo-convex pattern in which the protective fine concavo-convex pattern of the protective film for an optical member is shaped, the functional fine concavo-convex pattern of the optical member and the protective film for the optical member By arranging the optical member on the protective film for an optical member so that the protective fine concavo-convex pattern is completely fitted to each other, both can be firmly adhered without any gap. Therefore, since there is no gap between the optical member and the protective film for the optical member, water and dust do not enter, and the protected surface of the optical member is reliably protected even for long-term storage. Can do. Therefore, it can be set as the protective film which is excellent in storage stability and does not peel even in a post-processing process. In addition, by using a resin material having excellent releasability and having a protective film that does not have an adhesive layer, the protective film for optical members can be easily peeled off from the optical member. Furthermore, there is no adhesive residue on the protected surface of the optical member.

  In the present invention, it is particularly preferable that the protective fine concavo-convex pattern of the protective film for optical members is an original functional fine concavo-convex pattern having the optical function of the optical member. The functional fine uneven pattern of the optical member and the protection for the optical member are formed on the protective film for the optical member by forming an optical member having the functional fine uneven pattern in which the protective fine uneven pattern is shaped as an original plate. A laminated body in which the optical member and the protective film for an optical member are integrated so that the protective fine concavo-convex pattern of the film is closely adhered without gap and the functional fine concavo-convex pattern which is a protected surface of the optical member is protected. That is, the optical member protected by the protective film for optical members can be easily produced.

  Hereinafter, each structure of the protective film for optical members of this invention is demonstrated.

  The protective fine concavo-convex pattern in the protective film for an optical member of the present invention is a fine concavo-convex pattern having a concavo-convex shape opposite to the concavo-convex shape of the functional fine concavo-convex pattern having the optical function of the target optical member. Here, the “fine concavo-convex pattern” refers to a concavo-convex pattern that is peeled off without being attached to a normal pressure-sensitive adhesive layer, and specifically refers to a concavo-convex pattern having a concavo-convex period of the order of μm to nm. In addition, the period of unevenness means the average of the distance from the convex top part of an adjacent unevenness | corrugation to a convex top part, and points out the average of the distance represented by P in FIG. The period of unevenness in the protective fine uneven pattern is appropriately selected according to the functional fine uneven pattern of the target optical member, and specifically, is in the range of 50 nm to 100 μm. It is preferable.

  In addition, the height of the unevenness in the protective fine uneven pattern is not particularly limited as long as it is on the order of μm to nm, and is appropriately selected according to the functional fine uneven pattern of the target optical member. Specifically, it is preferably in the range of 100 nm to 50 μm. The height of the unevenness means an average distance from the convex top portion of the unevenness to the concave bottom portion, and indicates an average distance represented by Q in FIG.

  The protective film for optical members of the present invention is made of a resin material. The resin material is not particularly limited as long as it can form the protective fine concavo-convex pattern, and examples thereof include thermoplastic resins, thermosetting resins, and photocurable resins. Among these, a thermoplastic resin is preferable from the viewpoint of the manufacturing process.

  Examples of the thermoplastic resin include fluorine resin, polyethylene, polypropylene, polyvinyl chloride, polyvinyl fluoride, polystyrene, ABS resin, AS resin, polyamide, polyacetal, polyester, polycarbonate, modified polyphenylene ether, polysulfone, polyarylate, Polyetherimide, Polyamideimide, Polyimide, Polyphenylene sulfide, Liquid crystalline polyester, Polyethylene terephthalate, Polybutylene terephthalate, Polyethylene naphthalate, Polymicroxylene dimethylene terephthalate, Polyoxymethylene, Polyethersulfone, Polyetheretherketone, Polyacrylate , Polybutylene succinate, syndiotactic polystyrene, polyoxybenzoyl, polybude , Polymethylpentene, crystalline polybutadiene, isotactic polystyrene, polyvinyl alcohol, polylactic acid, polybutadiene, styrene-butadiene copolymer, ethylene-propylene random copolymer, liquid crystal polymers, and silicone and the like. Among these, polypropylene and polyethylene can be preferably used. This is because polypropylene and polyethylene are releasable, inexpensive and versatile. A multilayer structure having these as innermost layers may be used. Moreover, a mold release process may be performed or an EB process may be performed to increase heat resistance.

  As melting | fusing point of the resin material used for the protective film for optical members of this invention, it is the temperature which can be poured into the type | mold (original) of the protective film for optical members with an apparatus, and from the processing temperature at the time of optical member manufacture A high temperature is preferred. This is because the protective film for an optical member cannot be produced if the melting point is too high to be poured into a mold by an apparatus. On the other hand, if the melting point is lower than the processing temperature during the production of the optical member, the protective film for the optical member is deformed during the production of the optical member, and the optical member cannot be formed on the protective film for the optical member. Specifically, the melting point is appropriately selected according to a processing process such as ultraviolet (UV) curing or thermosetting at the time of producing an optical member, and is usually in the range of 40 ° C to 350 ° C. It is preferable that it is in the range, and it is more preferable that it exists in the range of 80 to 280 degreeC.

  The melt flow rate (MFR) of the resin material used for the protective film for optical members of the present invention is not particularly limited as long as it can be poured into the mold (original plate) of the protective film for optical members. The measurement value according to the measurement method defined in JIS K7210 (temperature 190 ° C., load 2.16 kg or temperature 230 ° C., load 2.16 kg or temperature 280 ° C., load 2.16 kg) is 0.1 g / 10 min to 40 g / 10 min. In particular, it is preferable to be in the range of 1.0 g / 10 min to 10 g / 10 min.

  Moreover, since the protective film for optical members of this invention peels from an optical member after use, it needs to have releasability. The means for imparting releasability to the protective film for optical members is not particularly limited, a resin material having releasability may be used, and a release agent may be added to the resin material. Although the release agent may be directly applied to the surface of the protective film for optical members, it is preferable to use a resin material having releasability or to add a release agent to the resin material. This is because the manufacturing process is not complicated. Examples of the release agent include silicone, higher fatty acid, fatty acid ester, fluorine and the like.

Although the protective film for optical members of the present invention may or may not have transparency, it is preferable to have transparency from the viewpoint of inspection of optical members.
Moreover, it is preferable that the protective film for optical members of this invention has flexibility from a viewpoint which winds up.

