JP2020069750A - Method for manufacturing resin molded article and display device - Google Patents

Abstract

To provide a method for manufacturing a resin molded article, by which excellent manufacturing efficiency and a yield can be obtained and a massive hue can be imparted.SOLUTION: The method for manufacturing a resin molded article includes the following steps (1) to (3). (1) A transfer sheet 70 having a transfer layer on a release sheet is disposed on one die 601 of a pair of upper and lower in-mold molding dies, and a molding sheet 80 having a shape that is complementary to a moth-eye structure and formed of a group of projections is disposed on the other die 602 of the dies. (2) The dies 601, 602 are fastened and an injection resin is injected into the inside of the dies 601, 602 so as to obtain a laminate in which a transfer layer side of the transfer sheet, an injection resin layer 20 and the molding sheet 80 are adhered to each other. (3) The dies 601, 602 are opened, and then the release sheet of the transfer sheet 70 and the molding sheet 80 are removed from the laminate to obtain a resin molded article 100 comprising the injection resin layer 20 having the moth-eye structure on one surface and the transfer layer 10 adhered to the opposite surface.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a resin molded body and a display device.

Vehicles such as automobiles are equipped with meters for displaying information such as speed, engine speed, remaining amount of fuel, water temperature gauge, and mileage.
Such an instrument has, for example, a display section for displaying information and a transparent plate arranged on the front surface side (light emission surface side) of the display section.

The display unit for displaying information has a basic configuration including a display element and a display plate arranged on the front surface side (light emission surface side) of the display element.
In Patent Document 1, as a display plate arranged on a display element, "a fine uneven portion having a predetermined pattern is formed on the front surface of a translucent substrate, and a ground color layer having a predetermined color tone is formed on the back surface of the substrate. A display plate formed with.

JP, 2008-132429, A

The fine concavo-convex portion of the display plate of Patent Document 1 is different from the fine concavo-convex portion of the central region and the ring-shaped region around the central region and the ring-shaped region by varying the degree of reflection of external light (how the surface shines). This is to increase the change in the texture of and (paragraph 0061).
However, the instrument of Patent Document 1 lacks a solid feeling of the tint of the ground color layer of the display section, and cannot satisfy a high-class feeling.

  Further, the display unit of Patent Document 1 is manufactured by forming a fine uneven portion with a mold and then printing a ground color layer (paragraphs 0054 and 0059). However, there is a problem in that the fine concavo-convex portion is damaged during the printing process and the yield is reduced.

  It is an object of the present invention to provide a method for producing a resin molded product which is excellent in production efficiency and yield and which can impart a profound tint. Another object of the present invention is to provide a display device capable of imparting a profound tint.

The present invention aims to provide the following [1] to [2].
[1] A method for producing a resin molded product, which includes the following steps (1) to (3).
(1) A transfer sheet having a transfer layer including a design layer on a release sheet is arranged on one side of a pair of upper and lower in-mold molding dies, and a convex group is formed on the other side of the mold. A step of disposing a shaping sheet having a shape complementary to the moth-eye structure portion A formed from
(2) The mold is tightened, injection resin is injected into the mold, and the surface of the transfer sheet on the transfer layer side, the injection resin layer containing the injection resin, and the shaping sheet are brought into close contact with each other. The process of obtaining the laminated body A.
(3) After the mold is opened, the release sheet and the patterning sheet of the transfer sheet are peeled off from the laminate A, and the moth-eye structure section A formed by the convex group is formed on one surface. A step of obtaining a resin molded body, which comprises: an injection resin layer and a transfer layer that is in close contact with the surface of the injection resin layer opposite to the moth-eye structure portion A.
[2] A display element, a display plate disposed on the light emission surface of the display element, and a transparent plate disposed on the light emission surface of the display plate via an air layer. ,
The display plate is in close contact with an injection resin layer having a moth-eye structure portion A formed of a group of protrusions on one surface and a surface of the injection resin layer opposite to the moth-eye structure portion A. A resin molded body having a transfer layer including a design layer formed by
The resin molded body is arranged such that the moth-eye structure portion A of the injection resin layer is on the light emitting surface side,
The said transparent plate is a display apparatus which has the moth-eye structure part B formed from the convex part group at the light-incidence surface side.

  According to the present invention, it is possible to provide a method for producing a resin molded article which is excellent in production efficiency and yield and which can impart a profound tint. Further, according to the present invention, it is possible to provide a display device capable of imparting a profound tint.

It is a schematic diagram showing one embodiment of each process of the manufacturing method of the resin molding of the present invention. It is a schematic sectional drawing which shows one Embodiment of the transfer sheet used for manufacture of the resin molding of this invention. It is an outline top view showing one embodiment of the resin molding of the present invention. It is a schematic sectional drawing which shows one Embodiment of the display apparatus of this invention. It is an enlarged view showing an example of a moth-eye structure formed from a convex part group.

  Hereinafter, embodiments of the method for producing a resin molded product and the display device of the present invention will be described. In addition, in this specification, AA-BB means that it is AA or more and BB or less.

[Method for producing resin molded body]
The method for producing a resin molded product of the present invention has the following steps (1) to (3).
(1) A transfer sheet having a transfer layer including a design layer on a release sheet is arranged on one side of a pair of upper and lower in-mold molding dies, and a convex group is formed on the other side of the mold. A step of disposing a shaping sheet having a shape complementary to the moth-eye structure portion A formed from
(2) The mold is tightened, injection resin is injected into the mold, and the surface of the transfer sheet on the transfer layer side, the injection resin layer containing the injection resin, and the shaping sheet are brought into close contact with each other. The process of obtaining the laminated body A.
(3) After the mold is opened, the release sheet and the patterning sheet of the transfer sheet are peeled off from the laminate A, and the moth-eye structure section A formed by the convex group is formed on one surface. A step of obtaining a resin molded body, which comprises: an injection resin layer and a transfer layer that is in close contact with the surface of the injection resin layer opposite to the moth-eye structure portion A.

  FIG. 1 is a schematic view showing an embodiment of each step of the method for producing a resin molded body 100 of the present invention. In addition, in FIG. 1, the transfer sheet 70 and the shaping sheet 80 are conveyed, but other methods such as a sheet-fed method may be used. Hereinafter, an embodiment of each step will be described.

<Step (1)>
In the step (1), a transfer sheet having a transfer layer including a design layer on a release sheet is arranged on one side of a pair of upper and lower in-mold molding dies, and the other side of the mold is arranged. It is a step of arranging a shaping sheet having a shape complementary to the moth-eye structure portion A formed of the convex group (FIG. 1A).

  In step (1), the surface of the transfer sheet on the transfer layer side faces the inside of the mold (the side in contact with the injection resin), and the surface of the mold sheet having the moth-eye structure is inside the mold ( Place it so that it faces the injection resin).

  In FIG. 1A, the transfer sheet 70 is arranged on the upper die 601 side, and the imprinting sheet 80 is arranged on the lower die 602 side. In FIG. 1, rolls 401 and 501 are sending rolls, and rolls 402 and 502 are winding rolls.

<< Transfer sheet >>
The transfer sheet used in the step (1) has a transfer layer including a design layer on the release sheet.
FIG. 2 is a sectional view showing an embodiment of the transfer sheet 70. The transfer sheet 70 of FIG. 2 has the transfer layer 10 including the design layer 11 on the release sheet 30. The transfer layer 10 of the transfer sheet 70 of FIG. 2 has an anchor coat layer 12 and an adhesive layer 13 in addition to the design layer 11.

[Release sheet]
The release sheet constituting the transfer sheet is not particularly limited as long as it can be peeled off after transferring the transfer layer to the injection resin layer, and has a single-layer structure of the support or a release layer on the support. A multilayer structure can be mentioned.