  The thickness of the protective film for an optical member of the present invention is not particularly limited as long as it can be wound up and the protective fine uneven pattern is covered. For example, the thickness is 0.1 μm to 1000 μm. It is preferably within the range, and more preferably within the range of 10 μm to 200 μm.

  The protective film for optical members of the present invention may or may not be destroyed when peeled from the optical member after use. In the case of destruction, a half cut or a cut may be made in advance in the protective film for optical members.

  As an application of the protective film for an optical member of the present invention, it is used for an optical member having a functional fine concavo-convex pattern having an optical function. The optical member having the functional fine concavo-convex pattern has, for example, an antireflection film having a moth-eye structure and a one-dimensional periodic structure as a subwavelength periodic structure element formed on the surface with a period equal to or less than the wavelength of the visible light region. Structural birefringence wave plate, light guide plate with micro uneven pattern on the light exit surface, polygonal prism shape such as triangular prism, or multiple prisms such as hemisphere, cone, square pyramid, truncated cone, square pyramid The prism sheet etc. which have the fine uneven | corrugated pattern which consists of in the light-incident surface can be mentioned. The antireflection film, the light guide plate, and the prism sheet will be described in detail in the section “B. Optical member laminate” described later. Other examples of the optical member having the functional fine concavo-convex pattern include a hologram, a wire grid, a water-repellent material, and an oil-repellent material.

  Moreover, the protective film for optical members of the present invention may be manufactured using a mold different from the optical member itself, or the optical member itself may be manufactured as a plate of the protective film for optical members. Since the manufacturing method of the protective film for optical members is described in the section of “C. Manufacturing method of optical member laminate” described later, description thereof is omitted here.

B. Next, the optical member laminate of the present invention will be described. The optical member laminate of the present invention is an optical member laminate comprising an optical member having a functional fine concavo-convex pattern having an optical function, and a protective film for an optical member for protecting the functional fine concavo-convex pattern, The protective film for an optical member has a protective fine uneven pattern having an uneven shape opposite to the uneven shape of the functional fine uneven pattern of the optical member, and the protective fine uneven pattern of the protective film for the optical member And the said functional fine uneven | corrugated pattern of the said optical member is fitted so that peeling is possible, The said protective film for optical members and the said optical member are laminated | stacked, It is characterized by the above-mentioned.

  The optical member laminate of the present invention will be described with reference to the drawings. FIG. 3 is a schematic cross-sectional view showing an example of the optical member laminate of the present invention. In FIG. 3, the optical member laminated body 5 has the optical member 2 which has the functional fine uneven | corrugated pattern 2a, and the protective film 1 for optical members which protects the functional fine uneven | corrugated pattern 2a. The protective film 1 for an optical member has a protective fine uneven pattern 1a having an uneven shape opposite to the uneven shape of the functional fine uneven pattern 2a of the optical member 2, and the protective fine film 1 for the optical member 2 is protected. The concave / convex pattern 1a and the functional fine concave / convex pattern 2a of the optical member 2 are detachably fitted. The optical member 2 has a base material 3 and an uneven layer 4 formed on the base material 3.

  According to the present invention, the protective film for an optical member has a protective fine concavo-convex pattern having a concavo-convex shape opposite to the concavo-convex shape of the functional fine concavo-convex pattern of the target optical member, and protects the protective film for an optical member Since the fine concavo-convex pattern for use and the functional fine concavo-convex pattern of the optical member are fitted to each other, the two can be adhered to each other without a gap. Therefore, the optical member and the protective film for the optical member are integrated so as to protect the functional fine concavo-convex pattern serving as the protected surface of the optical member, and it has excellent storage stability and does not peel off during the post-processing step. It can be a body. In addition, the optical member and the protective film for the optical member can be peeled, and the optical member can be peeled cleanly from the protective film for the optical member, so that the protected surface of the optical member is not contaminated. It is possible to easily incorporate the peeled optical member into another member without performing a process for converting into other members.

  Hereinafter, each structure in the optical member laminated body of this invention is demonstrated.

1. Protective film for optical member The protective film for optical member in the present invention is a protective fine unevenness having an uneven shape opposite to the uneven shape of the functional fine unevenness pattern of the optical member having a functional fine unevenness pattern having an optical function. It has a pattern and protects the functional fine concavo-convex pattern.
In addition, since it described in the said "A. protective film for optical members" about the protective film for optical members, description here is abbreviate | omitted.

2. Optical member The optical member in this invention has a functional fine concavo-convex pattern which has an optical function.

  About the period and height of the said functional fine uneven | corrugated pattern, it can be made to be the same as that of the protection fine uneven | corrugated pattern of the protective film for optical members described in the term of the said "A. protective film for optical members".

  The thickness of the optical member is appropriately selected according to the target optical member, and is, for example, in the range of 20 μm to 5000 μm.

The optical member in the present invention is not particularly limited as long as it has the functional fine concavo-convex pattern. Usually, the concavo-convex formed on a substrate and the functional fine concavo-convex pattern is provided. And a layer. A base material and an uneven | corrugated layer are suitably selected according to the target optical member. Examples of such an optical member include a moth-eye type antireflection film, a light guide plate, and a prism sheet.
Hereinafter, the antireflection film, the light guide plate, and the prism sheet will be described.

(1) Antireflection film As illustrated in FIG. 4, the antireflection film 21 is formed on the light transmissive substrate 22 and the light transmissive substrate 22, and is formed on the surface with a period equal to or less than the wavelength of the visible light region. And the antireflection layer 23 having fine irregularities. When the optical member used in the present invention is an antireflection film, the antireflection layer corresponds to the uneven layer having the functional fine uneven pattern, and the light transmissive substrate corresponds to the base material.
Hereinafter, each configuration in the antireflection film will be described.

(I) Antireflective layer The antireflective layer used for the antireflective film is formed on a light-transmitting substrate, and has fine irregularities formed on the surface with a period equal to or less than the wavelength of the visible light region. A desired antireflection function is imparted to the film. In the optical member used in the present invention, the antireflection layer corresponds to the concavo-convex layer and has the functional fine concavo-convex pattern, and the functional fine concavo-convex pattern includes the fine concavo-convex pattern. When the optical member used in the present invention is an antireflection film, the functional fine concavo-convex pattern composed of the fine concavo-convex and the protective fine concavo-convex pattern of the protective film for the optical member are fitted to protect the fine concavo-convex. Moreover, it becomes an optical member laminated body by which the protective film for optical members was laminated | stacked on the antireflection layer of the antireflection film.

  The fine unevenness is not particularly limited as long as it is formed with a period equal to or less than the wavelength of the visible light region, and any shape can be selected and used according to the use of the antireflection film or the like. . Especially, it is preferable that a fine unevenness | corrugation is what formed cone-shaped structures, such as a cone and a quadrangular pyramid, periodically.

  When a structure in which a cone-shaped structure is periodically formed is used as the fine unevenness, the cone-shaped structure may be formed with a flat top or an acute angle at the top. It may be what was done.

In the case where a conical structure is periodically formed as the fine unevenness, the antireflection function of the antireflection film mainly depends on the period, height, and interval at which the conical structure is formed. Will do.
In addition, the period, height, and space | interval in which the cone-shaped structure was formed point to the distance represented by P, Q, and R in FIG.

  The period of the conical structure is not particularly limited as long as it is equal to or shorter than the wavelength in the visible light region, and can be appropriately determined according to the use of the antireflection film. Here, the period affects the wavelength dependence of the reflectance of the antireflection layer, and the reflectance of light on the short wavelength side in the visible light region tends to increase as the period becomes longer. On the other hand, when the period is 200 nm or less, the change in the wavelength dependency of the reflectance in the visible light region due to the fluctuation of the period is small. For this reason, the period is preferably in the range of 50 nm to 250 nm, more preferably in the range of 70 nm to 200 nm, and even more preferably in the range of 80 nm to 150 nm. Further, in order to further improve the antireflection property, the cone shape having a period in the range of 50 nm to 250 nm has a high undulation with a height in the range of 50 nm to 50 μm and a period in the range of 100 nm to 100 μm. You may have the unevenness | corrugation comprised. If the period in which the conical structures are formed is shorter than the above range, the shape of each structure will be extremely small, which may make it difficult to form the structures with high accuracy. is there. Further, if the period is longer than the above range, the antireflection function for light on the short wavelength side of the antireflection layer may be insufficient.

The height of the cone-shaped structure can also be adjusted as appropriate within a range in which a desired antireflection function can be imparted to the antireflection layer, and is not particularly limited. Here, the higher the height, the lower the reflectance of the antireflection layer. On the other hand, when the height is lower, the reflectance on the long wavelength side tends to increase. Therefore, the height of the cone-shaped structure is preferably in the range of 100 nm to 500 nm, more preferably in the range of 150 nm to 400 nm, and in the range of 200 nm to 350 nm. Is more preferable.
If the height of the structure is higher than the above range, the individual structures may be easily damaged, and if the height is lower than the above range, the reflectance on the long wavelength side tends to increase. Because there is.

As the interval at which the cone-shaped structures are formed increases, the reflectance tends to increase in the entire wavelength region of visible light, and as the interval decreases, the reflectance tends to decrease in the entire wavelength region of visible light. For this reason, the interval at which the conical structures are formed can be appropriately adjusted within a range in which a desired antireflection function can be imparted to the antireflection layer, and is not particularly limited. However, it is preferably 100 nm or less, more preferably 50 nm or less, and even more preferably 10 nm or less. This is because if the interval at which the structures are formed is longer than the above range, sufficient antireflection performance may not be exhibited.
In addition, although the said space | interval may not be uniform in all the structures, the said distance in that case shall point out the average distance of the space | interval between the structures formed per unit area.

  The antireflection layer is made of a curable resin. The curable resin is not particularly limited as long as it can form a moth-eye structure having a desired shape.

  Examples of the curable resin include a thermosetting resin and a photocurable resin, and any curable resin can be preferably used. Among these, it is preferable to use a photocurable resin as the curable resin. By using a photocurable resin, it becomes possible to produce a product with a higher throughput than a thermosetting resin.

  The thickness of the antireflection layer is preferably in the range of 1 μm to 50 μm, more preferably in the range of 3 μm to 30 μm, and still more preferably in the range of 5 μm to 20 μm.

(Ii) Light-transmitting substrate The light-transmitting substrate used for the antireflection film supports the above-described antireflection layer, and in combination with the antireflection layer, imparts a desired antireflection function to the antireflection film. It is. In the optical member used in the present invention, this light-transmitting substrate corresponds to the base material. However, in the present invention, the transparent substrate may or may not be used.

  The material constituting the light transmissive substrate is appropriately selected according to the light transmittance and refractive index of the light transmissive substrate. Examples of the material used for the light-transmitting substrate include acrylic resin, polyolefin resin, thermoplastic resin, cellulose resin, polycarbonate, two-component curable resin, and glass (including ceramics).

  The thickness of the light transmissive substrate is preferably in the range of 10 μm to 300 μm, more preferably in the range of 20 μm to 200 μm, and still more preferably in the range of 40 μm to 100 μm.

(2) Light Guide Plate As illustrated in FIG. 6, the light guide plate 31 includes a light output surface 31a that is one main surface, a back surface 31b that is the other main surface facing the light output surface 31a, and a light output surface 31a. And two light incident surfaces 31c and 31d, which are a pair of opposite side surfaces among the four side surfaces between the back surface 31b. In addition, as illustrated in FIG. 7, the light guide plate 31 includes a main body portion 32 in which scattering particles 35 are uniformly dispersed in a base resin 34, and an optical element portion 33 formed on the light exit surface 31 a side of the main body portion 32. have. 7 is a cross-sectional view taken along line XX in FIG.
The main body portion 32 constitutes a back surface 31 b and light incident surfaces 31 c and 31 d of the light guide plate 31, and the optical element portion 33 constitutes a light exit surface 31 a of the light guide plate 31. The main body 32 has a flat surface parallel to the plate surface of the light guide plate 31 on the light exit surface 31a side and the back surface 31b side. That is, the main body 32 has the same cross section in any cross section parallel to both the directions perpendicular to the light incident surfaces 31c and 31d (light guide directions D1 and D2) and the normal direction nd of the plate surface of the light guide plate 31. It has a shape.
The optical element portion 33 includes a support portion (land portion) 36 formed on the main body portion 32 and a plurality of unit prisms 37 formed on the support portion 36 and constituting the light exit surface 31 a of the light guide plate 31. ing. The optical element portion 33 has a flat surface parallel to the plate surface of the light guide plate 31 on the main body portion 32 side, and an uneven surface inclined with respect to the plate surface of the light guide plate 31 on the light output surface 31a side. have.