As the support constituting the release sheet, polyolefin resins such as polyethylene and polypropylene, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, and other vinyl-based resins. Resins, polyester resins such as polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, acrylic resins such as poly (meth) acrylate and ethyl poly (meth) acrylate, styrene resins such as polystyrene, nylon 6 or nylon A plastic film made of a resin such as a polyamide resin represented by 66 or the like can be given.
Among these plastic films, a biaxially stretched polyester film, which has excellent heat resistance and dimensional stability, and has excellent suitability for alignment during transfer, is suitable.

  The thickness of the support is preferably 12 to 150 μm, and more preferably 25 to 100 μm, from the viewpoint of moldability, shape conformability and handling.

It is preferable that the release layer constituting the release sheet is mainly composed of resin.
The resin of the release layer is not particularly limited as long as it is a material having a predetermined film strength and low adhesion to the transfer layer, and it is a general-purpose thermoplastic resin, a cured product of a thermosetting resin composition, or ionizing radiation. Examples include a cured product of the curable resin composition. Specifically, fluorine resin, silicone resin, acrylic resin, polyester resin, polyolefin resin, polystyrene resin, polyurethane resin, cellulose resin, vinyl chloride-vinyl acetate copolymer resin, nitrified cotton. Etc.
Among these, a cured product of the thermosetting resin composition is preferable, and a thermosetting resin composition containing an acrylic polyol and an isocyanate is more preferable.

The release layer may further contain a release agent in order to improve releasability. Examples of the release agent include waxes such as synthetic wax and natural washes. The synthetic wax is preferably a polyolefin wax such as polyethylene wax or polypropylene wax.
The thickness of the release layer is preferably 0.10 to 6.50 μm, more preferably 0.50 to 6.00 μm, and further preferably 0.70 to 5.50 μm.

[Transfer layer]
The transfer layer forming the transfer sheet has at least a design layer, and examples thereof include the following configurations (Y1) to (Y6). In the following (Y1) to (Y6), “/” indicates the interface of layers, and the closer to the left side, the closer to the release sheet.
(Y1) Design layer single layer (Y2) Design layer / Adhesive layer (Y3) Design layer / Anchor coat layer / Adhesive layer (Y4) Protective layer / Design layer (Y5) Protective layer / Design layer / Adhesive layer (Y6) protective layer / design layer / anchor coat layer / adhesive layer

[[Design layer]]
The design layer is a layer having a role of imparting a design property such as tint to the resin molded body. The resin molded body obtained by the present invention has the injection resin layer having the moth-eye structure portion A in close contact with the transfer layer including the design layer, so that the color of the design layer when viewed from the injection resin layer side. It is possible to impart a profound feeling to the taste (≈color of the resin molded body).

  As shown in FIG. 2, the design layer preferably has a light-transmissive first region A1 and a light-impermeable second region A2. Further, it is preferable that at least a part of the second region is a dark color portion.

FIG. 3 is a plan view showing an embodiment of the resin molded body 100. Characters and scales are displayed on the resin molded body of FIG. The design layer corresponding to the characters and the scale is the first region A1 having light transmittance. Further, in FIG. 3, the design layer in the shaded area is light non-transmissive and constitutes the light non-transmissive second area A2.
When the resin molded body 100 shown in FIG. 3 is used as a member of a display device, it is preferable to add a pointer indicating an hour speed to the center of the resin molded body.

The first area A1 has a role of transmitting light emitted from the display element to visually recognize information such as letters, numbers, scales, and symbols. On the other hand, the second area A2 serves as a background of information such as characters displayed in the first area A1 as described above. The heavy tint of the resin molded body is mainly given to the second region A2.
Thus, the first area A1 has a role of visually recognizing information such as characters, while the second area A2 has a role of being a background of information such as characters. Therefore, the arrangement of the first area A1 and the second area A2 is not particularly limited as long as the above-described role is satisfied. From the viewpoint of making it easier to feel the solid feeling of the second area A2 due to the contrast between the first area A1 and the second area A2, the design layer has a plurality of independent first areas A1 in the plane, and It is preferable that the two areas A2 are formed so as to surround the individual first areas A1.

  The ratio of the area (S1) of the first area A1 to the area (S2) of the second area A2 is not particularly limited because it changes depending on the relationship between the information to be displayed and the design to be given, but the information by the first area A1 It is preferable that S1 / S2 is 0.01 to 1.0 from the viewpoint of making it easier to feel the solid feeling of the second area A2 due to the contrast between the first area A1 and the second area A2 while displaying It is more preferably 0.02 to 0.8, further preferably 0.05 to 0.5.

  The first region A1 of the design layer has a light transmissive property. The configuration of the first area A1 of the design layer may be adjusted so that the total light transmittance of the resin molded body in the area including the first area A1 is within the range described below. Therefore, as long as the region having the first region A1 of the resin molded body has a predetermined light transmissivity, no layer may be present in the first region A1 of the design layer.

  When the layer is present in the first region A1, the first region A1 of the design layer preferably contains a resin component, and further preferably contains a light diffusing agent and / or a colorant, if necessary.

  Examples of the resin component of the first region A1 include general-purpose resins such as polyvinyl resins, polyester resins, urethane resins, acrylic resins, polyvinyl acetal resins, and cellulose resins.

Examples of the light diffusing agent in the first region A1 include polymethylmethacrylate, polyacryl-styrene copolymer, melamine resin, polycarbonate, polystyrene, polyvinyl chloride, benzoguanamine-melamine-formaldehyde condensate, silicone, fluorine resin and polyester resin. Examples thereof include organic particles made of resin and the like, and inorganic particles made of silica, alumina, antimony, zirconia, titania and the like.
By including the light diffusing agent in the design layer of the first region A1, the viewing angle of information displayed on the display element can be widened, and the intensity of light can be reduced to make the information easy to see. The content of the light diffusing agent is not particularly limited and is preferably about 1 to 50 parts by mass with respect to 100 parts by mass of the resin component.

  The colorant in the first area A1 may be any colorant that can be distinguished from the second area, and it is preferable to use pigments and dyes capable of displaying bright colors such as white, yellow, red and blue. The content of the colorant is not particularly limited and is preferably about 1 to 50 parts by mass with respect to 100 parts by mass of the resin component.

  The second region A2 of the design layer is impermeable to light. Specifically, it is preferable that the portion corresponding to the second region A2 of the design layer is light opaque to such an extent that the total light transmittance of the resin molded body can be within the range described below.

The second region A2 of the design layer preferably has a dark color portion in at least a part thereof. By having the dark color portion, the solid feeling of the region corresponding to the dark color portion is increased, and the designability of the resin molded body can be easily improved.
The dark color portion is preferably formed in 50% or more of the total area of the second region A2, more preferably 70% or more, still more preferably 90% or more, still more preferably 99% or more.

The dark color means a color having a low brightness such as black, dark gray and brown, and a dark color having a low color. Specifically, it is preferable that the L ^* value, the a ^* value, and the b ^* value measured from the transfer layer side of the resin molded body are within the ranges described below. The dark portion is preferably black.

The dark portion of the second area A2 preferably contains a resin component and a pigment.
Examples of the resin component of the dark color portion include general-purpose resins such as polyvinyl resins, polyester resins, urethane resins, acrylic resins, polyvinyl acetal resins, and cellulose resins.
Examples of the pigment in the dark color portion include a mixed pigment in which a dark color pigment such as carbon black, a red pigment, a blue pigment, and a yellow pigment are mixed to darken the pigment. The content of the pigment is preferably about 1 to 100 parts by mass with respect to 100 parts by mass of the resin component.