  As illustrated in FIG. 6, the optical element unit 33 includes a plurality of unit prisms 37 arranged in a direction intersecting with the directions (light guide directions D1 and D2) orthogonal to the light incident surfaces 31c and 31d. Yes. That is, the arrangement direction A of the unit prisms 37 and the light guide directions D1 and D2 intersect each other. Each unit prism 37 extends linearly in a direction intersecting with the arrangement direction A. In particular, in FIG. 6, the plurality of unit prisms 37 are arranged without gaps in a direction orthogonal to the light guide directions D1 and D2. Each unit prism 37 extends linearly in a direction orthogonal to the arrangement direction A, that is, in the light guide directions D1 and D2. Each unit prism 37 is formed in a columnar shape and has the same cross-sectional shape along the longitudinal direction.

  As illustrated in FIG. 7, the cross-sectional shape of each unit prism 37 is a triangular shape protruding toward the light exit surface 31 a. In particular, in FIG. 7, the sectional shape of the unit prism 37 is an isosceles triangle from the viewpoint of intensively improving the luminance in the front direction in the angular distribution of luminance in a plane parallel to the arrangement direction A of the unit prisms 37. The unit prism 37 has a shape and is arranged so that the isosceles triangle shape of the cross section is symmetrical with respect to the front direction nd. Further, the top portion 38 of the unit prism 37 that protrudes toward the light exit surface 31 a is configured by an apex angle that is located between the equilateral sides of the isosceles triangle shape of the cross section.

When the optical member in this invention is a light-guide plate, an optical element part corresponds to the uneven | corrugated layer which has the said functional fine uneven | corrugated pattern, and a main-body part corresponds to the said base material.
Hereinafter, each structure in a light-guide plate is demonstrated.

(I) Optical element part The optical element part used for a light-guide plate is the several unit prism arranged in the direction which cross | intersects with respect to the direction (light guide direction) orthogonal to a light-incidence surface at the light emission surface side of a main-body part. It is what has. Since the optical element section includes a plurality of unit prisms arranged in a direction intersecting with the light guide direction, it is possible to collect light components along the direction intersecting with the light guide direction. In the optical member used in the present invention, the optical element portion corresponds to the concavo-convex layer and has the functional fine concavo-convex pattern, and the functional fine concavo-convex pattern includes the unit prism. When the optical member used in the present invention is a light guide plate, the functional fine concavo-convex pattern composed of the unit prism and the protective fine concavo-convex pattern of the protective film for the optical member are fitted to protect the unit prism. Then, an optical member laminate in which the protective film for the optical member is laminated on the optical element portion of the light guide plate is obtained.

  As the cross-sectional shape of the unit prism, for example, various polygonal shapes such as a triangular shape, a quadrangular shape such as a trapezoid, a pentagonal shape, and a hexagonal shape can be used. Moreover, the cross-sectional shape of the unit prism may be a shape corresponding to a part of a circular shape or an elliptical shape. Among them, the cross-sectional shape of the unit prism is preferably a triangular shape, and more preferably an isosceles triangular shape. The cross-sectional shape of the unit prism is preferably symmetrical with respect to the front direction. In particular, as illustrated in FIG. 7, the unit prism 37 has a cross-sectional shape of an isosceles triangle, and the isosceles triangle shape of the cross-section is arranged so as to be symmetrical with respect to the front direction nd. preferable. This is because the luminance in the front direction can be intensively improved in the angular distribution of luminance in the plane parallel to the arrangement direction of the unit prisms.

  Note that “triangular shape” is not only a triangular shape in a strict sense, but also a substantially triangular shape including limitations in manufacturing technology, errors in molding, and the like, and expects optical functions that are almost the same as the triangular shape. Including a substantially triangular shape that can be made. As an example, a substantially triangular shape in which chamfering is performed on the apex angle (for example, an angle R of about 10 μm or less) for various purposes is also included in the “triangular shape” herein.

The protruding height of the unit prism is preferably in the range of 1 μm to 50 μm. That is, when the cross-sectional shape of the unit prism is a right-angled isosceles triangle, it is preferable that the width of the bottom surface of the unit prism along the arrangement direction of the unit prism is in the range of 2 μm to 100 μm.
Note that the protruding height of the unit prism refers to the protruding height H of the unit prism 37 with respect to the surface of the support portion 36 along the normal direction nd to the plate surface of the light guide plate 31 in FIG. Further, the width of the bottom surface of the unit prism in FIG. 7 refers to the width W of the bottom surface of the unit prism 37 along the arrangement direction A of the unit prisms 37 on the surface of the support portion 36.

Further, when the cross-sectional shape of the unit prism is an isosceles triangle shape, from the viewpoint of intensively improving the luminance in the front direction, the apex angle that is located between the equilateral sides and protrudes toward the light exit surface side is 60 °. It is preferably 120 ° or less and particularly preferably 90 °.
The apex angle in FIG. 7 refers to an apex angle θa that is located between equal sides and protrudes toward the light exit surface 31a.

  The arrangement of the unit prisms is not particularly limited as long as a plurality of unit prisms are arranged in a direction intersecting with the direction orthogonal to the light incident surface (light guide direction). Arranged. The arrangement direction of the unit prisms is not particularly limited as long as a plurality of unit prisms are arranged so that the arrangement direction of the unit prisms intersects the light guide direction. A plurality of unit prisms are arranged so that the directions are orthogonal to each other. That is, the plurality of unit prisms are arranged so that the ridgelines of the unit prisms substantially coincide with the light guide direction.

  The optical element portion only needs to have a plurality of unit prisms.For example, the optical element portion may have a support portion formed on the main body portion and a plurality of unit prisms formed on the support portion. Only a plurality of unit prisms may be provided.

When the optical element portion has a support portion and a plurality of unit prisms, the thickness of the support portion is preferably in the range of 1 μm to 20 μm, and more preferably in the range of 2 μm to 10 μm.
In addition, the thickness of a support part means the thickness ts of the support part 36 along the normal direction nd to the plate | board surface of the light-guide plate 31 in FIG.

  The material used for the optical element part is not particularly limited as long as it is a material capable of forming a plurality of unit prisms, and is a general resin material used for unit prisms, specifically UV curable. An ionizing radiation curable resin such as a resin or an electron beam curable resin, a thermosetting resin, or a thermoplastic resin can be used. Among these, ionizing radiation curable resins are preferably used as the resin material. That is, the optical element part preferably contains a cured product of ionizing radiation curable resin.