  The thickness of the dark color portion is preferably 1 to 40 μm, and more preferably 2 to 30 μm from the viewpoint of the balance between darkness and thinning. The dark color portion may have a multi-layer structure in order to obtain predetermined optical characteristics.

The dark color part is measured by CIE (International Commission on Illumination) L ^* a ^* b ^* colorimetric system L ^* value, a ^* value and b ^* value in the following range. Preferably.
The L ^* value is preferably 12 or less, and more preferably 8 or less. The absolute value of a ^* value is preferably 8 or less, more preferably 6 or less. The absolute value of b ^* value is preferably 14 or less, and more preferably 7 or less.

  The design layer comprises, for example, (a) a step of applying a coating liquid containing a component constituting the first area A1 of the design layer onto a release sheet and drying, and (a) a second area A2 of the design layer. It can be formed by a step of applying a coating liquid containing the component to a release sheet and drying. If no layer exists in the first region A1 of the design layer, the step (a) can be omitted.

[(Adhesive layer)]
The adhesive layer is arranged on the farthest side from the release sheet of the transfer layer, if necessary, in order to improve the adhesiveness between the injection resin layer and the transfer layer and to improve the transfer operation.

  For the adhesive layer, it is preferable to use a resin having excellent adhesiveness to the injection resin layer. For example, when the material of the injection resin layer is acrylic resin, it is preferable to use acrylic resin. When the material of the injection resin layer is polyphenylene oxide / polystyrene resin, polycarbonate resin, or styrene resin, acrylic resin, polystyrene resin, polyamide resin, polyester resin, etc., which have an affinity for these resins, etc. Is preferably used. Further, when the material of the injection resin layer is polypropylene resin, it is preferable to use chlorinated polyolefin resin, chlorinated ethylene-vinyl acetate copolymer resin, cyclized rubber, and coumarone indene resin.

You may mix | blend additives, such as a ultraviolet absorber and an infrared absorber, with an adhesive bond layer.
The thickness of the adhesive layer is preferably 0.1 to 10 μm, more preferably 0.5 to 5 μm.

[[Anchor coat layer]]
The anchor coat layer is a layer provided as necessary in order to improve heat resistance to a high temperature environment during in-mold molding. The anchor coat layer is preferably formed between the design layer and the adhesive layer.

The anchor coat layer preferably contains a cured product of the curable resin composition.
Examples of the curable resin composition include a thermosetting resin composition and an ionizing radiation curable resin composition.
The embodiment of the thermosetting resin composition of the anchor coat layer, the ionizing radiation curable resin composition is the same as the embodiment of the thermosetting resin composition of the protective layer and the ionizing radiation curable resin composition described later. is there.
The thickness of the anchor coat layer is preferably 0.1 to 6 μm, more preferably 0.5 to 5 μm.

[(Protective layer)]
The protective layer is a layer provided as necessary to protect the design layer after transfer. The protective layer is arranged closer to the release sheet than the design layer in the thickness direction of the transfer layer.

The protective layer preferably contains a cured product of the curable resin composition as a main component. The main component means 50% by mass or more of the total solid content constituting the protective layer, the ratio is preferably 70% by mass or more, more preferably 80% by mass or more, and 90% by mass or more. Is more preferable.
Examples of the cured product of the curable resin composition include a cured product of a thermosetting resin composition and a cured product of an ionizing radiation curable resin composition, and among these, a cured product of an ionizing radiation curable resin composition is preferable.
The protective layer may contain a thermoplastic resin, but the amount thereof is preferably a very small amount from the viewpoint of improving scratch resistance. Specifically, the content of the thermoplastic resin in the protective layer is preferably less than 5% by mass, more preferably less than 1% by mass, further preferably less than 0.1% by mass, Even more preferably, it is 0% by mass.
Hereinafter, the cured product of the curable resin composition and the thermoplastic resin may be referred to as “resin component”.

  The thermosetting resin composition is a composition containing at least a thermosetting resin, and is a resin composition that is cured by heating. Examples of the thermosetting resin include acrylic resin, urethane resin, phenol resin, urea melamine resin, epoxy resin, unsaturated polyester resin, and silicone resin. In the thermosetting resin composition, a curing agent is added to these curable resins as needed.

The ionizing radiation curable resin composition is a composition containing a compound having an ionizing radiation curable functional group (hereinafter, also referred to as “ionizing radiation curable compound”). Examples of the ionizing radiation-curable functional group include (meth) acryloyl group, vinyl group, ethylenically unsaturated bond group such as allyl group, epoxy group, and oxetanyl group.
The ionizing radiation curable resin is preferably a compound having an ethylenically unsaturated bond group. From the viewpoint of suppressing damage to the protective layer in the process of producing a transfer sheet, a compound having two or more ethylenically unsaturated bond groups is more preferable as the ionizing radiation curable resin, and among them, an ethylenically unsaturated bond is preferable. A polyfunctional (meth) acrylate compound having two or more saturated bond groups is more preferable. As the polyfunctional (meth) acrylate compound, either a monomer or an oligomer can be used.
The ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing or crosslinking a molecule, and usually ultraviolet rays (UV) or electron beams (EB) are used. Electromagnetic waves such as X-rays and γ-rays, and charged particle beams such as α-rays and ion rays can also be used.

Among the polyfunctional (meth) acrylate compounds, examples of the bifunctional (meth) acrylate monomer include ethylene glycol di (meth) acrylate, bisphenol A tetraethoxy diacrylate, bisphenol A tetrapropoxy diacrylate, and 1,6-hexane. Examples thereof include diol diacrylate.
Examples of trifunctional or higher functional (meth) acrylate monomers include trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, dipentaerythritol hexa (meth) acrylate, di- Examples thereof include pentaerythritol tetra (meth) acrylate and isocyanuric acid-modified tri (meth) acrylate.
Further, the (meth) acrylate-based monomer may be one in which a part of the molecular skeleton is modified, and is modified with ethylene oxide, propylene oxide, caprolactone, isocyanuric acid, alkyl, cyclic alkyl, aromatic, bisphenol, or the like. It can also be used.

Examples of the polyfunctional (meth) acrylate oligomer include acrylate polymers such as urethane (meth) acrylate, epoxy (meth) acrylate, polyester (meth) acrylate, and polyether (meth) acrylate.
Urethane (meth) acrylate is obtained by, for example, reacting a polyhydric alcohol and an organic diisocyanate with hydroxy (meth) acrylate.
A preferable epoxy (meth) acrylate is a (meth) acrylate obtained by reacting a trifunctional or higher functional aromatic epoxy resin, an alicyclic epoxy resin, an aliphatic epoxy resin or the like with (meth) acrylic acid, and a bifunctional difunctional (Meth) acrylate obtained by reacting the above aromatic epoxy resin, alicyclic epoxy resin, aliphatic epoxy resin, etc. with a polybasic acid and (meth) acrylic acid, and a bifunctional or higher functional aromatic epoxy resin, It is a (meth) acrylate obtained by reacting an alicyclic epoxy resin, an aliphatic epoxy resin and the like with phenols and (meth) acrylic acid.
The above ionizing radiation curable resins may be used alone or in combination of two or more.

When the ionizing radiation curable resin is an ultraviolet curable resin, the protective layer-forming coating liquid preferably contains additives such as a photopolymerization initiator and a photopolymerization accelerator.
Examples of the photopolymerization initiator include one or more selected from acetophenone, benzophenone, α-hydroxyalkylphenone, Michler's ketone, benzoin, benzyldimethylketal, benzoylbenzoate, α-acyl oxime ester, thioxanthones and the like.
Further, the photopolymerization accelerator can reduce the inhibition of polymerization by air during curing and accelerate the curing rate, and for example, from p-dimethylaminobenzoic acid isoamyl ester, p-dimethylaminobenzoic acid ethyl ester and the like. At least one selected from the above is included.

  The curable resin composition is left in a semi-cured state at the time of forming the protective layer, and after transferring to the injection resin layer, the curing of the curable resin composition is advanced by heating, irradiation with ionizing radiation, or the like. , May be completely cured. By doing so, the followability of the protective layer with respect to the injection resin layer becomes good, so that the moldability can be made good.

  The thickness of the protective layer is preferably 0.5 to 30 μm, more preferably 1 to 20 μm, and further preferably 3 to 10 μm from the viewpoint of the balance between surface hardness and moldability.

<< Shaping sheet >>
The shape-imparting sheet used in the step (1) has a role as a shape-imparting material for forming a moth-eye structure on the surface of the injection resin layer.
As the shaping sheet, one having a shape complementary to the moth-eye structure formed of the convex group on one surface can be used. The complementary shape may be formed on a part of one surface of the shape-imparting sheet, but is preferably formed on substantially the entire one surface of the shape-imparting sheet.

The shape-imparting sheet is prepared, for example, by preparing a moth-eye master plate having a moth-eye structure formed from a group of protrusions, pouring a composition containing a curable resin into the master plate to form a coating film, and curing the curable resin. After that, it can be obtained by peeling off the coating film. The composition containing a curable resin may contain a release agent in order to improve the releasability of the shaped sheet.
Further, after the curable resin is poured into the moth-eye original plate, the base material is attached to the coating film made of the curable resin, the coating film is peeled off together with the base material, and the cured film is formed on the base material. It is also possible to obtain a shaped sheet.
From the viewpoint of the balance between strength and handleability, the thickness of the shaped sheet is preferably 12 to 250 μm, more preferably 25 to 200 μm, and further preferably 38 to 125 μm.
A specific example of the moth-eye structure shaped by the shaping sheet will be described later.

<Step (2)>
In step (2), the mold is tightened, an injection resin is injected into the mold, and a surface of the transfer sheet on the transfer layer side, an injection resin layer containing the injection resin, and the shaping sheet are formed. This is a step of obtaining a laminated body A that is in close contact (FIG. 1B).

It is preferable to use a thermoplastic resin as the injection resin. Examples of such a thermoplastic resin include polystyrene resin, polyolefin resin, ABS resin (including heat-resistant ABS resin), AS resin, AN resin, polyphenylene oxide resin, polycarbonate resin, polyacetal resin, acrylic resin, Examples thereof include polyethylene terephthalate resin, polybutylene terephthalate resin, polysulfone resin, and polyphenylene sulfide resin. Among these, a polycarbonate resin having good impact resistance is preferable.
The composition to be injected may contain additives such as an ultraviolet absorber and an antioxidant in addition to the injection resin.

  The thickness of the injection resin layer is not particularly limited and may be appropriately determined depending on the application. When the resin molded body is used as a front plate of a display element, it is preferably 1.0 to 5.0 mm, more preferably 1.5 to 2.5 mm, from the viewpoint of the balance between strength and thinning. preferable.

  In step (2), it is preferable to apply a pressing pressure to the mold after injecting the injection resin into the mold. By applying a pressing pressure, the shape of the shaped sheet can be easily reflected in the injection resin layer.

<Step (3)>
In the step (3), after the mold is opened, the release sheet and the patterning sheet of the transfer sheet are peeled off from the laminate A, and the moth-eye structure section A formed by the convex group on one surface is formed. It is a step of obtaining a resin molded body having an injection resin layer that is provided and a transfer layer that is in close contact with the surface of the injection resin layer opposite to the moth-eye structure portion A (FIG. 1). (C)).

  In the step (3), peeling of the release sheet and peeling of the shaping sheet may be performed at the same time or at different timings. When peeling the release sheet and peeling the shaping sheet are performed at different timings, either one may be performed first.

Further, in the step (3), the work of peeling the release sheet and / or the work of peeling the shaping sheet is performed after the mold is opened and after cutting the laminate A into a desired size. You can go.
As described above, after the laminated body A is cut into a desired size, the release sheet or the shaping sheet can be peeled off to cause the release sheet or the shaping sheet to function as a protective sheet for the resin molded body. It is useful in that the scratches of the resin molding can be suppressed. In particular, since the moth-eye structure portion is easily damaged, it is useful to peel off the shaping sheet after cutting.

According to the method for producing a resin molded body of the present invention described above, since it is possible to perform the shaping of the moth-eye structure portion A and the formation of the design layer at the same time, it is possible to reduce the number of steps and improve the production efficiency. Further, it is possible to prevent the moth-eye structure portion A from being damaged during the printing process, and it is possible to improve the yield.
In addition, the resin molded body obtained by the above-described method for producing a resin molded body of the present invention has the injection resin layer having the moth-eye structure portion A adhered to the transfer layer including the design layer. It is possible to give a profound feeling to the tint of the design layer (≈ tint of the resin molded body) when viewed from above.

[Display device]
The display device of the present invention comprises a display element, a display plate arranged on the light emission surface of the display element, and a transparent plate arranged on the light emission surface of the display plate via an air layer. The display plate has an injection resin layer having a moth-eye structure portion A formed from a group of protrusions on one surface, and a side of the injection resin layer opposite to the moth-eye structure portion A. Is a resin molded body having a transfer layer including a design layer formed in close contact with the surface of the resin molded body, wherein the resin molded body is arranged such that the moth-eye structure portion A of the injection resin layer is on the light emission surface side. The transparent plate has a moth-eye structure portion B formed of a group of convex portions on the light incident surface side.

FIG. 4 is a cross-sectional view showing an embodiment of the display device 1000 of the present invention.
The display device 1000 of FIG. 4 includes a display element 310, a display plate 100 arranged on the light emitting surface of the display element, and a transparent plate arranged on the light emitting surface of the display plate via an air layer 320. And 200. In addition, in FIG. 4, the display board (resin molding) 100 includes an injection resin layer 20 having a moth-eye structure portion A (21) formed of a group of protrusions on one surface, and an injection resin layer 20. The transfer layer 10 includes a design layer 11 that is in close contact with the surface opposite to the moth-eye structure portion A. Further, in FIG. 4, the resin molded body 100 is arranged such that the moth-eye structure portion A (21) of the injection resin layer 20 is on the light emission surface side. Further, in FIG. 4, the transparent plate 200 has a moth-eye structure portion B (202) formed of a group of convex portions on the light incident surface side.

<Display element>
The display element can be used as long as it can emit light, and it may be a simple light source such as an LED light source. However, it can selectively emit light at any place or can change the emission color at any place. Is preferred. Therefore, the display element is preferably a display element for a display such as a liquid crystal display element, an EL (inorganic EL or organic EL) display element and a plasma display element. It is also preferable that the display element is a projector such as a liquid crystal projector.
When the display element of the display device is a liquid crystal display element, a backlight is required on the surface of the liquid crystal display element opposite to the resin molded body.

<Display board (resin molding)>
The display plate constituting the display device of the present invention has an injection resin layer having a moth-eye structure portion A formed of a group of protrusions on one surface, and the moth-eye structure portion A of the injection resin layer. A resin molded body having a transfer layer including a design layer which is in close contact with the surface on the opposite side. The resin molded body is arranged such that the moth-eye structure portion A of the injection resin layer is on the light emitting surface side.

<< Injection resin layer >>
The injection resin layer preferably contains a thermoplastic resin as described above. Further, the injection resin layer may contain additives such as an ultraviolet absorber and an antioxidant in addition to the injection resin.