  Moreover, the optical element part may be comprised with the material same as a main-body part, and may be comprised with the material different from a main-body part.

(Ii) Main body The main body used for the light guide plate supports the above-described optical element portion, and has scattering particles uniformly dispersed in the base resin. In the optical member used in the present invention, the main body corresponds to the substrate.

Examples of the shape of the scattering particles include a substantially spherical shape such as a true sphere, an elliptic sphere shape, and an indefinite shape. Among them, a substantially spherical shape is preferable because of excellent dispersion stability.
The average particle size of the scattering particles is in the range of 0.7 μm to 5 μm, and preferably 1 μm to 3 μm.

  The scattering particles are capable of exerting an action of changing the direction of the light by refraction with respect to the light traveling in the main body, and are appropriately selected in consideration of the refractive index, dispersibility, and the like. As the scattering particles, either inorganic particles or organic particles can be used.

  The content of the scattering particles is appropriately adjusted according to scattering properties, dispersibility, and the like. For example, the content of the scattering particles may be within a range of 0.005% by mass to 1% by mass with respect to the total mass of the main body. it can.

  The base resin in the main body is a general resin used for the light guide plate, specifically ionizing radiation curable resin such as UV curable resin or electron beam curable resin, thermosetting resin, thermoplastic resin, etc. can do.

  The shape of the main body is not particularly limited as long as it is a flat plate shape. For example, the main body portion may have a substantially square shape or a disk shape. Note that the substantially square shape includes not only a square shape such as a square or a rectangle, but also a shape with missing corners or a shape with rounded corners.

  The thickness of the main body is appropriately adjusted and is not particularly limited, but is preferably constant, for example, in the range of 20 μm to 5000 μm.

(3) Prism Sheet As illustrated in FIG. 8, the prism sheet 41 includes a transparent base 42 and a lens unit 44 including a large number of unit prisms 43 formed on one surface S <b> 1 of the transparent base 42. The unit prism 43 forms fine irregularities. When the optical member in this invention is a prism sheet, a lens part corresponds to the uneven | corrugated layer which has the said functional fine uneven | corrugated pattern, and a transparent base material corresponds to the said base material.
Hereinafter, each configuration of the prism sheet will be described.

(I) Lens part The lens part used for a prism sheet is a prism group in which a large number of unit prisms having a triangular prism shape are arranged so that their ridge lines are parallel, provided on one surface of a transparent substrate. In the optical member used in the present invention, the lens portion corresponds to the concavo-convex layer and has the functional fine concavo-convex pattern, and the functional fine concavo-convex pattern includes the unit prism. When the optical member used in the present invention is a prism sheet, the functional fine concavo-convex pattern composed of the unit prism and the protective fine concavo-convex pattern of the protective film for the optical member are fitted to protect the unit prism. Thus, an optical member laminate in which the protective film for the optical member is laminated on the lens portion of the prism sheet is obtained.

  The prism sheet having the lens portion can be used in a single-sheet configuration, but in order to control the light diffusion angle in two directions (vertical direction, left and right direction), the two prism sheets having the lens portion are ridge lines. You may laminate | stack so that may orthogonally cross. In this case, it is most preferable that the two lens surfaces have the same direction because the light transmittance is high and the lens surface side may be configured to face each other.

  The protruding height, bottom width, apex angle, etc. of the unit prism are the same as those of the unit prism of the light guide plate described above.

  The thickness of the lens part is usually in the range of 1 μm to 1000 μm. In addition, the thickness of a lens part means the thickness from the top part of a unit prism to a plane part.

  Examples of the material of the lens part include a homopolymer of (meth) acrylic acid ester and a copolymer of (meth) acrylic acid ester (here, “(meth) acrylic acid” means acrylic acid or methacrylic acid). Transparent resin such as polyester, thermoplastic resin, (meth) acrylate crosslinked with active energy rays such as ultraviolet rays or electron beams, unsaturated polyester, two-component curable polyester, polycarbonate, etc. .

(Ii) Transparent base material The transparent base material used for the prism sheet is a main component of the prism sheet, and acts as a base material for the lens part, and allows most of the light from the light source to pass to the lens part side. Acts as follows. In the optical member used in the present invention, this transparent substrate corresponds to the substrate. However, in the present invention, the transparent substrate may or may not be used.

  Although the thickness of a transparent base material is not specifically limited, Usually, it exists in the range of 50 micrometers-500 micrometers in which roll winding is possible.

  Examples of the material constituting the transparent substrate include polyester resins, acrylic resins, thermoplastic resins, ionizing radiation curable resins, and polycarbonates.

C. Next, the manufacturing method of the optical member laminated body of this invention is demonstrated. The method for producing an optical member laminate of the present invention includes an optical member in which an optical member having a functional fine concavo-convex pattern having an optical function and a protective film for an optical member that protects the functional fine concavo-convex pattern are laminated. A method for producing a laminated body, comprising: preparing an original having the same fine unevenness pattern as the functional fine unevenness pattern; and forming an optical member protective film on the fine unevenness pattern of the original plate The protective film for an optical member having a protective fine uneven pattern having an uneven shape opposite to the uneven shape of the functional fine uneven pattern is formed by arranging and shaping a resin material for forming a protective film for a member. Forming a concavo-convex layer of the optical member on the protective concavo-convex pattern for protection of the protective film for optical member and the protective film for optical member And forming an uneven layer having the functional fine uneven pattern by arranging and shaping the resin material for forming an uneven layer for forming an optical member, thereby forming an optical member. It is a feature.

The manufacturing method of the optical member laminated body of this invention is demonstrated referring drawings. FIG. 9 is a process diagram showing an example of a method for producing an optical member laminate of the present invention. First, a master 10 having the same fine concavo-convex pattern 10a as the functional fine concavo-convex pattern 2a of the optical member 2 described later is prepared, and, for example, a heated protective film for an optical member is formed on the fine concavo-convex pattern 10a of the original 10 The resin material 11 for extrusion is extruded and arranged, and is pressure-bonded by the roller 15 to mold the fine uneven pattern 10a (FIG. 9A). Subsequently, by cooling, the protective film 1 for optical members which has the fine uneven | corrugated pattern 1a for protection which has the uneven | corrugated shape opposite to the uneven | corrugated shape of the functional fine uneven | corrugated pattern 2a of the optical member 2 is formed (FIG.9 (b)). , Protective film forming step for optical members).
Next, the resin material 14 for forming an uneven layer is disposed on the protective fine uneven pattern 1a of the protective film 1 for an optical member, and the base material 3 is further laminated and pressure-bonded by a roller 15, and the protective fine uneven pattern 1a. Is shaped (FIG. 9C). Subsequently, the uneven layer forming resin material 14 is cured by, for example, UV irradiation (FIG. 9D), and the uneven layer 4 having the functional fine uneven pattern 2a is formed, whereby the protective film 1 for the optical member is formed. The optical member laminated body 5 is obtained by forming the optical member 2 which has the base material 3 and the uneven | corrugated layer 4 on top (FIG.9 (e), optical member formation process).