On one surface of the injection resin layer, there is a moth-eye structure portion A formed of a convex group. The display device of the present invention has the moth-eye structure portion A on the light-emission surface side (viewer side) of the design layer of the injection resin layer, and the moth-eye structure portion B on the light-incidence surface side of the transparent plate described later. By having it, the tint of the design layer can be made profound.
Note that a means for forming a multilayer antireflection film in place of the moth-eye structure portion A or the moth-eye structure portion B can be considered. However, since the multi-layer antireflection film is designed on the assumption that it is viewed from a specific angle (in principle, from the front), the antireflection property deteriorates when viewed from a certain angle, and Color is generated in the light. Therefore, the multilayered antireflection film cannot provide the design layer with a solid tint.

The convex portion group forming the moth-eye structure portion A is characterized in that the individual convex portions are arranged in a cycle equal to or shorter than the wavelength of the visible light region.
Further, each of the convex portions has a shape in which the cross-sectional area of the horizontal cross section gradually decreases from the bottom to the top, and has a so-called taper shape. The shape of the bottom of the protrusion is not particularly limited, and may be circular, polygonal, or irregular. Further, the shape of the top of the convex portion is not particularly limited, and may be flat, acute, curved, or the like, but a curved surface is preferable from the viewpoint of moldability.

  The periods, heights, and intervals of the convex portions are preferably within the ranges described below. The period, height and interval mean the distances indicated by P, H and G in FIG.

The period P of the convex portion is not particularly limited as long as it is 780 nm or less, and can be appropriately determined according to the required antireflection function.
The period of the convex portion affects the wavelength dependency of the reflectance, and the longer the period, the more the reflectance for light on the short wavelength side of the visible light region tends to increase. On the other hand, when the period is 200 nm or less, the change in the wavelength dependency of the reflectance due to the change in the period is small. If the convex period is too short, it becomes difficult to form a convex group.
Therefore, the period of the convex portions is preferably 50 to 400 nm, more preferably 100 to 360 nm.
When the moth-eye structure is viewed obliquely, a structural color derived from the moth-eye structure is likely to occur. The moth-eye structure is easily suppressed by shortening the period of the convex portion. Therefore, from the viewpoint of suppressing the structural color and enhancing the solid feeling, the period of the convex portions is preferably 200 nm or less.
The period, height and interval of the protrusions are 20 periods, height and intervals observed by observing the vertical cross section of the protrusions using a scanning electron microscope (SEM) and atomic force microscope (AFM). Is measured and used as the average value of the measured values.

The height H of the convex portion can be appropriately adjusted within a range that does not impair the effects of the present invention, and is not particularly limited. The higher the height, the lower the reflectance can be. On the other hand, the lower the height, the reflectance on the long wavelength side tends to increase. Further, if the height is too high, the convex portion is likely to be damaged.
Therefore, the height of the convex portion is preferably 60 to 2000 nm, more preferably 100 to 800 nm.

  As the interval G between the convex portions becomes wider, the reflectance tends to increase in the entire wavelength region of visible light, and as the gap G becomes smaller, the reflectance tends to decrease in the entire wavelength region of visible light. The interval between the convex portions can be appropriately adjusted within a range that does not impair the effects of the present invention, and for example, is preferably 0 to 100 nm, more preferably 5 to 50 nm.

  The ratio (H / P) between the height H of the convex portion and the period P is preferably 0.3 to 2.5, and more preferably 0.5 to 2.3. When the ratio is 0.3 or more, the reflectance can be easily lowered, and when the ratio is 2.5 or less, the moth-eye structure can be easily shaped.

The period, height and interval of the convex portions may be uniform or non-uniform.
The structural color described above can be easily suppressed by randomly arranging the convex portions forming the convex portion group. That is, it is preferable to make the periods and intervals of the convex portions non-uniform from the viewpoint of easily improving the profound feeling when viewed from an oblique direction. In this case, it is preferable that the heights of the protrusions are substantially uniform.

  The total thickness of the injection resin layer is preferably 1.0 to 5.0 mm, and more preferably 1.5 to 2.5 mm, from the viewpoint of the balance between strength and thinning.

<< Transfer layer >>
The transfer layer forming the resin molded body includes at least a design layer. The transfer layer is in close contact with the surface of the injection resin layer opposite to the moth-eye structure portion A.
Further, it is preferable that the design layer included in the transfer layer has a first region having a light transmitting property and a second region having a light opaque property. Further, it is preferable that at least a part of the second region A2 of the design layer is a dark color portion.
The embodiment of the transfer layer is as described in the method for producing a resin molded product of the present invention.

  It is preferable to add a pointer indicating information to the display plate (resin molded body), if necessary. For example, in the case of the display plate (resin molded body) in plan view of FIG. 3, it is preferable to add a pointer indicating the speed to the central portion.

<< Optical characteristics >>
The resin molded body preferably has a total light transmittance of 50% or more, more preferably 70% or more, and further preferably 90% or more in a portion corresponding to the first region A1 of the design layer. .. By setting the total light transmittance of the first region A1 within the above range, for example, when the resin molded body is used as the front plate of the display element, the visibility of the display element can be improved through the first region.
Further, in the resin molded body, the haze of the portion corresponding to the first region A1 of the design layer is preferably 1 to 50%, more preferably 2 to 30%.

  The resin molded product preferably has a total light transmittance of 1% or less, more preferably 0.1% or less, at a portion corresponding to a dark color portion (dark color portion of the second region of the design layer). , 0.01% or less is more preferable, and 0.001% or less is still more preferable.

  In the present specification, “total light transmittance” means that measured according to JIS K7361-1: 1997, and “haze” means that measured according to JIS K7136: 2000. In addition, in the present specification, the total light transmittance and the haze mean an average value of measured values at 20 points. The incident surface of the total light transmittance and haze measurement light is on the light incident surface side of the display device.

<<< thickness >>>
The thickness of the resin molded body is preferably 1.0 mm or more. By setting the thickness of the resin molded body to 1.0 mm or more, the strength of the resin molded body can be easily improved.
The thickness of the resin molded body is preferably 1.0 to 5.0 mm, and more preferably 1.5 to 2.5 mm, from the viewpoint of the balance between strength and thinning.

<Air layer>
In the display device of the present invention, a display plate (resin molding) and a transparent plate are arranged with an air layer in between. In other words, in the display device of the present invention, the display plate (resin molded body) and the transparent plate are not arranged in close contact with each other, but the display plate (resin molded body) and the transparent plate are arranged at intervals. Usually, when the display device has an air layer, a double image is likely to occur, but the display device of the present invention can suppress the double image because the resin molded body and the transparent plate have the moth-eye structure portion. ..
The thickness of the air layer (the distance between the display plate and the transparent plate) is not particularly limited because it varies depending on the design of the display device, but is usually about 1 to 100 mm.

<Transparent plate>
The transparent plate constituting the display device of the present invention has a moth-eye structure portion B formed of a group of convex portions on the light incident surface side.
As described above, in the display device of the present invention, due to the moth-eye structure portion A of the injection resin layer and the moth-eye structure portion B of the transparent plate, the tint of the design layer can have a profound feeling. When the transparent plate has the moth-eye structure on the light-exiting surface side, the moth-eye structure is easily damaged by a person touching it with a finger, so that the effect cannot be maintained for a long period of time.

  The transparent plate 200 has a transparent base material 201 and a shape-imparting layer 202 having a moth-eye structure portion B (203) (FIG. 4), and a single-layer structure having a shape-imparting layer having a moth-eye structure portion B. There are things. Among these, those having a transparent substrate and a shaping layer are preferable from the viewpoint of handleability.