  According to the present invention, a protective film for an optical member having a protective fine concavo-convex pattern having a concavo-convex shape opposite to the concavo-convex shape of the functional fine concavo-convex pattern of the target optical member is prepared in advance, and this protective fine concavo-convex pattern By forming an optical member having a functional fine concavo-convex pattern formed by molding on the protective film for optical member, both the optical member and the fine concavo-convex pattern of the protective film for optical member are fitted together. The optical member can be formed in a state in which are closely attached without any gap. Therefore, since there is no gap between the optical member and the protective film for the optical member, water and dust do not enter, and the protected surface of the optical member is reliably protected even for long-term storage. Can do. Therefore, the optical member and the protective film for the optical member are integrated so as to protect the functional fine concavo-convex pattern serving as the protected surface of the optical member, and it has excellent storage stability and does not peel off during the post-processing step. You can get a body. Moreover, the optical member protected by the protective film for optical members can be easily obtained while manufacturing the optical member.

  Hereinafter, each process in the manufacturing method of the optical member laminated body of this invention is demonstrated.

1. Protective film forming step for optical member In the protective film forming step for optical member in the present invention, an original plate having the same fine concavo-convex pattern as the functional fine concavo-convex pattern of the optical member having a functional fine concavo-convex pattern having an optical function is prepared. The functional fine concavo-convex pattern of the functional fine concavo-convex pattern is prepared by arranging and shaping a resin material for forming a protective film for an optical member on the fine concavo-convex pattern of the original plate. It is the process of forming the protective film for optical members which has the fine uneven | corrugated pattern for protection which has the uneven | corrugated shape reverse to a shape.

(1) Optical member protective film forming resin material The optical member protective film forming resin material used in the present invention forms an optical member protective film and contains at least a resin material. The resin material is not particularly limited as long as it can mold the fine uneven pattern of the original plate, and can include thermoplastic resins, thermosetting resins, photocurable resins, etc. From the viewpoint of the process, a thermoplastic resin can be suitably used. As the thermoplastic resin, those described in the above-mentioned section “A. Protective film for optical member” can be used.

  The resin material for forming a protective film for an optical member used in the present invention may contain a release agent in addition to the resin material. In particular, when the resin material does not have releasability, it is preferable to add a release agent. This is because by adding a release agent, it is possible to impart releasability to the protective film for optical members produced by this step. As the mold release agent, the same ones as described in the above-mentioned item “A. Protective film for optical member” can be used.

  Moreover, the resin material for forming a protective film for an optical member may contain other additives as necessary. Examples of the additive include an antioxidant, a slip agent, an antiblocking agent, a UVA absorber, and a crystal nucleating agent.

(2) Master Plate The master plate used in the present invention has the same fine concavo-convex pattern as the functional fine concavo-convex pattern of the optical member having the functional fine concavo-convex pattern having an optical function. Such an original plate is not particularly limited as long as it is not deformed and worn when repeatedly used, and may be made of metal or resin, but is usually made of metal. Is preferred. This is because it is excellent in deformation resistance and wear resistance. Further, as a method for producing an original plate, a method of forming a concavo-convex pattern on the surface by anodizing aluminum and etching treatment is generally used.

  In this step, it is preferable to use a roll-shaped original plate. When the original plate is made of metal, the original plate itself can be used as a roll. When the original plate is made of resin, the original plate attached to the roll can be used.

(3) Method for forming protective film for optical member In this step, an original plate having the same fine concavo-convex pattern as the functional fine concavo-convex pattern of the optical member having the functional fine concavo-convex pattern having an optical function is prepared, The resin material for forming a protective film for an optical member for forming the protective film for an optical member is placed on the fine uneven pattern of the original plate and shaped to reverse the uneven shape of the functional fine uneven pattern. The protective film for optical members which has the fine uneven | corrugated pattern for protection which has this uneven | corrugated shape is formed. In addition, when giving durability etc. to the said protective film for optical members, the said protective film for optical members is made into a multilayer using the base material like a polyethylene terephthalate (PET) outside the said fine uneven | corrugated pattern for protection. Also good. Moreover, when giving release property to the said protective film for optical members, the resin material which added the release agent mentioned above may be used, and a release material may be apply | coated on the said protective film for optical members. Moreover, you may give EB process, after forming the protective film for optical members for heat resistance improvement.
Examples of a method for forming such a protective film for an optical member include an extrusion method and a coating curing method (UV curing, EB curing). Below, the formation method of the protective film for optical members at the time of using the suitable thermoplastic resin in this invention for the resin material for protective film formation for optical members is demonstrated concretely.

  As a method for arranging the resin material for forming a protective film for an optical member on the fine concavo-convex pattern of the original plate, for example, the resin material for forming the protective film for an optical member is heated above the softening point and extruded onto the fine concavo-convex pattern of the original plate. A method can be mentioned. The heating temperature at the time of extrusion is not particularly limited as long as the resin material for forming the protective film for optical members can be extruded from the extruder onto the fine uneven pattern of the original plate. For forming the protective film for optical members to be used It is appropriately set according to the resin material and the like.

  Moreover, as a method for shaping the fine uneven pattern of the original plate into the resin material for forming the protective film for optical members, for example, the resin material for forming the protective film for optical members extruded on the fine uneven pattern of the original plate is used as the optical member. The method of making it press-bond with an original plate with a roller under the temperature more than the softening point of the resin material for protective film formation for a film can be mentioned. When the resin material for forming a protective film for an optical member is a thermoplastic resin, the resin for forming a protective film for an optical member is formed after shaping the fine uneven pattern of the original plate at or above the softening point of the resin material for forming an optical member protective film. By cooling the material below its softening point, the fine uneven pattern formed on the resin material for forming the protective film for optical members can be fixed. The pressure at the time of pressure bonding is not particularly limited as long as the fine uneven pattern of the original plate can be molded, and is appropriately set according to the resin material for forming the protective film for optical members to be used. .