For a transparent plate having a single-layer structure, for example, a shaping plate having a shape complementary to the moth-eye structure portion B formed of a convex group on one surface is prepared, and a curable resin is poured into the plate. Can be obtained by peeling the coating film after forming the coating film with the above, curing the curable resin.
Further, for a transparent plate provided with a transparent base material, after pouring a curable resin into the plate, a transparent base material is attached onto a coating film made of the curable resin, and the coating film is peeled off together with the transparent base material. Can be obtained by

As the curable resin, the same resins as those exemplified for the protective layer can be used.
Further, as the transparent substrate, the plastic film exemplified as the support of the release sheet can be used. The plastic film as the transparent substrate is preferably a polycarbonate film from the viewpoint of impact resistance, and is preferably an acrylic film from the viewpoint of transparency.

  The embodiment of the moth-eye structure portion B formed of the convex portion group can be the same as the embodiment of the moth-eye structure portion A formed of the convex portion group described above.

  The thickness of the transparent substrate is preferably 25 to 250 μm, and more preferably 38 to 125 μm from the viewpoint of the balance between strength and handleability.

<< Antireflection layer >>
It is preferable to have an antireflection layer on the light emitting surface side of the transparent plate in order to suppress surface reflection.
Examples of the antireflection layer include a single layer structure of a low refractive index layer and a two layer structure of a high refractive index layer and a low refractive index layer (in the case of the two layer structure, the high refractive index layer is arranged on the adherend side). In addition, the antireflection layer may be formed of three or more layers.

The refractive index of the low refractive index layer is preferably 1.28 to 1.40, more preferably 1.32 to 1.38.
The thickness of the low refractive index layer is preferably 80 to 120 nm, more preferably 85 to 110 nm, further preferably 90 to 105 nm.

The method of forming the low refractive index layer can be roughly classified into a wet method and a dry method. As the wet method, a method of forming by a sol-gel method using a metal alkoxide or the like, a method of forming by coating a resin having a low refractive index such as a fluororesin, and a resin composition containing low refractive index particles A method of applying the coating liquid for forming the refractive index layer to form the coating liquid may be used. Examples of the dry method include a method of selecting particles having a desired refractive index from the low refractive index particles to be described later and forming them by physical vapor deposition or chemical vapor deposition.
The wet method is excellent in terms of production efficiency, and among the wet methods, it is preferable to use a coating liquid for forming a low refractive index layer containing a binder resin composition containing low refractive index particles. As the binder resin composition, for example, the curable resin composition exemplified in the protective layer can be used.

The low-refractive-index particles can be used without limitation, whether they are particles made of an inorganic compound such as silica and magnesium fluoride, or particles made of an organic compound, but from the viewpoint of improving antireflection properties by lowering the refractive index. Therefore, particles having a structure having voids are preferably used.
The particles having a structure having voids have fine voids inside and are filled with a gas such as air having a refractive index of 1.0, and therefore have a low refractive index of themselves. There is. Examples of particles having such voids include inorganic or organic porous particles, hollow particles, and the like. For example, porous silica, hollow silica particles, or porous polymer particles using an acrylic resin or the like. And hollow polymer particles.
The average particle diameter of the primary particles of the low refractive index particles is preferably 5 to 200 nm, more preferably 5 to 100 nm, further preferably 10 to 80 nm.

The high refractive index layer preferably has a refractive index of 1.55 to 1.85, more preferably 1.56 to 1.70.
Further, the thickness of the high refractive index layer is preferably 200 nm or less, and more preferably 50 to 180 nm.

  The high refractive index layer can be formed from, for example, a high refractive index layer coating liquid containing a binder resin composition and high refractive index particles. As the binder resin composition, for example, the curable resin composition exemplified in the protective layer can be used.

As the high refractive index particles, antimony pentoxide (1.79), zinc oxide (1.90), titanium oxide (2.3 to 2.7), cerium oxide (1.95), tin-doped indium oxide (1. 95 to 2.00), antimony-doped tin oxide (1.75 to 1.85), yttrium oxide (1.87), zirconium oxide (2.10) and the like.
The average particle diameter of the primary particles of the high refractive index particles is preferably 5 to 200 nm, more preferably 5 to 100 nm, further preferably 10 to 80 nm.

<< Hard coat layer >>
Further, it is preferable to have a hard coat layer on the light emitting surface side of the transparent plate for scratch resistance. Further, from the viewpoint of achieving both suppression of surface reflection and scratch resistance, it is preferable to have a hard coat layer and an antireflection layer in this order on the light emitting surface side of the transparent plate.

  The embodiment of the hard coat layer formed on the light emitting surface side of the transparent plate can be the same as the embodiment of the protective layer constituting the transfer layer described above.

<< Optical characteristics >>
The total light transmittance of the transparent plate is preferably 90% or more, more preferably 95% or more, further preferably 99% or more.
The haze of the transparent plate is preferably 1% or less, more preferably 0.5% or less, and further preferably 0.3% or less.

<Use>
The display device of the present invention can be used, for example, in a television, a desktop monitor, a notebook PC and a personal digital assistant, and can also be used in a vehicle instrument.

  Hereinafter, the present invention will be specifically described with reference to examples. The present invention is not limited to the form described in the embodiments.

1. Measurement and Evaluation The following measurements and evaluations were performed on the resin molded products or display devices obtained in the examples and comparative examples. The atmosphere for measurement and evaluation was 23 ° C. ± 5 ° C. and 40-65% humidity. Moreover, the target sample was exposed to the atmosphere for 30 minutes or more, and then measured and evaluated. The results are shown in Table 1.

1-1. Defect of moth-eye structure portion A The resin molded body of Comparative Example 3 before the screen printing after shaping the moth-eye structure portion A was used as a reference. The moth-eye structure portion A of the reference resin molded body, the resin molded body of Example 1, and the resin molded body of Comparative Example 3 were observed by an atomic force microscope (AFM), and the reference moth-eye structure portion A and Example 1 were used. And the moth-eye structure portion A of Comparative Example 1 were compared. As a result, the average pitch, the average height, and the average interval are substantially the same as those of the reference moth-eye structure portion A, and those that are substantially the same as the reference are “A”, the average pitch, the average height, and the average. “C” was defined as the interval which was not the same as that of the reference moth-eye structure portion A and in which a defect was found in the moth-eye structure portion as compared with the reference.
In addition, the average pitch, average height, and average interval of the comparison target were set to be substantially the same as the average pitch, average height, and average interval of the reference.

1-2. Profound feeling (front direction and diagonal direction of 45 degrees)
In a room in which a plurality of fluorescent lamps are arranged on the ceiling, the display elements of the display devices of the examples and comparative examples were visually observed from the front direction in a turned-on state. From the four age groups of 20s, 30s, 40s, and 50s, the total number of evaluators was 40 for each 5 men and women.
An average score of the above 40 persons, with 3 points for those who feel profound and excellent in designability, 2 points for those that can not be said to be either, and 1 point for those who feel that the profoundness is insufficient and inferior in designability Was calculated and ranked according to the following scores.
In addition, evaluation was performed when the display device was observed from an oblique direction of 45 degrees based on the same criteria as above.
<Evaluation criteria>
A: Average score is 2.5 or more B: Average score is 2.0 or more and less than 2.5 C: Average score is less than 2.0

2. Preparation of transfer sheet 2-1. Transfer sheet A
A white ink having a light-transmitting property is applied to a partial region of a release sheet (a polyethylene terephthalate film having a thickness of 50 μm and having a release layer formed on the surface) and dried to form a first region A1 of the design layer. did. Next, a light-impermeable black ink was applied to the rest of the release sheet and dried to form a second area A2 of the design layer, and a design layer composed of the first area A1 and the second area A2 was formed. The thickness of the design layer was 2.0 μm in both the first area A1 and the second area A2.
Next, an anchor coat layer forming coating solution having the following formulation was applied on the design layer so that the amount of adhesion after drying was 3.0 g / m ² , a coating film was formed, and then dried at 40 ° C. for 72 hours. Then, it was cured to form an anchor coat layer having a thickness of 2 μm.
Next, an adhesive layer-forming coating liquid having the following formulation was applied on the anchor coat layer so that the amount of adhesion after drying was 2.5 g / m ² , to form a coating film. The coating film was dried to form a heat-sealable adhesive layer having a thickness of 2 μm to obtain a transfer sheet A.