2. Optical member formation process The optical member formation process in this invention arrange | positions the resin material for uneven | corrugated layer formation for forming the uneven | corrugated layer of the said optical member on the said protective fine uneven | corrugated pattern of the said protective film for optical members. It is a step of forming an uneven layer having the functional fine uneven pattern by shaping, thereby forming the optical member.

(1) Resin material for forming an uneven layer The resin material for forming an uneven layer used in the present invention forms an uneven layer in an optical member, and contains at least a resin material. The resin material is appropriately selected according to the target optical member, and examples thereof include a photocurable resin, a thermosetting resin, and a thermoplastic resin. Preferably used.

  The resin material for forming an uneven layer used in the present invention may contain an additive in addition to the resin material, depending on the use of the optical member. The additive is not particularly limited as long as it can impart a desired function to the concavo-convex layer. For example, an antioxidant, a polymerization initiator, a polymerization inhibitor, a release agent, an antistatic agent, an ultraviolet ray, and the like. Stabilizers, ultraviolet absorbers, refractive index adjusters and the like can be mentioned.

(2) Forming method of optical member In this step, a resin material for forming an uneven layer for forming the uneven layer of the optical member is disposed on the protective fine uneven pattern of the protective film for the optical member. By forming, an uneven layer having the functional fine uneven pattern is formed, thereby forming the optical member. Examples of a method for forming such an optical member include an extrusion method (casting, melting), a coating curing method (UV curing, two-component curing, EB curing), an injection compression method, a vacuum molding method, and a pressure molding method. It is done. Hereinafter, a method for forming an optical member in the case where a photocurable resin suitable for the present invention is used will be described in detail by dividing the formed optical member into a sheet-like form and an elongated form. To do.

  In the embodiment in which the optical member to be formed is a single wafer, as illustrated in FIGS. 9C to 9E, a resin material for forming an uneven layer on the protective fine uneven pattern 1a of the protective film 1 for an optical member. 14, the base material 3 is further laminated | stacked, it is crimped | bonded by the roller 15, and the uneven | corrugated layer 4 which has the functional fine uneven | corrugated pattern 2a is formed by hardening the resin material 14 for uneven | corrugated layer formation by UV irradiation. Thereby, the optical member 2 which has the base material 3 and the uneven | corrugated layer 4 on the protective film 1 for optical members is formed.

  On the other hand, in the aspect in which the optical member to be formed is long or batch type, the resin material 14 for forming an uneven layer is disposed on the substrate 3 as illustrated in FIGS. Further, the protective film 1 for the optical member is laminated so that the protective fine uneven pattern 1a is in contact with the resin material 14 for forming the uneven layer, and is pressed by the roller 15, and the resin material 14 for forming the uneven layer is cured by UV irradiation. Thus, the concavo-convex layer 4 having the functional fine concavo-convex pattern 2a is formed. Thereby, the optical member 2 which has the base material 3 and the uneven | corrugated layer 4 on the protective film 1 for optical members is formed. 10A to 10E are process diagrams illustrating another example of the method for producing an optical member laminate of the present invention.

The pressure at the time of press-bonding in this step is not particularly limited as long as the protective fine uneven pattern for the protective film for optical members can be shaped, and is appropriately selected depending on the resin material for forming the uneven layer used. Is set.
Moreover, in this process, it is preferable that the temperature at the time of UV irradiation is a temperature lower than the softening point of the resin material for forming a protective film for an optical member. If the temperature at the time of UV irradiation is higher than the softening point of the resin material for forming the protective film for optical members, the protective film for optical members will be deformed at the time of UV irradiation. This is because the protective fine uneven pattern cannot be molded into the uneven layer forming resin material.

3. Other Steps The method for producing an optical member laminate of the present invention includes optional steps as necessary in addition to the optical member protective film forming step and the optical member forming step, which are essential steps. Also good. For example, the half-cut process process etc. which put a half cut in the protective film for optical members can be mentioned. By putting a half cut into the protective film for optical members, the protective film for optical members can be destroyed when the protective film for optical members is peeled off from the optical member.

D. Next, a method for manufacturing a member having an optical function according to the present invention will be described. The method for producing a member having an optical function according to the present invention includes an optical member laminate incorporating step of incorporating the optical member laminate obtained by the above-described optical member laminate production method into a member that requires an optical function, and It has a peeling process which peels the protective film for optical members from an optical member, It is characterized by the above-mentioned. In the present invention, the peeling step may be performed after performing the optical member laminate incorporating step, or the optical member laminate incorporating step may be performed after performing the peeling step. In the case where the optical member laminate incorporating step is performed after the peeling step, the optical member laminate incorporated in the optical member laminate incorporating step is only the optical member.

  According to the present invention, by incorporating the optical member laminate described above into a member that requires an optical function, any post-process can be appropriately performed as necessary while protecting the optical member. In addition, after the process, in the assembled optical member laminate, the optical member having a fine uneven pattern in which the optical function member is free from contamination such as adhesive residue by peeling off the protective film for the optical member from the optical member Therefore, a member having a good optical function can be obtained.

  Further, according to the present invention, in the optical member laminate, after the protective film for an optical member is peeled from the optical member, the optical member is incorporated into a member that requires an optical function, so that the surface to be protected can be protected. An optical member that is free from contamination such as adhesive residue can be incorporated as it is on a certain functional fine uneven pattern, so that a good optical function can be achieved without performing a process of cleaning the protected surface of the optical member after peeling. The member which has can be obtained and it becomes possible to aim at simplification of a process.

  Hereinafter, each process in the manufacturing method of the member which has an optical function of this invention is demonstrated.

1. Optical member laminate assembly step The optical member laminate incorporation step in the present invention is a step of incorporating the optical member laminate obtained by the above-described optical member laminate production method into a member that requires an optical function.

  In addition, since it described in the item of the said "B. optical member laminated body" about the optical member laminated body, description here is abbreviate | omitted. Hereinafter, a member requiring an optical function and an assembling method will be described.

(1) A member that requires an optical function Examples of the member that requires an optical function used in the present invention include an optical display device, a picture, and a photograph. Among them, an optical display device is used. It is preferable. Specific examples of the optical display device include a liquid crystal display device, an organic electroluminescence (EL) display device, and a plasma display device.

(2) Incorporation method In this step, the optical member laminate is incorporated into a member that requires an optical function. Specifically, the optical member laminate may be incorporated into a member that requires an optical function as it is, or the optical member laminate may be attached to a member that requires an optical function using an adhesive layer or the like. . After the optical member laminate is incorporated into a member that requires an optical function, the protective film for the optical member can be peeled from the optical member laminate.

2. Next, the peeling process in the present invention will be described. The peeling process in this invention is a process of peeling the protective film for optical members from an optical member.

  In this invention, since the optical member laminated body obtained by the manufacturing method of the optical member laminated body mentioned above is used, when peeling the protective film for optical members from an optical member by this process, functionality of an optical member It is possible to peel off the fine uneven pattern without any adhesive residue.

  The peeling method in this step is not particularly limited as long as the protective film for an optical member can be peeled without damaging the optical member. In addition, the protective film for optical members may be destroyed at the time of peeling, and does not need to be destroyed.

3. Others The member having an optical function obtained by the method for producing a member having an optical function of the present invention has a functionality having an optical function by peeling off the protective film for the optical member from the assembled optical member laminate. Since it has an optical member having a fine concavo-convex pattern, an excellent optical function can be exhibited.

  The present invention is not limited to the above embodiment. The above-described embodiment is an exemplification, and the present invention has substantially the same configuration as the technical idea described in the claims of the present invention, and any device that exhibits the same function and effect is the present invention. It is included in the technical scope of the invention.

  Hereinafter, the present invention will be specifically described by giving examples.

[Example 1]
(Preparation of protective film for optical members)
First, a sample A (MFR 5.0 g / 10 min, melting point 132 ° C.) of random polypropylene (random PP) is extruded as a resin material for forming a protective film for an optical member, and the concavo-convex shape is transferred and molded by a moth-eye mold roll. By doing so, the protective film for optical members was produced.
(Production of optical member laminate)
Next, a UV curable resin was poured between the protective film for an optical member and the base material as a resin material for forming an uneven layer, and UV curing was performed to prepare an antireflection film laminate.

[Example 2]
Random PP sample B (MFR 6.5 g / min, melting point 146 ° C.) was used as the resin material for forming the protective film for the optical member, and in the same manner as in Example 1 except that the mold roll for the light guide plate was used. A light guide plate laminate was prepared.

[Example 3]
Example except for using a high pressure low density polyethylene (LDPE) sample C (MFR 4.0 g / 10 min, melting point 111 ° C.) as a resin material for forming a protective film for optical members, and using a prism sheet mold roll In the same manner as in No. 1, a prism sheet laminate was produced.

[Comparative Example 1]
An antireflection film laminate was prepared by firmly bonding an adhesive protective film to the uneven surface of the moth-eye antireflection film.

[Comparative Example 2]
A light guide plate laminate was prepared by laminating an adhesive protective film on the uneven surface of the light guide plate film.

[Comparative Example 3]
A prism sheet laminate was prepared by bonding an adhesive protective film to the uneven surface of the prism sheet film.

[Comparative Example 4]
An antireflection film laminate was prepared by laminating an adhesive protective film weakly on the uneven surface of the moth-eye antireflection film.

[Evaluation]
The obtained optical member laminate was subjected to a water washing step, and it was visually confirmed that there was no peeling of the protective film. The results are shown in Table 1. In the case where it was not peeled off, ○ was given in the column of “peeling in the washing step” of “Evaluation” in Table 1, and in the case where it was peeled off, × was given. Next, the protective film was peeled off, and it was confirmed whether there was any adhesive residue on the optical member surface. In the case where there is no adhesive residue, “◯” is given in the “Adhesive residue” column of “Evaluation” in Table 1, and in the case where there is adhesive residue, × is attached.

DESCRIPTION OF SYMBOLS 1 ... Protective film for optical members 1a ... Protective fine uneven | corrugated pattern 2 ... Optical member 2a ... Functional fine uneven | corrugated pattern 3 ... Base material 4 ... Uneven layer 5 ... Optical member laminated body 10 ... Original 10a ... Fine uneven | corrugated pattern 11 ... Optical Resin material for forming protective film for member 14 ... Resin material for forming uneven layer

Claims (6)

A protective film for an optical member used for an optical member having a functional fine concavo-convex pattern having an optical function,
A protective film for an optical member having a protective fine uneven pattern having an uneven shape opposite to the uneven shape of the functional fine uneven pattern of the optical member.   The protective film for an optical member according to claim 1, wherein the protective fine uneven pattern is an original of the functional fine uneven pattern.   The protective film for an optical member according to claim 1 or 2, wherein the protective film is made of polypropylene or polyethylene. An optical member having a functional fine concavo-convex pattern having an optical function;
An optical member laminate having an optical member protective film for protecting the functional fine uneven pattern,
The protective film for an optical member has a protective fine uneven pattern having an uneven shape opposite to the uneven shape of the functional fine uneven pattern of the optical member,
The protective fine uneven pattern for protection of the protective film for optical member and the functional fine uneven pattern of the optical member are detachably fitted so that the protective film for optical member and the optical member are A laminated optical member characterized by being laminated. An optical member laminate manufacturing method in which an optical member having a functional fine concavo-convex pattern having an optical function and a protective film for an optical member protecting the functional fine concavo-convex pattern are laminated,
A protective film-forming resin material for an optical member for preparing an original plate having the same fine uneven pattern as the functional fine uneven pattern and forming the protective film for an optical member on the fine uneven pattern of the original plate. An optical member protective film forming step of forming the protective film for an optical member having a concave and convex shape for protection having a concave and convex shape opposite to the concave and convex shape of the functional fine concave and convex pattern by arranging and shaping;
The functional fine concavo-convex pattern is formed by arranging and molding a concavo-convex layer forming resin material for forming the concavo-convex layer of the optical member on the protective fine concavo-convex pattern of the protective film for the optical member. An optical member forming step of forming the concavo-convex layer, thereby forming the optical member.   An optical member laminate incorporating step of incorporating the optical member laminate obtained by the method for producing an optical member laminate according to claim 5 into a member that requires an optical function, and an optical member protective film from the optical member The manufacturing method of the member which has an optical function characterized by having the peeling process to peel.

Images