<Coating liquid for forming anchor coat layer>
Acrylic polyol 100 parts by mass (manufactured by Dainichiseika Co., Ltd., trade name: TM-VMAC, solid content 25% by mass)
(Toluene / ethyl acetate / methyl ethyl ketone mixed solvent)
Hexane methylene diisocyanate 10 parts by mass (manufactured by Dainichiseika Co., Ltd., trade name: PTC-RC3)
(Solid content 75% by mass, solvent: ethyl acetate)

<Coating liquid for forming adhesive layer>
-Thermoplastic resin 465 parts by mass (manufactured by Dainichiseika Co., Ltd., trade name: TM-R600, solid content 20% by mass)
・ Methyl ethyl ketone 40 parts by mass

2-2. Transfer sheet B
A low-refractive-index layer-forming coating solution having the following formulation was applied to the entire surface of a release sheet (a polyethylene terephthalate film having a thickness of 50 μm and having a release layer formed on the surface), dried, and then irradiated with ultraviolet rays to give a thickness. A low refractive index layer of 100 nm was formed.
Next, a coating liquid for forming a high refractive index layer having the following formulation was applied to the entire surface of the low refractive index layer, dried and then irradiated with ultraviolet rays to form a high refractive index layer having a thickness of 100 nm.
Then, a coating solution for forming a hard coat layer having the following formulation was applied on the entire surface of the high refractive index layer, dried and then irradiated with ultraviolet rays to form a hard coat layer having a thickness of 5 μm.
Next, the anchor coat layer-forming coating solution having the above formulation was applied onto the hard coat layer so that the amount of adhesion after drying was 3.0 g / m ^2, and a coating film was formed, followed by drying at 40 ° C. for 72 hours. Then, it was cured to form an anchor coat layer having a thickness of 2 μm.
Next, the coating liquid for forming an adhesive layer having the above formulation was applied onto the anchor coat layer so that the amount of adhesion after drying was 2.5 g / m ² to form a coating film. The coating film was dried to form a heat-sealable adhesive layer having a thickness of 2 μm to obtain a transfer sheet B.

<Coating liquid for forming low refractive index layer>
・ 7 parts by mass of photopolymerization initiator (BASF Corporation, trade name "Irgacure 127")
-UV curable resin 75 parts by mass (Shin Nakamura Chemical Co., Ltd., trade name "ATM-4P")
・ UV curable resin 25 parts by mass (Nippon Kayaku Co., Ltd., trade name "PET-30")
・ Hollow silica fine particle dispersion liquid 700 parts by mass (solid content 20%, average primary particle diameter 60 nm)
83 parts by mass of reactive silica fine particle dispersion (manufactured by Nissan Chemical Industries, Ltd., trade name "MIBK-SD", solid content 30%, average temporary particle size 10 nm)
・ Methyl isobutyl ketone 9300 parts by mass ・ Propylene glycol monomethyl ether acetate 1100 parts by mass

<Coating liquid for forming high refractive index layer>
-Propylene oxide-modified pentaerythritol tetraacrylate 100 parts by mass (trade name "ATM-4P", manufactured by Shin-Nakamura Chemical Co., Ltd., solid content 100%)
Antimony pentoxide-containing dispersion 988 parts by mass (trade name "V-4564", manufactured by JGC Catalysts & Chemicals, solid content 40.5%, average primary particle diameter 20 nm)
・ 300 parts by mass of fluorine-based leveling agent (trade name "Megafuck F568", manufactured by DIC, solid content 5%)
・ 8 parts by mass of photopolymerization initiator (trade name "Irgacure 127", manufactured by Ciba Specialty Chemicals)
・ Methyl isobutyl ketone 6800 parts by mass ・ Propylene glycol monomethyl ether acetate 6500 parts by mass

<Coating liquid for hard coat layer>
-Acrylic polymer (Brand name "BL-2002", manufactured by Seikou PMC, solid content 35%, mass average molecular weight 70,000, acrylic equivalent 265) 257 parts by mass-Acrylic polymer (Brand name "BL-2184", Starlight) PMC, weight average molecular weight: 9000, acrylic equivalent: 1000, solid content 45% 22 parts by mass Reactive silica fine particles (trade name "ELCOM V8802", manufactured by JGC Catalysts & Chemicals, solid content 40%, average primary particles Diameter 10 nm) 125 parts by mass Fluorine-based leveling agent (trade name "Megafuck F554", manufactured by DIC, solid content 100%) 0.3 parts by mass Photopolymerization initiator (Irgacure 184, manufactured by Ciba Specialty Chemicals) ) 4 parts by mass / methyl ethyl ketone 360 parts by mass

3. Preparation of Molding Sheet A commercially available moth-eye master plate having a moth-eye structure imprinted thereon was prepared. A solventless UV curable resin composition (manufactured by DNP Fine Chemicals, trade name: FS15) containing a photopolymerization initiator was poured into the moth-eye original plate, and a base material (PET film having a thickness of 50 μm) was formed on the coating film formed from the composition. Were adhered to each other, and the coating film was cured by irradiating ultraviolet rays, and then the base material and the coating film were peeled off to obtain a shaped sheet having a coating film thickness of 5.0 μm.

4. Preparation of resin molded product [Example 1]
The transfer sheet A prepared in “2-1” above is arranged on one side of a pair of upper and lower in-mold molding dies, and the mold formed in “3” above is formed on the other side of the mold. Arranged the sheets. The surface of the transfer sheet A on the transfer layer side faces the inside of the mold (the side in contact with the injection resin), and the imprinting sheet has the molding surface facing the inside of the mold (the side in contact with the injection resin). Placed in.
Next, the mold is tightened, injection resin (polycarbonate resin) is injected into the mold, the surface of the transfer sheet A on the transfer layer side, the injection resin layer containing the injection resin (thickness 2.0 mm), and the shaping sheet. A laminated body A in which and were integrated was obtained.
Next, after the mold was opened, the release sheet and the transfer sheet of the transfer sheet A were peeled off from the laminate A to obtain the resin molded body of Example 1. The resin molded body of Example 1 has an injection resin layer having a moth-eye structure portion A formed of a group of protrusions on one surface, and a surface of the injection resin layer opposite to the moth-eye structure portion A. And a transfer layer in close contact with. The average pitch of the convex portions of the moth-eye structure portion A was 200 nm, the average height was 300 nm, and the average interval was 50 nm.
The total light transmittance of the second region A2 of the resin molded body of Example 1 was 0.0001%. The L ^* value of the second region A2 of the resin molded body of Example 1 was 8 or less, the absolute value of the a ^* value was 6 or less, and the absolute value of the b ^* value was 7 or less. The light incident surface at the time of measuring the total light transmittance and the L ^* value and the like was on the transfer layer side.

[Comparative Example 1]
The transfer sheet A produced in the above “2-1” was placed on one side of the pair of upper and lower in-mold molding dies, and nothing was placed on the other side of the dies. The transfer sheet A was arranged so that the surface on the transfer layer side faced the inside of the mold (the side in contact with the injection resin).
Then, the mold is tightened, injection resin (polycarbonate resin) is injected into the mold, and the surface of the transfer sheet A on the transfer layer side and the injection resin layer (thickness 2.0 mm) made of the injection resin are integrated. A laminated body B was obtained.
Next, after opening the mold, the release sheet of the transfer sheet A was peeled from the laminate B to obtain a resin molded body of Comparative Example 1. The resin molded body of Comparative Example 1 has a transfer layer formed in close contact with one surface of the injection resin layer.

[Comparative example 2]
The transfer sheet A prepared in the above "2-1" was placed on one side of a pair of upper and lower in-mold molding dies, and the other side of the mold was prepared in "2-2" above. Transfer sheet B was placed. The transfer sheet A and the transfer sheet B were arranged such that the surface on the transfer layer side faced the inside of the mold (the side in contact with the injection resin).
Next, the mold is tightened, injection resin (polycarbonate resin) is injected into the mold, the surface of the transfer sheet A on the transfer layer side, the injection resin layer containing the injection resin (thickness 2.0 mm), and the transfer sheet B. A laminated body C in which the surface on the transfer layer side was integrated was obtained.
Then, after opening the mold, the release sheet of the transfer sheet A and the release sheet of the transfer sheet B were peeled from the laminate C to obtain a resin molded body of Comparative Example 2. The resin molded body of Comparative Example 1 has a transfer layer including a design layer on one surface of an injection resin layer, and an antireflection layer (two layers of a high refractive index layer and an antireflection layer) on the other surface of the injection resin layer. It has a transfer layer containing an antireflection layer).

[Comparative Example 3]
The imprinting sheet prepared in the above “3” was placed on one side of the pair of upper and lower in-mold molding dies, and nothing was placed on the other side of the dies. The imprinting sheet was arranged so that the imprinting surface faces the inside of the mold (the side in contact with the injection resin).
Then, the mold is tightened, injection resin (polycarbonate resin) is injected into the mold, and a laminate D in which the shaping sheet and the injection resin layer (thickness 2.0 mm) made of the injection resin are integrated is obtained. It was
Next, after opening the mold, the patterning sheet was peeled from the laminate D to obtain a laminate E. The laminate E has an injection resin layer having a moth-eye structure portion A formed of a group of protrusions on one surface. The average pitch of the convex portions of the moth-eye structure portion A was 200 nm, the average height was 300 nm, and the average interval was 50 nm.
Then, a white ink having a light-transmitting property is applied by a screen printing method to a partial area of the surface opposite to the surface having the moth-eye structure portion A of the laminate E, and the first area A1 of the design layer is dried. Formed. Then, a light-impermeable black ink is applied to the remaining area of the opposite surface by a screen printing method and dried to form a second area A2 of the design layer. From the first area A1 and the second area A2. Then, a resin layer of Comparative Example 3 was obtained. The thickness of the design layer was 2.0 μm in both the first area A1 and the second area A2.

5. Preparation of transparent plate A solventless UV-curable resin composition (manufactured by DNP Fine Chemicals, trade name: FS15) containing a photopolymerization initiator was poured onto the patterning surface side of the patterning sheet prepared in the above “3”, and the composition was prepared. A transparent base material (acrylic film having a thickness of 50 μm) is attached onto a coating film made of a material, and the coating film is cured by irradiating with ultraviolet rays, and then the transparent base material and the coating film are peeled off from the convex portion group. A transparent plate having a coating film having the formed moth-eye structure portion B on a transparent substrate was obtained. The average pitch of the convex portions of the moth-eye structure portion B was 200 nm, the average height was 300 nm, and the average interval was 50 nm.

6. Fabrication of display device [Example 1]
As a display element, a white light light table (trade name “LED Viewer Pro 4 × 5” manufactured by Fuji Film Co., external dimensions: 186 × 111 × 13 mm, light source: white LED) was prepared. The resin molded body of Example 1 was placed on the display element, and the transparent plate prepared in the above “5” was placed on the resin molded body with an air layer (interval of 10 mm) interposed therebetween. I got the device. The resin molded body was arranged so that the moth-eye structure portion A was on the light emitting surface side, and the transparent plate was arranged so that the moth-eye structure portion B was on the light incident surface side.

[Comparative Examples 1 to 3]
Display devices of Comparative Examples 1 to 3 were obtained in the same manner as the display device of Example 1 except that the resin molded product of Example 1 was changed to the resin molded products of Comparative Examples 1 to 3.
The resin molding of Comparative Example 1 was arranged such that the surface on the transfer layer side was the light emitting surface side. Further, the resin molded body of Comparative Example 2 was arranged such that the surface of the transfer sheet B on the transfer layer (transfer layer including the antireflection layer) side was the light emitting surface side. Further, the resin molded body of Comparative Example 3 was arranged such that the moth-eye structure portion A was on the light emitting surface side.

  From the results in Table 1, it can be confirmed that, according to Example 1, a resin molded product having excellent manufacturing efficiency and yield and capable of imparting a solid tint can be manufactured.

10: Transfer layer 11: Design layer 12: Anchor coat layer 13: Adhesive layer 20: Injection resin layer 21: Moth eye structure part A
30: Release sheet 70: Transfer sheet 80: Imprinting sheet 100: Resin molding (display board)
200: transparent plate 201: base material 202: imprinting layer 203: moth-eye structure part B
310: Display element 320: Air layer 401, 501: Sending roll 402, 502: Winding roll 601, 602: Mold 1000: Display device

Claims (8)

A method for producing a resin molded product, which includes the following steps (1) to (3).
(1) A transfer sheet having a transfer layer including a design layer on a release sheet is arranged on one side of a pair of upper and lower in-mold molding dies, and a convex group is formed on the other side of the mold. A step of disposing a shaping sheet having a shape complementary to the moth-eye structure portion A formed from
(2) The mold is tightened, injection resin is injected into the mold, and the surface of the transfer sheet on the transfer layer side, the injection resin layer containing the injection resin, and the shaping sheet are brought into close contact with each other. The process of obtaining the laminated body A.
(3) After the mold is opened, the release sheet and the patterning sheet of the transfer sheet are peeled off from the laminate A, and the moth-eye structure section A formed by the convex group is formed on one surface. A step of obtaining a resin molded body, which comprises: an injection resin layer and a transfer layer that is in close contact with the surface of the injection resin layer opposite to the moth-eye structure portion A.   The method for producing a resin molded body according to claim 1, wherein the design layer has a first region having a light transmitting property and a second region having a light transmitting property.   The method for producing a resin molded body according to claim 2, wherein at least a part of the second region of the design layer is a dark color portion. A display element, a display plate arranged on the light emitting surface of the display element, and a transparent plate arranged via an air layer on the light emitting surface of the display plate,
The display plate is in close contact with an injection resin layer having a moth-eye structure portion A formed of a group of protrusions on one surface and a surface of the injection resin layer opposite to the moth-eye structure portion A. A resin molded body having a transfer layer including a design layer formed by
The resin molded body is arranged such that the moth-eye structure portion A of the injection resin layer is on the light emitting surface side,
The said transparent plate is a display apparatus which has the moth-eye structure part B formed from the convex part group at the light-incidence surface side.   The display device according to claim 4, wherein the design layer has a first region having a light transmitting property and a second region having a light transmitting property.   The display device according to claim 5, wherein at least a part of the second region of the design layer is a dark color portion.   The display device according to claim 4, further comprising an antireflection layer on the light exit surface side of the transparent plate.   The display device according to any one of claims 4 to 7, which is for a vehicle instrument.